This technical audit report summarizes the findings of an audit of the Maneri Bhali Hydro Power Plant's Stage 1 and Stage 2 projects in Uttarakhand, India. The audit examined the plant's civil works, hydro-mechanical equipment, and electro-mechanical equipment. Key issues found include defective instrumentation, alarms, and automation systems across the plant's generators, turbines, governing systems, transformers, switchyard, and auxiliary equipment. The report provides over 80 detailed findings and recommendations to address deficiencies and improve plant operations and maintenance through replacement of worn parts, calibration of instruments, restoration of automation, and enhancement of record keeping.
This technical audit report summarizes issues found across various systems at the Maneri Bhali Hydro Power Plant. Key issues include: oil and water leaks across generator and turbine components needing repair; defective temperature sensors across units requiring calibration or replacement; non-functional auto-start, auto-synchronization, and governing systems in some units; and general illumination and equipment issues across control rooms, transformers, and switchyard requiring maintenance. The report provides a comprehensive list of specific maintenance and repair items to improve plant reliability and performance.
The document provides details on the scope of work for an EPC contract to design, engineer, procure, construct, erect, commission, and test a 10 MW biomass power plant. The broad scope includes supply and construction of a 48 TPH traveling grate boiler, turbo generator set, air cooled condenser, water treatment systems, piping, electrical systems, instrumentation, civil works, and commissioning. The contractor will also provide 2 years of operation and maintenance spares.
This Dairy Toolkit from Danfoss shown energy saving technologies and its application in dairy industries. It was used in the context of energy auditor training in Nepal in 2012 that was supported GIZ NEEP Programme.
The document describes water-cooled chiller units featuring oil-free turbocor compressors that use R1234ze refrigerant. The units offer high energy efficiency with class A EER up to 5.98 and excellent performance at full and partial loads with ESEER up to 9.87. They provide a green cooling solution utilizing a refrigerant with low global warming potential.
The document provides the procedure for start-up commissioning of the boiler for PLTU 1 Jatim-Pacitan (2×315MW) Project. It includes 10 sections that describe the purpose, scope, preparation, equipment details, tools, prerequisites, organization, commissioning procedure, safety measures, and appendices. The commissioning procedure involves checking conditions, valve testing, interlock testing, drying, boiling, pipe blowing, steam tightness testing, safety valve calibration, normal operation, and shutdown of the 40t/h oil-fired start-up boiler.
The document provides guidance on quality inspection procedures for low voltage switchboards. It discusses the justification and importance of quality inspection to ensure compliance with standards and customer requirements. The key aspects covered include incoming delivery inspection, in-process inspection during manufacturing, and final inspection. In-process inspection uses checklists to verify conformity after each production step is completed, while final inspection involves comprehensive checks of mechanical, electrical, and other characteristics before equipment is shipped. Maintaining rigorous quality inspection is important to reduce costs from defects, protect safety, and uphold the company's brand reputation.
The document discusses engine cooling system components and procedures for servicing them. It includes sections on general information, specifications, lubricants, sealants, special tools, troubleshooting, and procedures for checking the radiator, thermostat, water pump, hoses, and other components. The troubleshooting section provides charts to help diagnose issues like fans not operating or changing speed correctly.
SBIR, Low Cost High Performance State-of-the Art Phased Array Radar Coolingmartyp01
This document is the final report for Phase 1 of an SBIR project to demonstrate that a pumped liquid multi-phase cooling (PLMC) system using R-134a as the coolant is a superior alternative to a conventional ethylene glycol/water cooling system for cooling electronics. The report includes test results showing the PLMC system can cool a 54.4 kW load with an 84% lower coolant flow rate and 98% lower pump power requirements compared to the conventional system. It also finds the PLMC system has a smaller size, lower weight, and potential reliability advantages. Enclosures provide details on the system designs, test methods, and performance data for key components.
This technical audit report summarizes issues found across various systems at the Maneri Bhali Hydro Power Plant. Key issues include: oil and water leaks across generator and turbine components needing repair; defective temperature sensors across units requiring calibration or replacement; non-functional auto-start, auto-synchronization, and governing systems in some units; and general illumination and equipment issues across control rooms, transformers, and switchyard requiring maintenance. The report provides a comprehensive list of specific maintenance and repair items to improve plant reliability and performance.
The document provides details on the scope of work for an EPC contract to design, engineer, procure, construct, erect, commission, and test a 10 MW biomass power plant. The broad scope includes supply and construction of a 48 TPH traveling grate boiler, turbo generator set, air cooled condenser, water treatment systems, piping, electrical systems, instrumentation, civil works, and commissioning. The contractor will also provide 2 years of operation and maintenance spares.
This Dairy Toolkit from Danfoss shown energy saving technologies and its application in dairy industries. It was used in the context of energy auditor training in Nepal in 2012 that was supported GIZ NEEP Programme.
The document describes water-cooled chiller units featuring oil-free turbocor compressors that use R1234ze refrigerant. The units offer high energy efficiency with class A EER up to 5.98 and excellent performance at full and partial loads with ESEER up to 9.87. They provide a green cooling solution utilizing a refrigerant with low global warming potential.
The document provides the procedure for start-up commissioning of the boiler for PLTU 1 Jatim-Pacitan (2×315MW) Project. It includes 10 sections that describe the purpose, scope, preparation, equipment details, tools, prerequisites, organization, commissioning procedure, safety measures, and appendices. The commissioning procedure involves checking conditions, valve testing, interlock testing, drying, boiling, pipe blowing, steam tightness testing, safety valve calibration, normal operation, and shutdown of the 40t/h oil-fired start-up boiler.
The document provides guidance on quality inspection procedures for low voltage switchboards. It discusses the justification and importance of quality inspection to ensure compliance with standards and customer requirements. The key aspects covered include incoming delivery inspection, in-process inspection during manufacturing, and final inspection. In-process inspection uses checklists to verify conformity after each production step is completed, while final inspection involves comprehensive checks of mechanical, electrical, and other characteristics before equipment is shipped. Maintaining rigorous quality inspection is important to reduce costs from defects, protect safety, and uphold the company's brand reputation.
The document discusses engine cooling system components and procedures for servicing them. It includes sections on general information, specifications, lubricants, sealants, special tools, troubleshooting, and procedures for checking the radiator, thermostat, water pump, hoses, and other components. The troubleshooting section provides charts to help diagnose issues like fans not operating or changing speed correctly.
SBIR, Low Cost High Performance State-of-the Art Phased Array Radar Coolingmartyp01
This document is the final report for Phase 1 of an SBIR project to demonstrate that a pumped liquid multi-phase cooling (PLMC) system using R-134a as the coolant is a superior alternative to a conventional ethylene glycol/water cooling system for cooling electronics. The report includes test results showing the PLMC system can cool a 54.4 kW load with an 84% lower coolant flow rate and 98% lower pump power requirements compared to the conventional system. It also finds the PLMC system has a smaller size, lower weight, and potential reliability advantages. Enclosures provide details on the system designs, test methods, and performance data for key components.
This document provides guidance for carrying out pre-commissioning checks and tests for switchyard equipment at Power Grid Corporation of India Ltd. It outlines the constitution and responsibilities of the commissioning team, general safety procedures, documentation requirements, and pre-commissioning formats for recording test results. Specific guidance is provided for transformers, reactors, and other switchyard equipment such as circuit breakers, current transformers, surge arresters, and more. The aim is to ascertain the correctness and completeness of installation and healthiness of equipment before charging.
The alarms could indicate issues related to refrigerant charge levels like low or high pressure, which could be caused by low refrigerant, overcharging, or dirty coils. Other possible causes include problems with fans, filters, transducers, or economizer operation. Identifying the root cause of discrepancies between operating conditions and expected performance is important for fault detection and diagnosis of rooftop unit issues.
Ganesh Narendra Salvi is seeking a position as an Operation Supervisor - Engineer in the oil and gas sector. He has over 18 years of experience in control panel operations, process operations, and field operations in oil and gas plants, pipelines, and terminals in India and the Middle East. His experience includes monitoring equipment and processes, starting up and shutting down units, and ensuring safety systems are functioning properly.
The QuikSert turbine flow meter is designed for liquid applications requiring accuracy and reliability. It features a stainless steel body with a helical turbine and tungsten carbide shaft and bearings. The "between-the-flange" design eliminates the need for mating flanges, requiring less space and providing easy installation. Fluid passes through flow straighteners and the rotating turbine, with a magnetic pickup generating pulses proportional to flow rate. Optional electronics provide local flow rate monitoring and totalization compatible with various instruments. The meter is available in various sizes with pressure ratings up to 3,705 PSI and an operating temperature range of -150°F to 350°F.
Presentation on Meter Regulating Skid(MRS)harsitatpug
In this, natural gas is supplied through mild steel(MS ) and polyethylene(PE) pipelines to cater to the Natural gas demand in Domestic ,Commercial & Non-Commercial and industrial segments .
This document is a technical and service manual for split-type air conditioners. It provides information on:
- Model names and revisions made in the revised edition.
- Combinations of compatible indoor and outdoor units.
- Names and functions of outdoor unit parts.
- Electrical specifications and compressor technical data.
- Outlines and dimensions of the outdoor units.
- Wiring diagrams and refrigerant system diagrams.
- Troubleshooting procedures and disassembly process.
Turbophase utilizes reciprocating gas or diesel engines to drive an intercooled compressor and uses waste heat to heat the compressed air, increasing gas turbine output and efficiency by adding compressed air back into the combustion process. Field tests showed Turbophase modules increased gas turbine power by up to 9 MW and reduced heat rate by up to 1.7% through added compressed air injection. Turbophase systems are modular for flexibility, have simple integration with gas turbines, and demonstrated reliable power boosting and efficiency gains in both the Middle East and United States.
The document discusses several case studies of VRV heat pump installations in the United States. It describes projects like a 7,000 square foot installation at BlueHole Lodge in 2001, and renovations at Owensboro Christian Church and Daviess County Learning Center in Kentucky in the 2000s using Daikin VRV systems. It also summarizes installations at facilities like a Hilton Garden Inn in Texas, Staybridge Suites in Irving TX, and the Santa Fe A-Lofts hotel in Dallas.
Multistack International Limited is a global provider of modular chillers that are compact, flexible, and cost-effective. The document provides an overview of Multistack's history starting in 1985, their product range including water-cooled and air-cooled modular chillers, and their benefits such as being customizable to load requirements, high reliability with modular redundancy, and ease of maintenance.
This document contains the technical manual for split-type air conditioners. It includes 11 sections that cover: 1) part names and functions, 2) specifications, 3) data, 4) outlines and dimensions, 5) wiring diagrams, 6) refrigerant system diagrams, 7) troubleshooting, 8) function setting, 9) system control, 10) service data (parts name), and 11) optional parts. The manual provides specifications, performance data, diagrams, troubleshooting information, and other technical details for properly servicing the air conditioner units.
The document discusses steam turbine control and instrumentation. It describes various types of steam turbines including conventional cycle, combined cycle, and nuclear turbines ranging from 210MW to 800MW. It then discusses the aims of automation in steam turbines, including improved control quality, increased plant availability and efficiency. The document outlines the main subsystems of steam turbine control including control systems, monitoring and measurement systems, and protection systems. It provides details on an Automatic Turbine Run-Up System (ATRS) which automatically controls the start-up process. The ATRS utilizes functional group control philosophy and consists of sub-group controls, sub-loop controls, and drive interface controls. It also describes the turbine protection system and various tripping criteria to
Dekon , onf of the professional supplier and exporter for VRF system in China. Have exported to more than 30 different countries our products. Dekon vrf system brief introduction here just brief intro of our products DRV, any more info needed, pls visit us at dekon-china.com or chinavrf.com
Transformer vector group_test_conditionsSARAVANAN A
The document provides test conditions for various transformer vector groups including YNyn0, YNyn6, Dd0, Dd6, YNd1, YNd11, Dyn11, and Dyn1. For each vector group, 3 measurement conditions are listed that involve measuring voltages between different transformer terminals when voltage is applied to the HV side. The conditions are designed such that satisfying all 3 confirms the vector group by establishing the phase shift between the primary and secondary windings.
2016-01-21 Boiler Water Treatment Automation Project As-builtsAndrew Snider
This document describes the control logic for a boiler water treatment system. It contains information on blowdown control, chemical pump control, and the sequence of operations. For each boiler, blowdown time is calculated based on feedwater pump run time and a user adjustable multiplier. Chemical pump run time is also calculated based on feedwater pump time and a user adjustable multiplier. The system uses a timer to divide the day into sampling intervals, during which boiler parameters are monitored and chemical treatments are administered.
Gas Technology Institute, Boehlke Bottled Gas Corporation & AmeriGas - Statio...Wisconsin Clean Cities
Are you interested in the station installation guidelines for LPG? Learn about the basics guidelines, processes, and experiences of installing a LPG station.
Jatin Kumar Arvindbhai Patel has over 15 years of experience in project management, operations, maintenance, instrumentation, and control in industries including oil and gas, refinery, petrochemical, and power. He holds a diploma in instrumentation and is proficient in planning, engineering, commissioning, and executing large projects while meeting quality standards and KPIs. He has strong leadership skills and experience managing teams.
This document proposes installing a new differential pressure controller on the lubrication system for reactor 7 to reduce seal failures. The current system allows large pressure fluctuations that exceed the seal manufacturer's recommendations. The new system will use a digital controller to maintain a 50 psi differential between the lubrication pressure and reactor headspace pressure. This is expected to eliminate seal failures by preventing over-pressurization. The project will cost $24,020 and is estimated to save $149,788 annually by avoiding two seal failures per year.
Surge Control for Parallel Centrifugal Compressor OperationsVijay Sarathy
1. The document discusses different methods for controlling parallel gas compressors to prevent surge during varying load conditions.
2. The base load method operates one compressor at maximum flow while the other swings based on demand, but is inefficient and requires frequent intervention.
3. The suction side speed control and equal flow balance methods aim to control both compressors independently using a master pressure controller and additional elements, but have disadvantages related to complexity and control dynamics.
4. The equidistant to surge line method coordinates anti-surge and load sharing controllers to keep the operating points of both compressors equally distanced from the surge line to handle varying loads while preventing surge.
Mohan has over 9 years of experience as an Instrument Technician in oil and gas industries. He currently works for ADGAS in Abu Dhabi maintaining instruments for gas treatment plants. His responsibilities include calibration and maintenance of transmitters, valves, gauges and other process instruments to ensure accuracy. He is experienced with automation systems like Honeywell, Allen Bradley and GE. Mohan aims to upgrade his technical skills and career through challenging work in the field of instrumentation.
Mpc implementation for cdu (2002 nprc gcc)Yang Lee
This document summarizes the implementation of a multivariable controller for a crude unit at a Nippon Petroleum refinery in Marifu, Japan. The controller was implemented by Honeywell using their Profit controller software. The crude unit processes different crude types in different operating modes. A nonlinear model was used to develop 15 inferential measurements of product properties to use as inputs to the Profit controller. Two separate controllers were implemented, one for the crude unit section and one for the associated gas plant, for improved operation and maintenance. Initial results showed good control of product properties during normal operation and crude switches.
This document provides specifications for the MHRC-AE-060-VS-01 5-ton air-cooled chiller from Multiaqua. The chiller uses a variable speed scroll compressor and can operate in simultaneous heating and cooling mode. It has a brazed plate heat exchanger and variable speed condenser fans. Electrical requirements include a 380V DC primary supply and 208/230V AC secondary. Performance data is provided for cooling, heating and simultaneous heating/cooling modes.
In-Country Training
On
Operation, Maintenance, Protection & Control of 33/11 kV Substation
Project Name: Design, Supply, Installation, Testing & Commissioning of 33/11 kV sub-stations with source end feeder bays.
Contract No: BREB/UREDS/W-01A-001/02/2016-2017
BREB/UREDS/W-01A-002/03/2016-2017
BREB/UREDS/W-01A-004/04/2016-2017
This document provides guidance for carrying out pre-commissioning checks and tests for switchyard equipment at Power Grid Corporation of India Ltd. It outlines the constitution and responsibilities of the commissioning team, general safety procedures, documentation requirements, and pre-commissioning formats for recording test results. Specific guidance is provided for transformers, reactors, and other switchyard equipment such as circuit breakers, current transformers, surge arresters, and more. The aim is to ascertain the correctness and completeness of installation and healthiness of equipment before charging.
The alarms could indicate issues related to refrigerant charge levels like low or high pressure, which could be caused by low refrigerant, overcharging, or dirty coils. Other possible causes include problems with fans, filters, transducers, or economizer operation. Identifying the root cause of discrepancies between operating conditions and expected performance is important for fault detection and diagnosis of rooftop unit issues.
Ganesh Narendra Salvi is seeking a position as an Operation Supervisor - Engineer in the oil and gas sector. He has over 18 years of experience in control panel operations, process operations, and field operations in oil and gas plants, pipelines, and terminals in India and the Middle East. His experience includes monitoring equipment and processes, starting up and shutting down units, and ensuring safety systems are functioning properly.
The QuikSert turbine flow meter is designed for liquid applications requiring accuracy and reliability. It features a stainless steel body with a helical turbine and tungsten carbide shaft and bearings. The "between-the-flange" design eliminates the need for mating flanges, requiring less space and providing easy installation. Fluid passes through flow straighteners and the rotating turbine, with a magnetic pickup generating pulses proportional to flow rate. Optional electronics provide local flow rate monitoring and totalization compatible with various instruments. The meter is available in various sizes with pressure ratings up to 3,705 PSI and an operating temperature range of -150°F to 350°F.
Presentation on Meter Regulating Skid(MRS)harsitatpug
In this, natural gas is supplied through mild steel(MS ) and polyethylene(PE) pipelines to cater to the Natural gas demand in Domestic ,Commercial & Non-Commercial and industrial segments .
This document is a technical and service manual for split-type air conditioners. It provides information on:
- Model names and revisions made in the revised edition.
- Combinations of compatible indoor and outdoor units.
- Names and functions of outdoor unit parts.
- Electrical specifications and compressor technical data.
- Outlines and dimensions of the outdoor units.
- Wiring diagrams and refrigerant system diagrams.
- Troubleshooting procedures and disassembly process.
Turbophase utilizes reciprocating gas or diesel engines to drive an intercooled compressor and uses waste heat to heat the compressed air, increasing gas turbine output and efficiency by adding compressed air back into the combustion process. Field tests showed Turbophase modules increased gas turbine power by up to 9 MW and reduced heat rate by up to 1.7% through added compressed air injection. Turbophase systems are modular for flexibility, have simple integration with gas turbines, and demonstrated reliable power boosting and efficiency gains in both the Middle East and United States.
The document discusses several case studies of VRV heat pump installations in the United States. It describes projects like a 7,000 square foot installation at BlueHole Lodge in 2001, and renovations at Owensboro Christian Church and Daviess County Learning Center in Kentucky in the 2000s using Daikin VRV systems. It also summarizes installations at facilities like a Hilton Garden Inn in Texas, Staybridge Suites in Irving TX, and the Santa Fe A-Lofts hotel in Dallas.
Multistack International Limited is a global provider of modular chillers that are compact, flexible, and cost-effective. The document provides an overview of Multistack's history starting in 1985, their product range including water-cooled and air-cooled modular chillers, and their benefits such as being customizable to load requirements, high reliability with modular redundancy, and ease of maintenance.
This document contains the technical manual for split-type air conditioners. It includes 11 sections that cover: 1) part names and functions, 2) specifications, 3) data, 4) outlines and dimensions, 5) wiring diagrams, 6) refrigerant system diagrams, 7) troubleshooting, 8) function setting, 9) system control, 10) service data (parts name), and 11) optional parts. The manual provides specifications, performance data, diagrams, troubleshooting information, and other technical details for properly servicing the air conditioner units.
The document discusses steam turbine control and instrumentation. It describes various types of steam turbines including conventional cycle, combined cycle, and nuclear turbines ranging from 210MW to 800MW. It then discusses the aims of automation in steam turbines, including improved control quality, increased plant availability and efficiency. The document outlines the main subsystems of steam turbine control including control systems, monitoring and measurement systems, and protection systems. It provides details on an Automatic Turbine Run-Up System (ATRS) which automatically controls the start-up process. The ATRS utilizes functional group control philosophy and consists of sub-group controls, sub-loop controls, and drive interface controls. It also describes the turbine protection system and various tripping criteria to
Dekon , onf of the professional supplier and exporter for VRF system in China. Have exported to more than 30 different countries our products. Dekon vrf system brief introduction here just brief intro of our products DRV, any more info needed, pls visit us at dekon-china.com or chinavrf.com
Transformer vector group_test_conditionsSARAVANAN A
The document provides test conditions for various transformer vector groups including YNyn0, YNyn6, Dd0, Dd6, YNd1, YNd11, Dyn11, and Dyn1. For each vector group, 3 measurement conditions are listed that involve measuring voltages between different transformer terminals when voltage is applied to the HV side. The conditions are designed such that satisfying all 3 confirms the vector group by establishing the phase shift between the primary and secondary windings.
2016-01-21 Boiler Water Treatment Automation Project As-builtsAndrew Snider
This document describes the control logic for a boiler water treatment system. It contains information on blowdown control, chemical pump control, and the sequence of operations. For each boiler, blowdown time is calculated based on feedwater pump run time and a user adjustable multiplier. Chemical pump run time is also calculated based on feedwater pump time and a user adjustable multiplier. The system uses a timer to divide the day into sampling intervals, during which boiler parameters are monitored and chemical treatments are administered.
Gas Technology Institute, Boehlke Bottled Gas Corporation & AmeriGas - Statio...Wisconsin Clean Cities
Are you interested in the station installation guidelines for LPG? Learn about the basics guidelines, processes, and experiences of installing a LPG station.
Jatin Kumar Arvindbhai Patel has over 15 years of experience in project management, operations, maintenance, instrumentation, and control in industries including oil and gas, refinery, petrochemical, and power. He holds a diploma in instrumentation and is proficient in planning, engineering, commissioning, and executing large projects while meeting quality standards and KPIs. He has strong leadership skills and experience managing teams.
This document proposes installing a new differential pressure controller on the lubrication system for reactor 7 to reduce seal failures. The current system allows large pressure fluctuations that exceed the seal manufacturer's recommendations. The new system will use a digital controller to maintain a 50 psi differential between the lubrication pressure and reactor headspace pressure. This is expected to eliminate seal failures by preventing over-pressurization. The project will cost $24,020 and is estimated to save $149,788 annually by avoiding two seal failures per year.
Surge Control for Parallel Centrifugal Compressor OperationsVijay Sarathy
1. The document discusses different methods for controlling parallel gas compressors to prevent surge during varying load conditions.
2. The base load method operates one compressor at maximum flow while the other swings based on demand, but is inefficient and requires frequent intervention.
3. The suction side speed control and equal flow balance methods aim to control both compressors independently using a master pressure controller and additional elements, but have disadvantages related to complexity and control dynamics.
4. The equidistant to surge line method coordinates anti-surge and load sharing controllers to keep the operating points of both compressors equally distanced from the surge line to handle varying loads while preventing surge.
Mohan has over 9 years of experience as an Instrument Technician in oil and gas industries. He currently works for ADGAS in Abu Dhabi maintaining instruments for gas treatment plants. His responsibilities include calibration and maintenance of transmitters, valves, gauges and other process instruments to ensure accuracy. He is experienced with automation systems like Honeywell, Allen Bradley and GE. Mohan aims to upgrade his technical skills and career through challenging work in the field of instrumentation.
Mpc implementation for cdu (2002 nprc gcc)Yang Lee
This document summarizes the implementation of a multivariable controller for a crude unit at a Nippon Petroleum refinery in Marifu, Japan. The controller was implemented by Honeywell using their Profit controller software. The crude unit processes different crude types in different operating modes. A nonlinear model was used to develop 15 inferential measurements of product properties to use as inputs to the Profit controller. Two separate controllers were implemented, one for the crude unit section and one for the associated gas plant, for improved operation and maintenance. Initial results showed good control of product properties during normal operation and crude switches.
This document provides specifications for the MHRC-AE-060-VS-01 5-ton air-cooled chiller from Multiaqua. The chiller uses a variable speed scroll compressor and can operate in simultaneous heating and cooling mode. It has a brazed plate heat exchanger and variable speed condenser fans. Electrical requirements include a 380V DC primary supply and 208/230V AC secondary. Performance data is provided for cooling, heating and simultaneous heating/cooling modes.
In-Country Training
On
Operation, Maintenance, Protection & Control of 33/11 kV Substation
Project Name: Design, Supply, Installation, Testing & Commissioning of 33/11 kV sub-stations with source end feeder bays.
Contract No: BREB/UREDS/W-01A-001/02/2016-2017
BREB/UREDS/W-01A-002/03/2016-2017
BREB/UREDS/W-01A-004/04/2016-2017
The document summarizes the overhaul of field instruments for the TG701 gas turbine during a turnaround in 2015. Key activities included:
1. Removing 171 instruments according to the turbine dismantling process and calibrating them in the workshop before reinstalling with turbine reassembly.
2. Special preparations for modifications like installing new vibration probes at bearing 1 due to a rotor replacement, replacing transmitters for the control system upgrade, and installing a new shut-off valve outside the turbine compartment.
3. Replacing damaged devices like thermocouples, limit switches, and a level switch. Future recommendations focused on checking spare parts and developing test setups.
Operation and maintenance of distribution transformers is important to prevent failures and repairs. Key aspects include:
- Regularly check oil levels, insulation resistance, and test oil samples for breakdown voltage and acidity.
- Maintain clean bushings, tight connections, and functional protection devices like fuses and lightning arrestors.
- Common defects include oil leaks, overheating, and ineffective breathers. Causes may be corrosion, worn gaskets, overpressure, or inadequate ventilation/circulation.
- Proper maintenance following schedules can maximize transformer life and minimize failures in the distribution system.
The REXA Xpac X2L Linear Actuators allow for modulating duty cycle and precise positioning independent of load variation. Hydraulic pressure is generated by an internal positive displacement gear pump driven by a stepper or servo motor with no limitations on starts, stops, or reverse cycles. This self-contained electro-hydraulic system locks the cylinder in place when
no movement is required. This minimizes wear-and-tear on moving components and eliminates unnecessary power consumption.
The document provides an overview of the operation and maintenance activities at the Pirana substation. It discusses:
1) The key equipment at the Pirana substation including 400/220kV transmission lines, transformers, reactors, and GETCO substations connected.
2) Training and maintenance activities undertaken by the author including commissioning of a Nitrogen Injection Fire Protection system, relay testing, equipment repairs and inspections.
3) Operating principles and maintenance of key substation equipment such as circuit breakers, current transformers, voltage transformers, surge arresters and isolators.
This document summarizes the summer training report submitted by four students from Amritsar College of Engineering & Technology at the Punjab State Power Corporation Limited Transformer Repair Workshop in Amritsar. The workshop repairs damaged transformers to save costs compared to the private sector. It has two main circles and aims to repair 120 units per month. The report describes the workshop organization and sections for washing, repairing, drying, assembling, testing and storing transformers. It also explains transformer components, types, workings, efficiency tests and applications.
IRJET- Systematic Steps in Overhauling of a TransformerIRJET Journal
1) Overhauling a large transformer is a complex process that involves systematically draining the oil, removing internal components like the core and coils, cleaning them, performing inspections and repairs, and reassembling the transformer.
2) Key steps include draining the oil, lifting out the core and coils, cleaning the core with hot oil jets, inspecting windings and insulation, addressing any issues found, and lowering the core back into the tank.
3) The overhauling allows a thorough inspection and maintenance of all internal components to ensure the transformer continues operating safely and efficiently.
IRJET- Systematic Steps in Overhauling of a Transformer
Presentation-MB-1
1. TECHNICAL AUDIT REPORT
OF
MANERI BHALI HYDRO POWER PLANT
STAGE-I, 3X30 MW (MB-I)
&
STAGE-II, 4X76 MW (MB-II)
of
UTTRAKHAND JAL VIDUYAT NIGAM
LIMITED
BY:- Er. J S Pabla
2. TECHNICAL AUDIT REPORT
OF
MANERI BHALI POWER PLANTS
1. CIVIL WORKS
2. HYDRO MECHANICAL EQUIPMENTS
3. ELETRO MECHANICAL EQUIPMENTS
3. MEMBERS OF TECHNICAL AUDIT TEAM
1. Er.V.K.Kanjlia, Secretary/CBIP, & Former E.D./ NHPC
2. Er.V.K.Kapoor, Former E.D./ NHPC
3. Er.A.K.Sachdeva, Former E.D./ NHPC
4. Er.P.P.Wahi, Director/CBIP & Former C.E/BBMB
5. Er.A.C.Gupta, Director/CBIP & Former Executive
Member/Naravda Control Authority (NCA)
6. Er.J.S.Pabla, Advisor (Power) & Former C.E/BBMB
7. Er.Hakam Singh, Asstt. Manager (Technical)
4. REPORT ON MANERI BHALI POWER
PLANT STAGE-I (MB-I) - 3X30 MW
A. Generator
Excitation system: Automatic Voltage Regulator
(AVR) of all the units is on manual control. Auto
circuit needs to be resort.
Insulation Resistance (IR) recorded as 44.5 MΩ (15
Sec), 105.8 MΩ (60 Sec) & 366 MΩ (600 Sec) in
respect of unit-II is low. Heat run of generator may
be carried out and values recorded again.
At present status of brake pads is checked
physically before start of unit as most of the limit
switches provided for brakes “ON” & “OFF” lamp
indications are defective in respect of all the units.
Limit switches need replacement on priority.
5. Defective water flow relays for Upper Guide Bearing
(UGB), Lower Guide Bearing (LGB) & Thrust
Bearing (TB) of all generators need to be replaced.
Defective cooling water Pressure gauges of LGB of
unit-II & III need to be replaced.
Oil level High/Low indicating relays for UGB, LGB
& TB of all generators are defective & need repair /
replacement.
Auto circuit of braking unit for all machines is out of
order & brakes are applied manually at 25% rated
speed. Auto circuit needs to be restored.
Most of the RTDs provided for Stator Core, Stator
Winding, Cold Air etc. are defective.
6. TSD’s for Thrust Bearing (TB) showing
temperatures as 61ºC & 69ºC for Unit No.1
need to be calibrated/replaced.
TSD’s for UGB (Pad No.4), LGB (Pad No.3 &
7) & TB (Pad No.1 & 5) for Unit No.2 are
showing either high or low readings. Needs to
be calibrated/replaced.
Defective TSD’s for LGB pad number 3 & 5
showing temperatures as 12ºC and 40ºC for
Unit No.3 need to be calibrated/replaced.
Defective TSD for TB pad number 5 showing
temperature as 36ºC for Unit No.3 needs to be
calibrated/replaced.
7. B. Turbine
Heavy leakage of water observed from turbine gland
shaft seal & top cover of Unit No.2 & 3, needs be
rectified during annual maintenance.
Marking scale on servo motor (all units) showing the
position of guide vanes is missing.
Centralised Grease Lubricating (CGL) system
automation for all units is out of order.
CGL tank of Unit No.3 found empty. Needs to be
replenished with grease.
Auto system of ejector unit is out of order.
Alarm scheme for TGB oil sump, water flow relays &
CGL system needs to be made operative for all units.
Defective cooling water Pressure gauge of TGB of
unit-II needs to be replaced.
8. Oil level indicating relay for oil sump of Turbine
Guide Bearing (TGB) of Unit No.1 is defective.
Needs to be replaced.
Defective TSD for TGB Pad No.5 showing temperature
as 30°C for Unit No.3 needs to be calibrated / replaced.
Defective TSD’s for TGB Pad No.1 & 5 showing
temperatures as 42ºC and 35ºC respectively for Unit
No.2 need to be calibrated/replaced.
9. C. Governing System
Governing System: All the units are running on
manual mode. Auto mode needs to be restored on
priority.
In all units, leakage of oil from valves, lever pins etc.
on top cover of oil sumps of Oil Pressure Units
(OPU)
has been observed. Needs to be attended.
In all units, auto circuit of governor oil pumps for Oil
Pressure Unit (OPU) is faulty. Needs rectification.
D. Power Plant Control Room
At present all the units are synchronised with the grid
manually. Auto synchronisation though
commissioned needs to be made operative.
10. All the protective relays for units, transmission lines,
Bus-Bar etc. have been tested by Alsthom during
8/2014 but report still awaited. Needs to be expedited.
Faulty “Pole Trip Circuit-2 Supervision Relay C” for
220kV Bus-Coupler needs to be replaced.
Control & protection schematic drawings are required
to be displayed in the control room for the guidance
& knowledge of operational staff.
Air conditioning system not provided in the control
room. As static numerical relays are installed on
220kV transmission lines and Bus-Bar panels, A.C.
system needs to be provided.
11. E. Unit Transformers (T-1 to T-3)
Break Down Voltage (BDV) recorded as 40kV &
48kV in the first two shots for transformer T-3 is lower
than the recommended value of 50kV (minimum)
indicating that the transformer oil is not healthy &
needs to be filtered on priority. Due to same reason
Polarisation Index (PI) value (1.14) is also low which
may be due to higher content of water (PPM) in
transformer oil.
Minor oil leakage observed from valves, flanges,
Buchhloz relays etc. for all the unit transformers needs
to be rectified.
12. Oil cooler pumps for all the unit transformers are run
manually as per requirement and not on auto with
rise in temperature of winding. Auto running of
these pumps with the rise in temperature of
H.V.winding needs to be made operational.
Insulation Resistance (IR) in respect of transformer
T-2 recorded as 362 MΩ for both 15 Sec and 60 Sec
is same showing discrepancy in measurement. Needs
to be checked again during shut down to ascertain
the correctness of IR.
13. In case of transformer oil, only Break down Voltage
(BDV) is recorded. To check the overall quality of
transformer oil other tests such as Water content
(PPM), Resistivity, Acidity, Flash Point, Interfacial
Tension, tan delta, Pour Point, Dissolved Gas Analysis
(DGA) etc may be carried out annually during
summer.
Colour of silicagel in the breathers of transformers T-1
& T-2 found to be pink & needs to be reconditioned /
replaced.
Defective cooling water pressure gauge of transformer
T-1 needs to be replaced.
To rectify leakage of water observed from the oil
coolers of transformer T-1.
14. TSD’s provided for H.V. winding & oil temperature
of unit transformers T-2 & T-3 need calibration as
H.V.winding temperature is lower than the oil
temperature.
To protect unit transformers against any fire
incidence, Nitrogen Injection Fire Protection System
(NIFPS) is recommended.
Lighting lamps & heaters of Marshalling Kiosks
(MK) in respect of all unit transformers need to be
made operational.
F. D.C.Batteries
Temperature correction chart for specific gravity
needs to be provided in the D.C.Battery rooms of
Power Plant & Switchyard.
15. G. Unit / Station Auxiliaries
a) Fire Fighting
In order to prevent major fire hazard to the
equipments installed in the Power House Control
room and power & control cables in the cable gallery,
fire protective system is recommended to be provided.
Date of refilling of DCP /CO2 cylinders needs to be
marked on each cylinder. Records of refilling of
cylinders also be maintained for ready reference.
Portable DCP/CO2 cylinders placed at various
locations for fire fighting are inadequate. More
cylinders need to be placed at vulnerable places.
16. b) H.P. Compressors
Auto operation of H.P. compressor motors is faulty.
c) Dewatering & Drainage pumps
Level switches of Dewatering & Drainage pumps are
defective and hence, auto circuit of these pumps is
faulty.
d) Over Head Crane
Alignment of rail track for over head crane needs to be
checked & rectified.
For smooth running of cranes in parallel, complete
overhauling needs to be carried out.
Sparking & over heating of power cables observed when
cranes are in operation. Defective & undersized power
cables need to be replaced with XLPE / FRLS cables.
17. e) 11kV / L.T. supply Panels
Regular testing of oil & maintenance of 11kV MOCB’s
may be carried out pending replacement under R&M.
Fused lamps or defective assemblies of lamp indications
on 11kV MOCB’s need to be made operational.
Various lamp indications on L.T. panels / boards are out
of order & need to be made operational.
11kV MOCB’s room found very dusty. Needs regular
cleaning.
18. H. Switchyard
a) 220 kV System
Main isolators for Unit No.1 & 2 connecting to 220 kV
Bus-A are not closing properly and are at about 80
degree. Immediate alignment of these isolators is
needed.
Broken R-ph Surge counter of LA in respect of 220kV
feeder No.82 needs to be replaced.
b) Power Transformers 25MVA 220/33KV (T-1 & T-2)
Silicagel breather for Transformer T-1 is near the oil
level gauge of conservative tank which is approachable
only after switching off the unit transformer & providing
temporary earthing. Needs to be extended at
approachable height from the ground.
19. Colour of Silicagel in breathers of transformer T-1 &
OLTC of transformer T-2 found to be pink and needs to
be reconditioned / replaced.
Two number cooling fans of radiator of transformer T-1
found to be removed & need to be restored for proper
cooling of transformer oil.
TSD’s for oil & H.V. winding of both the transformers
need calibration.
c) Air Driers
Air driers provided for dryness of air for pneumatic
control of isolators are full of dust & web-cobs & needs
regular cleaning.
All the lamp indications on air drier panels of both the
air driers units not working. Needs to be made
operational.
20. d) 33 kV System
Regular testing of oil & maintenance of 33 kV
MOCB’s may be carried out pending replacement
under R&M.
At many places strands of 33 kV Main Bus conductor
found broken, repaired and even loose. 33 kV Main
Bus conductor for such sections needs to be replaced
on priority.
Conductor strands of number of 33 kV jumpers in 33
kV yard areas found broken / repaired. These need to
be replaced on priority.
21. e) Yard Area
Lighting provided in the yard areas is inadequate.
More lighting fixtures need to be provided.
Growth of wild grass observed in the yard area
which needs to be removed.
I. General
Illumination in most of the control & protection
panels, excitation panels, Governor panels,
Marshalling kiosk etc. at various floors/switchyard
not functional. Maintenance staff carries out day
to day maintenance activities with the help of hand
lamps. Fused lamps / tubes in panels need to be
replaced.
Number of Machine Hall tiles are badly broken/
damaged & require replacement.
22. J. Records/Manual
Maintenance schedule for each equipment needs to be
prepared. Maintenance needs to be carried out
according to these schedules & recorded/documented
in proper formats.
History Sheet of each equipment installed in the Power
Plant i.e. Name of equipment manufacturers,
Make, Type, Date of installation/commissioning,
Detail of major failures, repair & replacement
carried out etc. need be maintained.
Unit wise/equipment wise Fault record history i.e.
Detail of all faults occurred since its commissioning
along with time/date of occurrence, nature of fault,
Protection operated, analysis of fault, action taken to
restore the equipment, remedial measures taken etc.
need be maintained.
23. Maintenance Record of testing of various
equipment such as protective relays, power
transformers, transformer oil, generator, excitation
protection system, Breakers, Current Transformer,
Capacitive Voltage Transformer (CVT), Isolators
D.C. batteries, Unit/Station Auxiliaries need be
maintained / documented for ready reference.
Record of Maximum temperature recorded for
important parameters such as Power Transformer
oil & winding temp., UGB/LGB/TB/TGB/Stator
winding/stator core/ Hot/ cold air temperatures etc.
is available in log sheets. Same needs to be
maintained in a register for ready reference.
24. Operation & Maintenance Manual is required to be
prepared for the guidance of O & M staff, safe
operation & preventive maintenance of plant
equipment on priority. Important information included
in the Operation & Maintenance manual may be as
under:
General Layout
Details of civil structures
Hydro Mechanical & Electro Mechanical data of
various equipment installed
Starting/stopping sequence of unit
Control & Protection Relay Panels
Auxiliary Supply System
D.C. System
Governor, Excitation & synchronising scheme
25. 220 kV Sub-Station control
Protection, Signals & Annunciations
Maintenance Schedules for each equipment
Miscellaneous Operating Instructions
Trouble shootings, Possible Causes & their Remedies
Fire Protection System
List of Drawings & equipment manual
Civil Defence Measures etc.