FEDERAL REPUBLIC OF NIGERIA

COUNCIL FOR THE REGULATION

OF ENGINEERING IN NIGERIA

WORK EXPERIENCE REPORT

IN PARTIAL FULFILMENT FOR REGISTRATION AS

REGISTERED ENGINEER

MECHANICAL ENGINEER

By: Abiodun Destiny

Application ID: 44600
Phone: 081 3940 5361
Email: destinyabiodun@gmail.com, AUGUST, 2022
REPORT ON REPAIR OF CAVITATION OF 2G4 HYDRAULIC TURBINE
GENERATOR AT JEBBA HYDRO POWER PLANT

BY ABIODUN DESTINY AKARUTU

B.Eng. (Hons) Mechanical Engineering

IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR

REGISTRATION WITH THE COUNCIL FOR THE REGULATION OF
ENGINEERING IN NIGERIA (COREN)

AUGUST, 2022
 Table of Contents

Table of Contents
CHAPTER ONE............................................................................................................................................................................ 5
CHAPTER TWO...........................................................................................................................................................................6
2.0 Summary of Work Experience...............................................................................................................................................6
CHAPTER THREE........................................................................................................................................................................ 7
3.0 DETAILS OF ENGINEERING WORK EXPERIENCE....................................................................................................................7
3.1 EMPLOYER........................................................................................................................................................................... 7
3.1.1 Kainji................................................................................................................................................................................. 7
3.1.2 Jebba................................................................................................................................................................................ 8
3.2 BRIEF OVERVIEW OF HYDRO POWER GENERATION............................................................................................................8
3.2.1 Energy Conversion in Hydro Electric Power Generation..................................................................................................9
3.3 Scope of work at Jebba Hydro Power Plant Mainstream Energy Solution limited..............................................................9
3.4 CAVITATION REPAIR...........................................................................................................................................................10
3.4.0 Abstract.......................................................................................................................................................................... 10
3.4. 1 INTRODUCTION.............................................................................................................................................................10
3.4.2 CAVITATION.................................................................................................................................................................... 11
3.4.3 MEASURES TO MINIMIZE CAVITATION INCLUDE:...........................................................................................................11
3.5 PROCEDURE FOR REPAIR OF CAVITATION: GOUGING........................................................................................................11
3.5.1 TESTING OF THE GOUGED AREA.....................................................................................................................................11
3.5.2 CARBON STEEL ELECTRODE BUILD UP............................................................................................................................12
3.5.3 ANTI CORROSIVE OVER LAY............................................................................................................................................12
3.5.4 REPAIR OF DRAFT TUBE FINS AND VENTS.......................................................................................................................12
3.5.5 PROCEDURE.................................................................................................................................................................... 12
3.5.6 REPAIR OF CAVITATION ON BLADE BODY AND TIPS........................................................................................................13
3.5.7 REPAIR OF CAVITATION ON WITHOUT GOUGING...........................................................................................................13
3.5.8 ELECTRODE SPECIFICATION............................................................................................................................................13
3.5.9 TOOLS AND EQUIPMENTS REQUIRED FOR CAVITATION REPAIR WORK..........................................................................13
3.5.9.1 SAFETY PRECAUTION...................................................................................................................................................14
3.5.10 Bill of Engineering Measurement and Evaluation [BEME] And Take off Sheet.............................................................16
3.5.11 SUBJECT........................................................................................................................................................................ 17
3.5.12 Project: The Scope of works is as indicated in the table below....................................................................................17

3
3.5.13 Bill of Engineering Measurement and Evaluation (BEME)............................................................................................18
3.6 Challenges encountered and Solutions...................................................................................................................19
3.6.1 Experience Gained...............................................................................................................................................19
CHAPTER FOUR........................................................................................................................................................................20
4 Conclusion...................................................................................................................................................................20
CHAPTER 5........................................................................................................................................................................... 21
5.1 Endorsement.................................................................................................................................................................21
5.2 Endorsement.................................................................................................................................................................21

4
 CHAPTER ONE
1.0 INTRODUCTION

My name is Abiodun Destiny Akarutu, a native of Igarra, Akoko-Edo LGA of Edo State. I was born on 30th,
March, 1993 in Jebba,Moro local government, Kwara State. I attended NEPA Staff Nursery /primary school,
Jebba South between 1999 to 2004. I had my secondary school education in PHCN Staff Secondary School,
Jebba Niger State between 2004 to 2010. Then I processed to Ahmadu Bello university Zaria, Kaduna State,
where I studied mechanical engineering and I was awarded Bachelor of Engineering with Second Class
(Upper division) in mechanical engineering in 2015.
I proceeded for my National Youth Service Commission (NYSC) in Taraba State where I was attached with
Taraba Road Construction and Maintenance Agency (TARCMA) in 2016 for a one-year mandatory service.
There, I was attached with the maintenance department where we maintain heavy duty road construction
machinery. After my service, I returned to Mainstream Energy Solutions Limited (MESL) as a volunteer
trainee with the company from 2018 to 2019. In 2019, I was sponsored to National Power Training Institute of
Nigeria (NAPTIN) for a comprehensive power training and thorough understanding of the inter-relationship
between the various sectors of the Nigerian energy supply industries and the relationship between the
generation, transmission, and distribution sectors. The National Graduate Skills Development Program
training under NAPTIN spanned from 2019 through 2021 where I graduated as the best student in generation
and overall best graduating student in the training.
I had my Orientation Program in RTC, Kainji. My Class Module 1 and 2 also in RTC, Kainji. My Inter Sub
Sectorial Posting were Jebba Transmission Station and Ibadan Electricity Distribution Company for the
Transmission and Distribution field experience respectively. The technical report of my field experiences
includes Power System Components identification and system operations, maintenance (Routine Preventive
Maintenance), Annual Maintenance experience on the turbine and generator, Trouble report interventions
Overhauling. The departments of my work experience include Generator/Workshop Department and the
Turbine Department in the Mechanical Maintenance Department in Jebba Hydro Power Plant.
I presently work with Mainstream Energy Solutions Limited, Mechanical Maintenance Department, Jebba
Hydro Power Plant where I continuously get exposed to firsthand experience on evolving hydro-power plant
technologies, international plant safety practices and inter managerial skills.

5
 CHAPTER TWO
2.0 Summary of Work Experience
Period Detail of Projects/Activities Duration Supervisor
(Months)
Name Signature

EMPLOYER: Mainstream Energy Solutions Ltd

Position: Plant Officer (Maintenance)

March, Project: Annual Maintenance of 2G1 to 2G5

2022 to
July, 2022 Activities undertaken were: -
i. Preparation of annual maintenance
plan
ii. Material selection, period
schedules/duration and job safety
analysis
iii. Categorize maintenance work into
different interventions i.e. Periodic,
Spot improvement and routine
maintenance.
iv. Conduct Annual District Road
Inventory and Condition Survey. 5 Eng. S.M Tahir
v.

6
 CHAPTER THREE

3.0 DETAILS OF ENGINEERING WORK EXPERIENCE

This section of the report explains the overview of my employer, hydro-power generation, and the detailed
maintenance projects involved with.

3.1 EMPLOYER
Mainstream Energy Solutions Limited (MESL) was incorporated in 2011 and licensed as a power generating
company MESL took over Kainji and Jebba Hydro Power Plants (HPP) with a total installed capacity of
1338.4MW through a concession agreement in November 2013.
The two hydro plants are cascaded 100km apart with Kainji dam being on the upstream of Jebba.
The two hydro power plants; the Kainji and Jebba have installed capacities of 760MW and 578.4MW
respectively.
Upon takeover in November 2013, the total available capacity of the two plants was 582MW. as of today, MESL
has proudly restored it to 922MW over the course of three years. We currently generate an average 20 percent of
Nigeria's power. Kainji was commissioned as Nigeria first Hydro Power plant in 1968 while Jebba Power plant
was commissioned in 1985.
MESL is a privately-owned company being governed by a Board of Directors and Executive Management that
oversee the day-to-day operations of the plants.

3.1.1 Kainji
Located on the course of the Niger River at Kainji gorge, New Bussa, the original development plan for Kainji
Plant provided for twelve units of 80MW each, with projected total installed capacity at 960MW. However, at the
completion of the project in 1978, the total installed capacity was 760MW with 8 units, leaving four number open
pits with no generating units installed. Statutory overhaul was not carried out on the Generating Units at Kainji in
over forty (40) Years of the plant’s existence, such that most of the units went out of operational service or de-
rated over the years. Presently 346 MW has been recovered out of the installed 760 MW.

Figure 1. Generator Housing Overview of Jebba Hydro-Power Plant

7
3.1.2 Jebba
Jebba hydroelectric plant was officially commissioned on 13th April 1985 although commercial operations
commenced in 1983. It has six (6) fixed blade propeller hydraulic turbines with a total installed capacity of 578.4
MW that is, 96.4MW each.
Five units are available for generation. The sixth unit 2G6 is not available due to a major fire incident on the
Generator / AVR system which occurred on the 21st of April 2009. Recovery process has commenced

JEBBA PLANT UNIT’S DATA & COMMISSIONING DATES

S/N UNIT MANUFACTURE TURBINE TYPE INTALLED CAPACITY
DATE COMMISSIONED

1 2G1 Escher-Wyss Fixed propeller 96.4 MW 05/12/1983

2 2G2 Escher-Wyss Fixed propeller 96.4 MW 15/02/1984
3 2G3 Escher-Wyss Fixed propeller 96.4 MW 22/03/1983
4 2G4 Escher-Wyss Fixed propeller 96.4 MW 17/03/1984
5 2G5 Escher-Wyss Fixed propeller 96.4 MW 25/07/1984
6 2G6 Escher-Wyss Fixed propeller 96.4 MW 19/05/1988
Table 1: Jebba plant units’ data and commissioning dates.

3.2 BRIEF OVERVIEW OF HYDRO POWER GENERATION

Hydroelectric power generation is a renewable source of energy generation which have no effect on the
environment (ECO- Friendly) and a very cheap source of energy in the world, easy for maintenance compared to
other sources of energy generation method. The choice of hydro system to generate high power carries a higher
economic value of the water resource used, although hydro power plant projects require high initial investment
cost but are easy to run and generally have low maintenance cost compared to other sources of energy. (1) Every
Hydro station is comprised of concrete dam structure, the powerhouse, the intake, (upstream), the discharge (tail
race or downstream), Generator, Powerhouse, Transmission Line, Penstock, Turbine, Draft Tube, Transformer,
and Switch Yard.

Figure 2: Diagram of a Conventional Hydroelectric Facility

8
3.2.1 Energy Conversion in Hydro Electric Power Generation
Hydroelectric power is the generation of electricity by harnessing the energy of water. To generate
hydroelectricity, a reliable supply of water is needed, this sound simple but it usually requires a large dam and
robust engineering technique. Therefore, generation of electricity in Hydro Power station is the transformation of
Energy from one form to another until Electrical Energy is achieved. At first, Potential Energy (P.E) at
Dam/Reservoir (stand still energy) is converted to Kinetic Energy (K.E) at the penstock (intake), this energy is
further converted to Mechanical Energy (M.E) at the turbine and the Mechanical Energy is also converted to
Electrical Energy (E.E) at the Generator field.
Potential Energy (PE) to Kinetic Energy (KE) to Mechanical Energy (ME) to Electrical Energy (EE)

3.3 Scope of work at Jebba Hydro Power Plant Mainstream Energy Solution limited
I worked as a graduate engineer in this project with a team of skilled supervisors.
On 2G4 Hydro Turbine Generator Annual Maintenance 27th April 2022 to 18th May 2022,
S/NO Task Name Duration Start Time Finish Time
1 Opening of the draft tube access door/ 1 Day Wed Wed 27/04/22
beam manholes 27/04/22
2 Installation of rollers for the beam 1 Day Wed Wed 27/04/22
27/04/22
3 Erection of platform beam, cross members, 1 Day Wed Wed 27/04/22
and assembling of planks 27/04/22

4 Erection of scaffolds 1 Day Thu Thu 28/04/22

28/04/22
5 Inspection of runner blades and draft tube 1 Day Thu Thu 28/04/22
fins for cavitation, rust and erosion 28/04/22
6 Open up runner cone cover and check all 1 Day Fri 29/04/22 Fri 29/04/22
bolts for looseness
7 Measure the runner blade tip clearance 1 Day Fri 29/04/22 Fri 29/04/22
8 Pre-heating of draft tube fins 2 Days Mon Tue 03/05/22
02/05/22
9 Measurement of blades clearance 1 Day Mon Mon 30/04/18
02/05/22
10 Covering of the runner cone cover 1 Day Mon Mon 02/05/22
02/05/22
11 Pre-grouting checks/repairs 1 Day Mon Mon 02/05/22
02/05/22
12 Drilling of marked areas for grouting 2 Days Mon Mon 02/05/22
02/05/22
13 Draft tube grouting 3 Days Mon Wed 04/05/22
02/05/22
14 Welding of eroded spots on blades 2 Days Tue Wed 04/05/22
03/05/22
15 Welding of cover plate to the fin holding 5 Days Tue Mon 09/05/22
bolts 03/05/22
16 Welding-filling of draft tube fins 5 Days Tue Mon 09/05/22
03/05/22
9
 17 Measurement of turbine guide bearings (As 1 Day Tue Tue 10/05/22
met) 10/05/22
18 Inspection of draft tube drainage valve 1 Day Tue Tue 10/05/22
10/05/22
19 Removal of scaffold 1 Day Tue Tue 10/05/22
10/05/22
20 Painting of runner cone 2 Days Wed Thu 12/05/22
11/05/22
21 Painting of grouting points, fins and vents 2 Days Wed Thu 12/05/22
11/05/22
22 Removal of platform planks, cross 2 Days Fri Mon 14/05/22
members and beams 13/05/22
23 Closing of draft and beam manholes 1 Day Mon Mon 14/05/22
14/05/18
24 Final inspection after watering up the unit 2 Days Tue17/05/22 Wed 18/05/22
Table 2: Scope of Work

3.4 CAVITATION REPAIR

Report on Repairs of Areas Affected by Cavitation on Turbine Runner Hub, Turbine Runner Blades and all 8No
Pins at Unit 2G4 Draft tube at Jebba Hydro Power Plant

3.4.0 Abstract
Cavitation is an important problem in hydraulic machines that negatively affects their performance and may cause
damages, for achieving higher efficiency of hydro turbines with time. Turbines show declined performance after
few years of operation, as they get severely damaged due to various reasons. Cavitation is a phenomenon which
manifests itself in the pitting of the metallic surfaces of turbine parts because of the formation of cavities. In the
present project research, studies undertaken in this field by several investigators have been discussed extensively,
different causes for the declined performance and efficiency of the hydro turbines and suitable remedial measures
suggested by various investigators have been discussed.

3.4. 1 INTRODUCTION
As the powerhouse is becoming older it is necessary to have qualified and trained personnel to maintain and repair
it. This maintenance can greatly reduce the repair cost and increase productivity, high efficiency, and longer
service life. Among all the renewable energy sources available, hydropower is considered as the most promising
source of energy. In many parts of the country, especially hill states streams coming down the hills posses’
sufficient potential energy that can be utilized. The hydraulic turbine used to convert the potential energy of water
to mechanical energy. Flowing water is directed on to the blades of a turbine runner, creating a force on the blades
Preventive maintenance is an important of every maintenance programme. It is essential if the unit is to deliver its
rated output. The basic objective of good maintenance is to prevent interruption of the unit thereby reducing the
down time of the machine. This can be achieved by strict adherence to the inspection, scheduling and follow up of
preventive maintenance programme. In addition to these scheduled programme, also good records of breakdown
repairs are kept knowing the frequency of maintenance and problem areas. Prior to the scheduled maintenance,
thorough inspection of the turbine and generator was carried out to ascertain if there is any malfunctioning part of
the unit, so that repairs could be incorporated to reduce the machine downtime for good cost estimate of the
maintenance and duration repairs.

10
3.4.2 CAVITATION
Cavitation is a failure of mechanism caused by formation and collapse of gas bubbles in a fluid over a metal
surface.
Cavitation pitting damage occurs as the result of the mechanical effect of repeated fluid impact on the surface of a
point that occurs during bubbles collapse and the formation of vapour bubbles in the liquid flowing through any
hydraulic turbine. Cavitation occurs when the static pressure of the liquid falls below its vapour pressure,
Cavitation erosion problems are found in turbine runner as well as in other parts of the turbine system.

3.4.3 MEASURES TO MINIMIZE CAVITATION INCLUDE:

1) Correct design hydraulic turbine runner, reduces the hydraulic turbine cavitation coefficient
2) Enhancement manufacture quality, the guaranteed leaf blade's geometry shape and the relative position are
correct, guarantee leaf blade surface smooth bright and clean.
3) Uses the anti - cavitation material, reduces the cavitation to destroy, and for example uses the stainless-steel
runner.
4) Calculates the installation elevation of hydraulic turbine correctly.
5) Improves the running condition, avoids the hydraulic turbine for a long time running under the low head and
the low load. Usually does not allow the hydraulic turbine to transport under the low output (For example: Is
lower than 50% fixed outputs).
6) Prompt maintenance and pays attention to the patching welding the polish quality avoids the cavitation the
malignant development.
7) Uses the air supplemental equipment to send the air into the draft tube, eliminates possibly has the cavitation
oversized vacuum.

3.5 PROCEDURE FOR REPAIR OF CAVITATION: GOUGING

Gouging is an air arc cutting process in which metals to be cut are melted by the heat of carbon arc. The molten
metal is removed by a high velocity blast of compressed air. The air jet is external to the consumable carbon
graphite electrode. It strikes the molten metal immediately behind the arc.
 After full isolation and issuance of permit for the unit
 Install platform in the draft tube
 Erect scaffold on the platform to the level of the runner hubs, blades, draft tube vents and fins.
 Provide full illumination
 Inspect all the areas affected by cavitation
 Use permanent chalk marker to mark the cavitation areas
 Determine the limit of area to be gouged
 Gouge the area affected to the sound metal
 Grind and smooth the gouged portion with grinding disc, cutter tools of different shapes and sizes
 Use bright torchlight to ascertain the sound metal is reached, making sure no scale or debris of the eroded
part is left
 Measure the length, width, and depth of the gouged area of the runner hub

3.5.1 TESTING OF THE GOUGED AREA

Non-destructive testing method (Liquid Penetrant Testing PT) is carried out to identify flaws, cracks, laps,
porosity, shrinkage, and similar discontinuities in the welding.
 Blow the gouged cavity with compressed service air to remove chips and debris
 Apply pre-cleaner spray in the cleaned gouged cavity and wipe out with clean molten rag
 Spray penetrant on the inside and surface of the cavity and allow to penetrate for about 10 minutes
 Clean the penetrant with pre-cleaner to clear away the red mark of the penetrant from the cavity
11
  Spray developer on the cleaned penetrant and allow to for 10 minutes within which the developer will start
to indicate cavity areas not properly grinded, this is indicated by dark red spots. The discontinuity is
revealed as the penetrant bleeds back up to the surface
 Complete white surface appearance indicate that sound metal is reached, and gouging confirmed
successful and ready for weld build up.

3.5.2 CARBON STEEL ELECTRODE BUILD UP

The metal build up is carried out with electrode melt drop in the cavity using specified E7018 electrode to be
preheated at 300 to 350 Degree Celsius for 2 hours before start of welding (details of the electrode specification is
shown below). The build-up will be done up to 3mm to 5mm above the hub surface to accommodate grinding of
the weld build up to 3mm below the original hub surface to give room for anti-corrosive weld over lay. After
grinding, the build-up is now tested to confirm no welding flaws or porosity the same way it was carried out after
gouging operation. In the event weld flaws is discovered the build-up must be grinded off and start a new one and
test to be carried out again and again till flawless weld is achieved.

3.5.3 ANTI CORROSIVE OVER LAY

After certification of carbon steel electrode build up test, the anti-corrosive over lay is carried out on the build up
to prevent fast cavitation erosion on the runner hub. For the anti-corrosive build up specified electrode E307 is
used and pre heated to 120 to 200 Degrees Celsius for 2 hours. The over lay is to be over layer 3mm to 5mm
above the hub to give room for grinding and final polishing to the hub profile. After the final grinding smoothing
and polishing, the penetration test is carried out to confirm no flaw in the anti-corrosive over lay. (See PT
procedure as in gouging operation).

3.5.4 REPAIR OF DRAFT TUBE FINS AND VENTS

Repair of rust erosion on the pins and turbo vents is as important as the runner hub. Continuous eroding and
subsequent cut off fins and vent add up to causes of cavitation, which eventually leads to rupture of water
continuous spin down the draft tube exit to tailrace. The fins and vents need to be inspected and repairs carried out
during every annual maintenance.

3.5.5 PROCEDURE
 After inspection and marking out of the affected areas
 Preheating of the area is required with acetylene gas flame
 Grinding of the area to remove all the unwanted eroded area on the fins and vents
 Carry out penetration test to confirm no part of eroded part is left on the parent metal
 Any of the vents discovered cut off because of erosion must be fabricated and replaced
 Weld fill the grinded portion of the vents and fins to form the profile of the original fin and vents must be
achieved
 Check with bright torch light to confirm there is no water seepage from the fins and vents
 Carry out penetration test to confirm no flaws or porosity in the welding part
 If the test is confirmed flaws free, smooth and polish the welded area thoroughly for easy water flow and
spin on the fins
 The fins and vents should be painted with bitoxy marine protection paint to protect and give the fins a
smoother surface.

12
3.5.6 REPAIR OF CAVITATION ON BLADE BODY AND TIPS
 Preheat the area with gas flame
 Grind the corrosion affected area
 Weld fill the area with E308 anti corrosive electrode
 Grind off the weld fill to the profile of the blade
 Smooth and polish the welded area to the original profile of blade body and tips
 Carry out penetration test to check for flaws in the welding
 The procedure is repeated for all the five blades

3.5.7 REPAIR OF CAVITATION ON WITHOUT GOUGING

o During every annual maintenance the repaired cavitation must be inspected to check the condition of the
area, if any erosion is observed the area should be grinded, smooth, and polished.
o Carry out penetration test,
o Apply anti corrosive liquid metal on the surface
o Allow to cure and set
o Grind smooth and polish properly
o Carry out penetration test to confirm no porosity

3.5.8 ELECTRODE SPECIFICATION

CARBON STEEL - AWS E 7018
STAINLESS STEEL - E 308 L-17

3.5.9 TOOLS AND EQUIPMENTS REQUIRED FOR CAVITATION REPAIR WORK

1 ELECTRODES
2 GOUGING TONG
3 WELDING TONG
4 WELDING MACHINE
5 GOUGING MACHINE
6 AIR SUPPLY
7 EXTRACTION FANS
8 GOUGING NOSE MASK
9 WELDING APRON
10 NOSE MASK
11 CUTTER TOOLS
12 ALUMINIUM FOIL 0.5MM
13 FIRE RESISTANT TARPAULINE
14 OXYGEN AND ACETYLENE GAS
15 FLAW DETECTOR CLEANER
16 FLAW DETECTOR PENETRANT
17 FLAW DETECTOR DEVELOPER
18 BRIGHT TORCH LIGHT
19 FIRE EXTINGUISHERS
21 SEARCH LIGHTS
22 CHIPPING HAMMER
23 WHITE CHALK MARKER
24 TAPE RULE
13
25 BITOXY MARINE PAINT PART A&B
26 MOLTEN RAG
27 SODA WATER
28 DRINKING WATER
29 LEATHER HAND GLOVES
30 GOUGING GOWN
31 GOUGING SAFETY BOOT
20 FLOOD LIGHTS21 SEARCH LIGHTS
22 CHIPPING HAMMER
23 WHITE CHALK MARKER
24 TAPE RULE
25 BITOXY MARINE PAINT PART A&B
26 MOLTEN RAG
27 SODA WATER
28 DRINKING WATER
29 LEATHER HAND GLOVES
30 GOUGING GOWN
31 GOUGING SAFETY BOOT

3.5.9.1 SAFETY PRECAUTION

Safety precaution is very important and need to be observed, supervised, and enforced before, during and after
cavitation repair work, this is because the involvement of personnel, equipment, dust, toxic fumes, grinding chips,
weld slag, heat, electric current, height of work area, confined space and water below the draft tube platform.
To ensure accident-free work and safe environment this salient precaution need to be taken and observed
i. All welding gas cylinders must be connected and tested and confirm no gas leaks
ii. All welding machines must be connected to jointless cables and tested
iii. Air hoses must be tested and confirm free from leaks
iv. Fireproof tarpaulin to be provided to cover the electric cables and air hoses from welding slag falling from
above of the platform
v. Gouging, and welding nose respirators must be always worn
vi. 15 minutes rest out of work area is necessary after each 1 hour of welding, gouging, or grinding work
vii. Extractor fans must be installed
viii. Use of PPE is necessary at all time

Figure 3: Picture of runner hub showing marked areas affected by cavitation

14
Figure 4: Indication of porosity in welding after penetration test

Figure 5: Picture of caveated runner blade after inspection

15
Figure 6: Picture of draft tube fin affected by cavitation after inspection

Figure 7: Picture of draft tube vent affected by cavitation erosion

16
3.5.10 Bill of Engineering Measurement and Evaluation [BEME] And Take off Sheet.
Prequalification
Prequalification is normally used with Requests for Bids and is optional depending on the nature and complexity
of the Goods, Works, or Non-consulting Services.
In prequalification, minimum requirements are normally assessed on a pass/fail basis against such criteria as:
a) Eligibility
b) Nationality
c) Conflict of Interest
d) Bank Eligibility
e) Historical Contract Non-Performance
f) Suspension Based on Execution of Proposal Securing Declaration by the Employer
g) Financial Capabilities
h) Average Annual Turnover
i) Experience
j) General Experience
k) Specific Experience
All Applicants to a prequalification that substantially meet the qualification requirements are invited to submit a
Bid.

3.5.10.1 List of things consider during Evaluation CAC- corporate affairs commission
VAT- value added tax certificate
Income tax clearance certificate
Other list depending on the company
Pension remittance to the relevant tax and authorities
Original equipment manufacturer (OEM) Representation certificate
Evidence of field annual returns
Business objectives relating to the area of arrangement

3.5.11 SUBJECT
Report on Repairs of Areas Affected by Cavitation on Turbine Runner Hub, Turbine Runner Blades and all 8No
Pins at Unit 2G4 Draft Tube
REP: MESL/JHPP/674/PROC.11/Vol.1 /2018
The need to carry-out effective maintenance work on any unit is vital to sustain and improve the unit’s operating
condition. To avert sudden breakdown and cost implication of such, effective maintenance is normally carried out
periodically (in this case, annually).
From the previous observation of cavitation effects on Runner Hub and Runner Blade carried-out it was
anticipated by the User Department that similar effects will be found on the Draft Tube of Unit 2G4.
To effectively carry out the work Messrs. Sly- Okea Integrated Services who was involved and trained on
Welding works by Andritz Team whose performance tracked record on such work is considered proficient was
promptly contacted considering the timely requirement for execution of the works. Messrs Sly- Okea Integrated
Services submitted a proposal of N1,606,500 (One Million, Six Hundred and Six Thousand, Five Hundred Naira
Only) VAT Inclusive.

17
3.5.12 Project: The Scope of works is as indicated in the table below.
S/N Job Description Amount
1 Transportation of Personnel from Jebba to Site daily for the N 30,000.00
work periods (15 working days)
2 Gouging of the affected areas of the blade’s trunnions on the N 150,000.00
Runner Hub
3 Build up welding of the grinded area with E7018-1 H4R N 250,000.00
Electrode
4 Build-up by weld-filling of 8Nos Fins. N 300,000.00
5 Grinding of built-up welded areas on the 8Nos Fins. N 150,000.00
6 Grinding of the Runner Blade before weld-filling. N 100,000.00
7 Welding of the 5No Runner Blade body and tip with Stainless N 200,000.00
Steel Electrode.
8 Grinding and smoothing of the welded areas on the 5No Runner N 150,000.00
Blade.
9 Grinding and welding of 4No Turbo Vent. N 150,000.00
10 Painting of the welded surfaces with bitoxy paint A&B N 50,000.00
Total N
1,000,000.00
Table 3: Negotiated Scope of Work

From the above Scope the sum of N1,000,000.00 (One Million Naira Only) Vat inclusive was negotiated and
agreed upon after much deliberation with Messrs. Sly-Okea Integrated Services for the work.
In view of the above, it is hereby recommended for your approval, the issuance of works Order for Repairs of
Areas affected by Cavitation on Runner Hub, Runner Blades and 8No pins at Unit 2G4 Draft Tube in favor of
Messrs. Sly-Okea Integrated Services at a total cost of N1,000,000.00 (One Million Naira Only) VAT inclusive.

3.5.13 Bill of Engineering Measurement and Evaluation (BEME)

S/ Unit Rate quantity Cost in Amount in

No Bill Activity Naira Naira
1 Mild Steel Welding Electrode E 6013 100 pack ₦4,000.00 ₦ 400,000
2.5mm
2 Stainless Steel Welding Aws E 7018 50 pack ₦ 4,500.00 ₦ 225,000
Electrode
3 High Carbon Steel-less 2.50x350mm 60 pack ₦ 4,800 ₦ 288,000
Electrode
4 Low Carbon Steel-less 2.250x350m 30 pack ₦ 4,500 ₦ 135,000
Electrode m
5 Mild Steel Welding Rod E 6013 6 Carton ₦ 32000 ₦ 192,000
6 Arc Welding ₦ ₦
7 Miller Welding Machine Gold star 602 1 piece ₦1,650,000 ₦ 1,650,000
8 Flood ligts21 Search Lights ₦ ₦
9 Gouging Safety Boot 15pieces ₦ 16360 ₦ 245,400
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 10 Gouging Tong 1 piece ₦ 35,000 ₦ 35,000
11 Welding Tong 1 piece ₦ 45,000 ₦ 45,000
12 Welding Machines Industry 300 1 piece ₦ 300,000 ₦ 300,000
Amp
13 Cutting Tools 8 Carton ₦ 7500 ₦ 60,000
14 Aluminum Foil 0.5mm As sG2 wire 1 carton ₦ 15,000 ₦ 15,000
15 Extraction Fans Available Available ₦------------ ₦-----------
16 Gouging Nose Mask 10 ₦ 1200 ₦ 1,200
17 Air compressor Supply Available Available ₦ ----------- ₦----------
18 Fire Resistant Tarpaulin Available Available ₦------------ ₦-----------
-
19 Oxygen and Acetylene Gas 4 pieces ₦ 15,000 ₦ 60,000
20 Flaw Detector Cleaner 600x600 3 Carton ₦ 26,000 ₦ 78,000
21 Flaw Detector Penetrant 600x600 3 Carton ₦26,000 ₦ 78,000
22 Flaw Detector Developer 600x600 3 Carton ₦ 26,000 ₦ 78,000
23 Bright Torch Light 15pieces ₦ 4500 ₦ 67,500
24 Fire Extinguishers Available Available ₦------------ ₦-------------
-- -
25 Search Lights 15pieces ₦ 2,500 ₦ 3,750
26 Chipping Hammer 5 pieces ₦ 1,500 ₦ 7,500
27 White Chalk Marker 2 Carton ₦ 3000 ₦ 6000
28 Tape Rule Available Available ₦------------ ₦------------
-
29 Bitoxy Marine Paint Part A&B Available Available ₦------------ ₦-------------
-- --
30 Molten Rag 6 rows ₦ 5,000 ₦ 30,000
31 Leather Hand Gloves 6 Carton ₦ 9,500 ₦ 57,000
32 Gouging Gown 15pieces ₦ 6,000 ₦ 90,000
Table 4: Table of Cost Summary

3.6 Challenges encountered and Solutions

Challenges are part of every project execution, but with teamwork, dedication and skilled personnel, no
challenge is unsurmountable. During this work, some challenges faced were
a. Carrying out work (welding) in a confined space
b. Distance of worksite to workshop/office
c. Contractor to engineer worries
Every challenge is surmountable as earlier said. How we tackled the challenges that arose are;
a. Ensuring proper ventilation as much as possible by providing enough extractor fans at worksite
b. We had to provide some office tools at worksite, and we brought refrigerator to site to ensure we have
chilled water as much fluid is needed for the job
c. Human relationship skill was a challenge at first in explaining what exactly we wanted the contractor to do
and how we wanted it executed so we implored the help of our supervisor who had previously worked
with the contractor and understood how to tender our complains to him better.

3.6.1Experience Gained

The experiences gained during this project work were: -

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a) To be more familiar with plant activities, understanding how confined space jobs are
executed and understanding the importance of Health Safety and Environment personnel
with plant engineers.
c) Loading of scaffolding members and assembling of platforms at draft tube region to
ensure safe workspace.
d) Understanding that welding is a special skill required in the plant and understanding how
to carry out crack/failure tests on welded zones and portions
e) Working with a team outside my regular team, learning contract rites and agreement and
understanding how to engage with contractors

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 CHAPTER FOUR
4 Conclusion

As I have narrated above in this report, I have gained adequate Work Experience in Mechanical
Engineering (hydro power plant maintenance, auxiliary functionalities, welding, and cavitation
works, spill way hydraulics, governor hydraulics) as well as knowledge in procurement matters,
project management and contracts administration. I have now managed to bridge theories and
reality in the plant. I have faced many challenges while implementing projects and I have also been
able to look for the solution to those problems.

Further I certify that, this report results from my involvement in various hydro power plant
engineering works carried out and is not copied from any unauthorized materials and thus the
activities written in this report were carried out under close supervision of Registered Engineers.

Regarding the professional engineering work experience I have gained so far, I finally wish the
COREN to consider, evaluate and approve my application for registration as an Engineer

Name: ...............................................

Signature:…………………………… Date:

………………………………….

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 CHAPTER 5
5.1 Endorsement

I, the undersigned, have gone through the report that has been prepared and we endorse the
experience attained and reported by the writer. Based on our personal knowledge of the character
and professional reputation of the applicant, I recommend for acceptance of this Work
Experience report by the COREN in Partial fulfillment of the requirements for registration as
Registered Mechanical Engineer.

NAME SIGNATURE AND DATE

5.2 Endorsement

I, the undersigned, have gone through the report that has been prepared and we endorse the
experience attained and reported by the writer. Based on our personal knowledge of the character
and professional reputation of the applicant, I recommend for acceptance of this Work
Experience report by the COREN in Partial fulfillment of the requirements for registration
as Registered Mechanical Engineer.

NAME SIGNATURE AND DATE

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 REFERENCES
1 Escher Wyss Limited (1981) Volume 1 of 8 Data sheets and catalogues for Propeller Turbines, Governors,
Unwatering and Fire Protection System. Jebba Dam (Nigeria)
2 Escher Wyss Limited (1981) Volume 7 0f 8 Data sheets and catalogues for Propeller Turbines, governors,
Unwatering and fire protection system. Jebba Dam (Nigeria)
3 2016weldguru.com
4 Engr. A. Y. Ribadu (1997) Salient Electrical Features in Annual Maintenance of Hydroelectric Generator.
Lecture delivered at NSE Minna Branch, Shiroro (Nigeria)
5 Engr. Liadi Danjuma MNSE (2018) Repair of cavitation in hydraulic turbine

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