Unit 6

Testing ,
Commissioning,
Operation and
Maintenance
Testing and Commissioning of MHP 1
Testing , Commissioning, Operation
and Maintenance (5 hours)
 Head works, Electro‐mechanical equipment, Alternator,
Loading machine on main load, Taking readings, Setting
up trips.
 Types of manuals‐operation manual, component
manual, installer manual, preventive maintenance
schedule, log sheet, repair manual, training manual,
responsibility of designers, installer and users as regards
to O and M.

Testing and Commissioning of MHP 2

Introduction
 O+M procedures should be planned.
 Longevity of plant depends how properly operated and
maintained
 It prevents breakdowns and power outages.
 It also ensures correct choice of spare parts and tools as
well as safety.
Responsible stakeholders
 Design engineer
 Installers
 Users

Testing and Commissioning of MHP 3

Responsibility and Roles of Designer for O&M
 Should have O and M in mind throughout the design
process.
 Should have an understanding of skilled levels, motivation,
availability and cost of O and M staff in order that
appropriate designs are used.
 Must know the user of the scheme well in advance and
write the O and M schedule for them specifying the task of
resident O and M staff, local workshops, manufacturers
etc.
 Must choose appropriate equipment which can be repaired
easily by local workshops.
 Must arrange and supervise proper training courses for O
and staff and write the training manuals.

Testing and Commissioning of MHP 4

Responsibility and Roles of Installer for O&M
 Will have supervised specifications to work to in case of
large scheme.
 Will be responsible for detailed design and quality control
in case of smaller scheme.
 Should be present during a quality check stage and during
commissioning and testing stage and should be bound by
contract to make good any inadequacies.
 Should provide full O and M documentation associated
with special equipment.
 Should conduct formal training courses for operators in
presence of design engineer.

Testing and Commissioning of MHP 5

Responsibility and Roles of Users for O&M
 Responsible for O and M duty and recruitment of O and M
staff.
 Should implement O and M schedule and make sure that
spare parts are replaced and stocked in time.
 Should recruit and pay the wages to O and M staff.
 Should implement the training schedule specified by the
design engineer.
 Should make sure that the recommendation of the design
engineer are followed by the local workshop in case of
complex repairs.
 More complex repairs should be referred to the
manufacturers ( e.g. Repair of the runner)

Testing and Commissioning of MHP 6

O+M Documents:
1. Operation Manual
2. Components Manual
3. Installer’s Manual
4. Maintenance Schedule
5. Repairs Manual
6. Log Book
7. Training Manual

Testing and Commissioning of MHP 7

Testing and Commissioning of MHP 8
Testing and Commissioning of MHP 9
Basic operation
1. Check following points before starting operation
① Transmission and distribution line
・ Damages of lines and poles
・ Approaching branches
・ Other obstacles
② Waterway facilities
・ Damages of structures
・ Sand sedimentation in front of the intake
・Suspended trash at screens
・ Sand sedimentation in the settling basin and the forebay

Testing and Commissioning of MHP 10

③ Turbine, generator and controller
・ Visual inspection
・ Wear of brush
・ Insulation resistance of circuits
（２） Starting operation
After checking the turbine and generator are okay for
operation. Procedure of starting operation is as follows:
（Preparation）
① Close the flushing gate of the intake weir
② Open the intake gate and intake water into the
waterway system.
Testing and Commissioning of MHP 11
(Starting operation）
③ Open the inlet valve gradually.
④ If there is a guide vane, open the inlet valve fully, and
then open the guide vane gradually.
⑤ Confirm that voltage and frequency or rotating speed
increase up to the regulated value.
⑥ Turn the load switch on (parallel in).
⑦ Control inlet valve or guide vane so that voltage and
frequency are within the regulated range.

Testing and Commissioning of MHP 12

(３） Role of operators during operation:
① Control the inlet valve or guide vane so that voltage
and frequency are within the regulated range.
② Check vibration and noise of equipment, and then
stop operation if necessary.
③ Check temperature of equipment
④ Check any abnormal condition of equipment, and
then stop operation and take a measure if necessary.
⑤ Record result of operation and condition of
equipment according to fixed format.

Testing and Commissioning of MHP 13

(4) Stopping operation:
At first, need to inform the village.
① Close the inlet valve or the guide vane.
② Cut load switch off (load rejection).
③ Close the inlet valve and the guide vane completely.
④ Close the intake gate.
When load is suddenly cut due to an accident, operator
must close the inlet valve or the guide vane immediately
to avoid runaway speed of the turbine and the generator
for long time.

Testing and Commissioning of MHP 14

Operation in case of Emergency
 In case of flood
 In case of earthquake
 In case of shortage of water
 In case of accident

Testing and Commissioning of MHP 15

Maintenance
Daily patrol
 In order to check if there is anything strange at
waterway facilities, electric equipment, transmission
and distribution line, operators daily conduct patrol
along the course that has been fixed in advance
 Operators must record result of patrol and take a
measure if necessary.

Testing and Commissioning of MHP 16

Daily Patrol record sheet

Testing and Commissioning of MHP 17

Periodic Inspection:
 Operators must conduct inspection periodically to
check if there are any troubles in facilities and
equipment.
 Operators should be able to perform repair works in
case there are troubles during inspection.

Testing and Commissioning of MHP 18

Items and frequency of periodic inspection

Testing and Commissioning of MHP 19

Special Inspection
 In case of earthquake, flood, heavy rain and accident,
operators must stop operation and inspect facilities.
Recording
 Operators must keep a record of the operation and
maintenance of the micro-hydropower plant.
 Records will provide much help to operators in
monitoring the conduct of the regular or scheduled
activities for the operation and maintenance.
 It also provides good data in determining the causes of
trouble in case of accident.

Testing and Commissioning of MHP 20

A sample of operation record and daily patrol check sheet

Testing and Commissioning of MHP 21

Daily Inspection and Maintenance
Before Start up
 Clean the trash racks at the intake, desilting basin, and forebay.
 Check whether sufficient water is flowing through the headrace.
If not, the plant load should be reduced accordingly or the plant
should not be started at all.
 During the monsoon season, flush the forebay and desilting
basin (every other day if there is less debris).
During Operation
 Check the temperatures, and vibration level of housing casings
of the turbine and generator bearings.
 Check leakage from valves, turbine housing, or and base frame.
 If there is excessive leakage from any location, repairs should be
organized straight away or as the situation demands.

Testing and Commissioning of MHP 22

Weekly Inspection and Maintenance
 Walk to the intake via the headrace/pipeline and
check for damage such as water leakage, cracked pipe,
or water emerging from the ground above the pipeline.
 Flush the forebay and desilting basins. Make a detailed
inspection of civil structures and surrounding areas for
such things as breakage, sliding, and rock falls
 Check the penstock for water leakage or damage, for
example from stones.

Testing and Commissioning of MHP 23

Monthly Inspection and Maintenance
 Walk from the powerhouse along the penstock to the forebay
and check all expansion joints, flanges and welds for leakage.
 Close all the turbine valves and open up the bearings and put two
fingers full of grease in each. Do the same for the generator
bearings using a grease gun.
 Inspect the generator, MCB switch, and ELC box and feel the
cables to check if they are very hot. Also check to see if the color
of the cables has changed.
 Check the fencing around the high voltage transformer if
installed.
 Inspect all the civil structures, including the penstock and
surrounding areas, for landslides and damage, or impending
signs al landslides.

Testing and Commissioning of MHP 24

Six Monthly Inspection and Maintenance
 Inspect the condition poles and repair any damaged ones.
 Check the clearance of the transmission line from the ground
and tree branches.
 Check the line connections of lightning arrestors and jumpers.
 Check the tension of the stay wire.
 Check the connections of distribution wires.
 Inspect distribution switches, fuses, etc,
 One of the six-monthly inspections should be undertaken
immediately after the monsoon season,
Cold Season Work:
 Inspect all places where water may have leaked from tanks or the
headrace/pipeline andtake corrective action.

Testing and Commissioning of MHP 25

Yearly Inspection and Maintenance
 Open the side plate of the generator and clean any dust
collected on the windings,
 Clean any dust. cobwebs. or other matter collected on the
inside and outside of the ELC box and the main switch.
Clean any sediment deposited in the ballast tank
 Test the earthing wire connection inside the powerhouse.
Test the 240 volt insulators on the transmission line and
distribution line approached from either side at the lines.
 Inspect the power control devices and service wires at
consumers homes.
 Cut down tree branches pear the transmission lines
 Inspect if trash racks and repair or replace them if
necessary.
Testing and Commissioning of MHP 26
Testing and Commissioning of MHP 27
 Introduction

Testing describes an assessment of the function of

the civil works and installed electro-mechanical
equipment under simulated operational
conditions.

 It is normally carried out separately for individual

MHP components including civil works,
electromechanical works, etc.

Testing and Commissioning of MHP 28

Commissioning describes the formal process of
taking the MHP plant into operation, closely
supervised and documented by the major
stakeholders.

 It also marks the formal handover of the

completed works by the contractor to the project
owner.

Testing and Commissioning of MHP 29

 Importance

To check all the components are functioning

properly as per the design.

Provides the record of the operational status of the

plant at start up which is reference for the future.

Helps to identify and remove the problems before

the operation of the plant.

Testing and Commissioning of MHP 30

 Testing procedure
Should carry out with trained personnel.
 Proper schedule planning.
Budget should be allocated.

Head Works
Channel:
It should be cleaned and flushed of all loose soil,
stones, dirt, etc.
 cracks and damages should be checked and repaired if
any.

Testing and Commissioning of MHP 31

Intake:
Intake should be clean.
The intake gate opens properly.

Desilting:
The flushing valve functions properly.
Desilting basin is clear of all debris.

Gates/Stop-logs:
They operate properly.

Testing and Commissioning of MHP 32

Penstock supports:
All the nuts on the straps are tightened properly.
There is no damage to the supports or anchor blocks.
Drainage arrangement around the anchor blocks
should not be blocked.

Penstock:
All bolts are tightened properly.
It has not sagged at any point.
Water is passed to remove any objects if present.
It should be pressure checked.
Testing and Commissioning of MHP 33
Turbine:
The turbine is well mounted and in good
operation.
Corrosion protection and paint are ok.
The ball bearings are well
lubricated.
The shaft is running smoothly,
there is no noise or vibration.
The turbine alternator alignment is ok.
All the nuts and bolts are properly tightened.

Testing and Commissioning of MHP 34

Alternator:
well mounted and in good condition.
Corrosion protection and paint are ok.
The ball bearings are well lubricated.
The shaft is properly coupled and running
smoothly.
There are no loose bolts.
The alignment with turbine is ok.
The ventilation system is not blocked.
The stator windings to terminal is properly
connected. Contd…

Testing and Commissioning of MHP 35

Contd…

All cabling is ok and fixed well.

The nameplate has correct information.
The insulation resistance is ok.
The continuity of each grounding circuit throughout
the system is ok.

Testing and Commissioning of MHP 36

 Transmission and Distribution
The resistance of all earthing system is within the
given limit.
There is excessive sag in any section.
The ground clearance of all transmission lines is
satisfactory.
The lightening protection system is in place.
The connections to transformer are properly
tightened.
The transmission line is clear of trees and branches.
Cut those too close to the lines(within 2 meters of
transmission lines).
All service wires are properly connected.
All poles are undamaged, vertical, and fixed properly.
Testing and Commissioning of MHP 37
Control panels:
Panels are properly fixed, doors and locks function
properly.
Paint is ok.
Earthing are done properly, screws and terminals are
right.
All cabling terminals, connections and wiring are ok
and there is no loose connection.
The general cabling layout is ok and there is no
damage.
Labels are well fixed, have the correct information and
are readable.
Wiring diagram are available. Contd…
Testing and Commissioning of MHP 38
contd…
All insulators are undamaged.
All connections to the insulators are properly made.
All joints and splices in the transmission are properly
made.

After above tests are found satisfactory:

Waterways are filled with water to taste overflow
system and the leakage.
All gates ,stop-logs ,penstock and flushing valves must
be operated to ensure their normal operating
conditions.
This test should be carried out for at least 24 hours
while canal remains full and some flow is spilling from
forebay. The system is monitored for any leakage and
damage. Testing and Commissioning of MHP 39
Commissioning and Performance Tests
 The turbine valve is opened slowly to start rotating the turbine at
low speed with generator connected.
 The unusual sound ,vibration ,etc are checked and if noticed,
should be investigated and rectified.
 The turbine speed is increased gradually to attain normal
operating speed.
 The generator excitation is ON with no load or with very small
load, for 2 hours. The temperature rise in bearings and alternator
windings are checked.
 The load on machine is increased in steps until maximum
output is reached. At every step, the system is allowed to reach a
steady state.
 The performance tests of machine is carried out by taking
readings at different loads.
 The flow pressure, turbine speed, bearing and winding
temperature, voltage, phase current and voltage drop should be
measured.
Testing and Commissioning of MHP 40
The different reading should be taken at steps of 20%
upto the rated power output of the plant.
In case of ELC, the power output may be increased by
increasing the water flow. The ELC automatically
switches on ballast to maintain the correct speed
The tests can be continued using blast load but it is
advisable to use external load.

Testing and Commissioning of MHP 41

 Setting up trips
The trips should be set up so that the plant can be
handed for use after the performance test of the
machine is found satisfactory.
The trips should be tested.
It is better to allow the trips to trip the circuit than
under set them.

Testing and Commissioning of MHP 42

 Rectifying Faults
The faults may be detected during commissioning
tests.
The severity of faults are assessed and amended.
The problems may be:
Serious problems:
It may be safety related and operational like machine
faults, inadequate spillways,etc.
Stop commissioning until rectified.
Ordinary problems:
Minor water leakage
Paint damage
It can be amended straight away.

Testing and Commissioning of MHP 43

 Endurance Tests
 The plant should be run for 24 hours after test is completed
to find out machine will give continuous and trouble free
service.
 It the test against vibration, noise, overheating, output loss,
deviations in frequency ,voltage and current.
 Any problems detected should be rectified.
 After completing this test successfully, the plant is almost
ready to be handed to the owner manager.
 It is recommended to continue the operation of the plant
for 2-3 days under the supervision of installers.
 The plant should be started ,stopped, load varied, flow
varied to monitor the overall operation and behaviour of
the power plant.
Testing and Commissioning of MHP 44
Testing and Commissioning of MHP 45
Testing and Commissioning of MHP 46
Testing and Commissioning of MHP 47
Testing and Commissioning of MHP 48
Testing and Commissioning of MHP 49
Testing and Commissioning of MHP 50
Testing and Commissioning of MHP 51
Testing and Commissioning of MHP 52
Testing and Commissioning of MHP 53
Testing and Commissioning of MHP 54
Testing and Commissioning of MHP 55
Testing and Commissioning of MHP 56
Testing and Commissioning of MHP 57
Testing and Commissioning of MHP 58
Testing and Commissioning of MHP 59
Testing and Commissioning of MHP 60
Testing and Commissioning of MHP 61
Testing and Commissioning of MHP 62
Testing and Commissioning of MHP 63
Thank You

Testing and Commissioning of MHP 64