Quarterly maintenance of generating units of Koteshwar HEP

All the 04 units of Koteshwar HEP were taken for quarterly maintenance/600hrs maintenance as per schedule. The sequence of activities is planned so as to contain the quarterly maintenance within 15 days. Under this, the main generating unit and all the unit & station auxiliaries were put under maintenance as per recommended activities in O&M manual, activities suggested by OEM/ BHEL Designer and also other need based activities. The schedule observed for different units is as follows: Unit Start date Finish date Running Hours Reason Upto Date 1 2 3 4 7.11.11 02.04.12 28.5.12 28.6.12 23.11.11 17.05.12 22.6.12 26.7.12 Start Delay Completion For in

Generator & Its Auxiliaries Main activities that were performed for the main generating unit i.e. generators are as follows: Thorough cleaning and Red gel Coating of stator windings ( upper & lower overhang winding portion) Thorough cleaning and Red Gel Coating of rotor poles, CC Leads, Interpolar connections Measurement of gap between spider and stopper, and between stopper & rotor rim plate Adjustment of gap of air baffle Tightening of oil pipeline of brake circuit Checking of Oil coolers & tightening.

Oil testing & Centrifuging of LGB & UGB oil. Checking of the entire fastener on Lower bracket, upper bracket, stator foundation, core, radial jack assembly etc. Checking of welding seams of rim wedges, spider covering, CC lead, Pole keys etc. Operation of limit switches of Brake system. Cleaning of filters of HS lube system

Before boxing up of generator, generator IR values are taken and entire winding area is carefully inspected for ensuring absence of foreign particle, inadvertent left out T&Ps. Thereafter, winding plates are closed followed by covering of TOP cover plates. Other equipment like Generator Transformer, LAVT,NG Cubicle and Bus Duct were cleaned for dirt depositions, tightening of Nut Bolt/fasteners, porcelain cleaning. Oil of Gen Transformer was tested for DGA, PPM and BDV. HV to LV, HV-E and LV-E IR values of Gen Transformer were taken after completion of work and before chairging. PTs in the LAVT cubicles were meggered before charging. Post insulators in the entire length of Bus-duct were cleaned with CRC, dried and Bus Duct was meggered before charging. Similarly in the Electrical Panels viz 415 V LT panels, Unit Control Board, Protection panel and Excitation Panel maintenance activities that were performed includes Vacuum air cleaning of Electronic Modules and Relays, cleaning of panel component & tightening of terminals of components & terminal block, tightening of bus bars. In LT switchgear particularly activities such as cleaning of breaker contacts, checking of arc chute for any carbon deposition, checking of interlocks, checking of selector switches were persuaded. All CT & PT connections were tightened and Auot/manual operation reaffirmed.

There are 02 nos of

Dry Type Transformers ( 13.8/0.415 kV and 11/0.415 kV )

associated with LT switchgear and 01 nos of Dry Type Transformer associated with Excitation system( Excitation transformer 13.8/0.490k, 1485kVA). These Dry Type Transformers were also taken under quarterly maintenance and they were cleaned along with tightening of bus bars, interconnecting links with busduct, checking of CT & PT connection, dressing of cables and tightening of terminals. Each of the Dry type transformers were meggerd before charging. After completion of all the scheduled activities, entire system on bus duct is connected i.e, bus duct, Unit auxiliary transformer, Excitation transformer and generator transformer and its IR value is measured. Unit was put on mechanical run and meggered on hourly basis. After achieving satisfactory PI values which usually comes after 10-15 hrs of run, the unit is connected from Line side with Bus duct. Thereafter Unit was excited and subsequently synchronised.

Turbine & Its Auxiliaries Major activities that were performed for the Turbine & auxiliaries i.e. H.P/L.P Compressed air system, Oil pumping unit(OPU),HMC governor, Cooling water system, Oil leakage unit (OLU), and Drainage and Dewatering pump station is are as follows:Turbine : Checking of water path in spiral casing for erosion / damage. Where ever the epoxy paint in the water path surface was peeled off ,same was repainted with black koltar epoxy paint. Checking of cavitation in guide vanes and runner. For inspection of runner a platform was erected beneath the runner inside the draft tube cone. Checking of top & bottom and bedding gaps in guide vanes. Checking of draft tube liner and unit dewatering grill, for inspection a ladder was installed from El 529.0 m to bottom of the draft tube at the elevation of 520.0m. from inside the draft tube cone.

Inspection of shaft seal. Turbine guide bearing oil leakage checking and filtering of Oil with portable oil purification unit. Testing of oil quality .

Governor

Checking of linking arms,pilot pins, adjustment screws for back lash, wear and breakage. Checking of wire rope and counter weights on return motion Lubrication of all swivel joints and friction parts of the governor with oil that is used for governing system. Cleaning of duplex strainers of the main distributing valve and pilot valve. Checking of oil level in gear box and replenish as per requirement Cleaning of pressure reducer filter.

Oil pressure unit (OPU)

Cleaning/checking of return filters. Cleaning of OPU tank and its filter assembly. Filtration of oil with portable oil purification unit. Checking of pump motor alignment and coupling bolts. Testing of oil in certified laboratory. Check the leaks in piping and tightening of all the fasteners.

Oil pressure accumulator

Checking of air and oil leakage. valve glands packing were changed and valve glands adjusted for arresting leakage through valve glands. If required valves were changed.

Oil leakage unit

Checking of coupling of pump and motor Cleaning of suction filter of gear oil pump.

H.P. Compressed air system

Cleaning/replacement of air filter. Inspection of crank case oil visually for contamination Cleaning of intercooler, after cooler and discharge line piping externally. Cleaning of cylinder block cooling fins. Checking of motor pulley alignment and belt tension. Checking of air leakages and tightening of all bolts. Checking of mounting bolts of compressor of air dryer unit Cleaning of condenser

L.P. Compressed air system

Cleaning/replacement of air filter. Checking of coolant level. Checking of discharge temperature of air, and separator element differential. Checking of air leakages and tightening of all bolts. Cleaning of wire mesh Checking of mounting bolts of compressor of air dryer unit Cleaning of condenser

Unit cooling water system

Cleaning ( back washing of cooling of filter strainers). Cleaning of shaft seal filters.

Unit dewatering and drainage pumping station

Checking and tightening of nuts and bolts of piping flanges and pump & motor. Checking of NRV operation. Checking of oil level in bearing housing of pump. Cleaning of ratchet assembly.

 Mechanical Spinning After completion of all the scheduled activities following course of activities are performed: Man hole inspection covers of draft tube and spiral casing are closed.

OPU unit is made ready for start up by filling the air and oil in the pressure accumulator vessel and maintain 63 kg/cm2 pressure Servomotor operation for opening & closing of guide vanes is checked in manual mode from HMC Governor Reference setting of governor operation is checked if required auto rod of HMC governor is adjusted. Water conductor path is filled from tailrace end and after checking for any leakages from the pipe line the upper path of the water conductor system was filled from HRT end.

Unit auxiliary transformer, Excitation transformer and generator transformer are connected into Bus Duct and IR value of entire connected system is measured. Generator Neutral terminal is connected and IR value of generator at 2.5kV at star point wrt earth is measured. Cooling water pipeline is charged and only stator air cooler water pipeline valve is closed for dry out run Unit was put on mechanical run and meggered on hourly basis (2,5kV, star point to earth). Values of 30 sec, 60 sec and 600sec are recorded. Temperatures of Thrust bearings, LGB, UGB,TGB and TB Oil reservoir is monitored After achieving satisfactory PI values (above 3.5) which usually comes after 1015 hrs of run, the unit is stopped.

Synchronisation

Generator links are connected at Line side with Bus duct.

Unit was excited and subsequently synchronised.