NORTH SOUTH POWER COMPANY LIMITED

SHIRORO HYDROELECTRIC POWER STATION

WORK PROCEDURE FOR SERVICING OF GENERATOR BRAKES
12 BRAKES
 Preparation of tools, instruments and documentation.
o Dismantle the brakes base bolts.
o Dismantle the brakes limit switches.
o With the aid of crane transfer, the 12 number brakes to
service/testing area.
o Dismantle the brakes lining (pads).
o Unscrew the brakes spring retainers
o Remove the brake springs.
o With the aid of crane and sling wire, remove the piston from the
brake drum.
o Remove the brake diaphragm.
o Inspect the brake drum piston for dent/scratches.

ASSEMBLY/TESTING OF BRAKES
 Thorough cleaning of brake drums and piston with emery cloth, solvent and
molten rags.
 With the aid of compressor, blow the cleaned piston/brake drum to
remove possible residual particles.
 Clean/blow the brake springs and retainers.
 Clean the new brake diaphragm and fix to the piston.
 Smear the piston and inner walls of the brake drum with a film of TELUS 68
oil to reduce friction/tearing the diaphragm while mounting back.
 With the aid of chain blocks and sling wire, lower the piston carefully into
the brake drum with special attention to the diaphragm seals.
 Place the brake springs into their slots.
 Screw the spring retainers back to the brake drums.
 Tie the brake pad base to the piston.
 With the aid of crane, place and secure the assembled brakes to the brake
testing device.
 Connect the hydraulic jack (with pressure gauge above 200 bars) to the
inlet air piping connection of the brakes in preparation for testing.
 Close the air outlet line of the brakes.
 Apply pressure up to 200 bars for duration of 15 minutes.
 If pressure drop is below 0.05 bars, the brake is certified ok.
 Release the hydraulic pressure to 0 bar.
 Unsecure the brakes from the brake testing device.
 With the aid of crane, remove and transfer the brakes to brake lining
assembling point.
 Position and secure the new brake pads to their base.
 Clean and remove all working tools from the work place.
TOOLS/MATERIALS
 Hydraulic jack.
 Overhead crane.
 Iron bar
 Sling wire.
 Mobile air Compressor.
 Brake testing device.
 Hammer.
 Molten cloth.
 Solvent.
 Brake diaphragm.
 ATF hydraulic.
 Brake table.
 Screw driver.
 Chisel.
 Mallet.
 Spanners opening 13, 17, 19, 24,27,30,36 and 46.
 Smooth emery cloth.
 Spirit level.
 Lubricating oil.