398 - O & M Manual

PROJECT: LOWER ALEO HEP
(2x2.0MW + 30% COL)

LOWER ALEO HEP
(2 x 2 MW+ 30% COL)
CUSTOMER: M/s Baragarh Hydro Power Co. Pvt Ltd
OPERATION & MAINTENANCE MANUAL TURBINE
Supplier:
B Fouress (P) Limited – India

Plot No.7, P.B.No.11, KIADB Industrial Area, Hoskote – 562 114. Bangalore District, India.
Phone: 080-27971641 to 646. Fax: 080-27971455.
E-Mail: info@bflhydro.com. Web: www.bflhydro.com
Operating & Maintenance Doc No. : 398
B FOURESS (P) Page : Page 1 of 50
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Manual For Horizontal Full Rev. No. : 00
Kaplan Turbine Rev. Date : 05.08.13
Prepared By: JMR Approved By: PSN
PROJECT NAME : LOWER ALEO HEP

PROJECT NO. : 398
CUSTOMER : M/s Baragarh Hydro Power Co. Pvt Ltd
PROJECT DETAILS :
Description Particulars
Capacity of the Plant 2 Units x 2.0 MW + 30% COL
Project Location Lower Aleo HEP Located Near Lower Aleo
Prini, Tehsil Manali District, Kullu
Himachal Pradesh.
Country INDIA
SUPPLIER : M/s. B Fouress (P) Limited

Plot No. 7, Post Box No. 11
K.I.A.D.B Industrial Area,
Hoskote - 562 114,
Bangalore District, Karnataka, INDIA.
Phone: +91-80-27971641 to 646
Fax: +91-80-27971455
Email: info@bflhydro.com
Web: www.bflhydro.com
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Introduction
The Power House is situated near Lower Aleo prini tehsil, Manali district, Kullu,
Himachal Pradesh, India.
This manual covers installation, operating and maintenance for those
components supplied by M/s. B Fouress (P) Limited.
The items covered are:

1. Turbine unit consisting mainly of Inlet Casing, Guide Vane Operating
assembly, Runner chamber, Draft tube and Rotating assembly etc.
2. Turbine Guide Bearing Water lubricated.
3. Gear Box with lube oil system
4. Synchronous Generator.
5. The Hydraulic system required to operate the turbine runner blades and
guide vanes & brake.
6. Cooling water System
7. Drainage and De-watering system
The installation instructions contained in this manual are intended to serve only as
a reference outline for the procedures involved and are not exhaustive in scope or
detail. The actual installation must confirm to the conditions present at site at the
time of installation with allowances made for the tools, equipment and skilled
craftsmen which may or may not be available.
Each individual component of the turbine unit must be placed, aligned, anchored
and /or embedded only under the direct supervision of the BFL Field Engineer.
Improper alignment will have an adverse effect on turbine performance and
component service life.
Warning:
Before working with these turbo-generating units, read this entire manual and
all other manuals pertaining to the work to be performed. Follow all plant and
industry safety precautions. Failure to follow instructions can cause injury and
/ or property damage
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Salient Features of Lower Aleo Project
Sl.
No. Particular Specification
01 Type of Machine Horizontal Full Kaplan
02 Rating & no. of units 2 Unit of 2000kW
03 Max Power of Turbine 2778 kW
04 Runner Diameter 1600 mm
05 Overload 30%
06 Rated Head 22 m
07 Min. Head 19.5 m
08 Max. Head 23 m
09 Rated speed 430 rpm
10 Rated flow 11.03 m3/sec
11 Min. & Max. TWL elevation 1794 and 1795 msl
12 Max runaway speed (Turbine) 1293 rpm
Anticlockwise looking from
13
Direction of rotation (Turbine) Generator end
14 Max. Pressure rise 40%
15 Max. Speed rise 45%
10 sec normal & 8 Sec
16
Guide vane closing time emergency
17 Guide vane opening time 10 sec
18 Crane Capacity 25/5 T
19 GD2 in the system 15500 Kg-m2
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CONTENTS
Chapter 1 - Specifications
Chapter 2 - Description
Chapter 3 – Assembly of Components
Chapter 4 – Starting / Stopping Procedure
Chapter 5 - Maintenance procedure
Chapter 6 - Do’s & Don’ts
Chapter 7 - General Information.
Chapter 8 - Safe Operating conditions
Chapter 9 - Fault Diagnosis.
Chapter 10 - Health & safety at work
Chapter 11 – Tools & Tackles
Chapter 12 – Spares for Turbine

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CHAPTER 1 – SPECIFICATIONS
1.1 Turbine
Manufacturer M/s. B Fouress (P) Limited.

Type Horizontal full Kaplan
Rated net head 22 m
Rated discharge 11.03 m3/Sec
Rated turbine output 2137 kW at Rated head and discharge
Runner diameter 1.6 m
Rated speed 430 rpm
Unit centre line 1790.32 m
elevation
1.2 Turbine OPU
Supplier M/s Yuken India (P) Ltd

Pump / Motor rating 23 LPM / 5.5 kW
Tank capacity 300 Ltrs
Accumulator capacity 2 X 40 Ltrs
1.3 Generator
Supplier M/s. Crompton Greaves Ltd.

Type Horizontal Shaft Synchronous
generator
Output 2 MW
Rating 2222 KVA
Voltage between phases 3.3 KV
Rated Power Factor 0.90
Speed 750 RPM
1.4 Flexible Coupling (Between Gear box and Generator)
Make M/s. Esco Couplings & Transmissions

Pvt.Ltd.
Type ESCOGEAR FST 215 EM
1.5 Rigid Coupling (Between Turbine & Gearbox)
Make M/s. Elecon Peripherals Ltd.

Type Rigid
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1.6 Cooling Water Pump
Make M/s. Kirloskar Ltd

Type Monobloc
Pump / Motor rating 400 LPM / 14 M, 2.2 kW/3 HP
Model KDS 325 ++
1.7 De-watering Pump
Make M/s. Lubi Industries LLP.

Type Vertical Submersible Pump
Pump / Motor rating 1400 LPM /14 m / 10 HP
Model LAS 41035
1.8 Drainage Pump
Make M/s KIRLOSKAR

Type Vertical Submersible Pump
Pump / Motor rating 200 LPM / 14 m / 1.5 Kw
Model 1500CW
1.9 Turbine Bearing (Front Bearing)
Make M/s Thordon Bearing

Type / Size Thordon SXL
Type of cooling Water
Water Flow requirement 90Lpm
1.10 Duplex Filter
Make M/s AOF Filtration Systems (P) Ltd

Flow rate 600 LPM
Degree Filtration 300 Micron
1.11 EOT Crane
Make M/s TECHNO INDUSTRIES

Span length 15.55 m
Capacity 25 T / 5 T
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1.12 GEAR BOX with LOS
Supplier M/s. Elecon

Type Vertical offset Helical speed increaser
In put shaft speed 430 rpm
Output Shaft speed 750 rpm
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CHAPTER 2 - DESCRIPTION
2.1 General :
The turbine is of horizontal shaft of S-type Kaplan, with movable guide

vanes and runner blades. The water flow is regulated by adjusting the
angle of guide vanes and runner blades simultaneously. Thus, maintaining
fore bay water level within selected limits. The turbine shaft is coupled to
a Synchronous generator. Auxiliaries necessary for operation of the turbine
are also supplied, Gear Box, Lube oil system for gear box, including the
EOT Crane, hydraulic system, lubrication and cooling water & De-Watering
system.
2.2 Inlet Casing
Inlet casing is a fabricated steel body which guides the inflow of water to
the guide vane operating assembly. It has hub and four stay vanes
connected in between for transmitting loads. Upstream side of the inlet
casing is bolted to the Anchor frame. The downstream end is bolted to the
Outer guide vane casing of guide vane operating assembly.
WARNING: Ensure all the man holes are closed before starting the
turbine.
2.3 Guide vane Operating Assembly
Guide vane operating assembly consists of outer casing, inner casing,

guide vanes and regulating ring assembly. Outer casing is a fabricated
steel cone which guides the inflow of water to the turbine runner. Between
the outer and inner casings, radially arranged are the 24 no. of guide
vanes to direct the water against the runner blades. A cast steel bulb
(Inner Casing) is fastened to inlet casing which closely matches the inner
radius of the guide vanes. The inner casing contains a bearing housing for
a water lubricated Turbine guide bearing which carries the upstream end of
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the front bearing shaft. The outer casing is fastened to the inlet casing on
upstream side and to the runner chamber on the downstream side.
WARNING: Ensure proper connection of hydraulic hose pipe between

cylinder and OPU.
2.4 Runner Chamber Assembly:
Runner chamber is fabricated from Stainless steel. It comprises of two

identical cylindrical halves joined at the flange (split flange) longitudinal to
the centre line on each side. The inner surface is machined to hemispherical
shape to form hydraulically advantageous contour which closely fits the
radius of the runner blades. The downstream end is connected to the draft
tube suction cone flange via a sliding joint (slip flange) which can be split
horizontally.
2.5 Draft Tube:
Draft tube is fabricated from steel plate with welded steel external stiffening
ribs. It consists of cone, bend and tail piece. The upstream end the draft
tube (cone) is bolted to a slip-flange which fits over the down stream end of
runner chamber. At the downstream, the draft tube bends downward,
widens out and finally discharges through an un-valved rectangular opening
into a concrete conduit leading to the tailrace. A flanged opening is
provided on the upper curved surface (bend) of the draft tube to allow
protrusion of the turbine shaft from the draft tube in order to couple turbine
shaft with the generator. A manhole is provided on the top of the suction
cone of the draft tube just downstream from the runner chamber.
WARNING: Ensure all the man holes are closed before starting the turbine.
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2.6 Shaft Seal
The non-asbestos gland packing controls leakage around the turbine shaft.
The shaft is provided with a P. Bronze Sleeve. Gland packing and lantern
ring are placed over the turbine shaft sleeve and secured in stuffing box
housing against header ring.
The stuffing box will have connection for supply of clean, filtered water to
lantern ring and the leakage collected in the water box will be discharged to
drain. This design makes the replacement of the gland packing easy.
WARNING: Ensure leakage proof piping from shaft sealing assembly to
Draft Tube / Drainage Sump.
2.7 Hub and Runner
Runner has four cast Stainless steel blades and carbon steel hub and
associated internals (crank, piston rod, piston, bearings, seals etc.).One
end of hub is connected to front bearing shaft and the other end to turbine
shaft. The flowing water imparts high mechanical force to the runner blades
which rotates the runner in turn the turbine shaft connected to it.
Ultimately, the rotating shaft will drive the generator connected to turbine
shaft through coupling, thereby producing electric power. The
hydrodynamic profile of the runner blades are designed to maximise the
transfer of energy to each blade as water flows over it, and this accounts
for the very high efficiency of the BFL turbine unit. The blades are firmly
mounted on movable cranks which are located in the hub body. These
cranks are internally connected to the piston rod at one end and the piston
will be mounted at the other end of piston rod. Piston will be located inside
the Piston cylinder (Front bearing shaft forms the blade regulating servo
motor). Pressure is applied to the piston through control tubes to move the
piston rod which rotates the crank & in turn the runner blades. The blade
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regulating servo motor will be operated at an oil pressure of about 50 - 80

Kg/cm2 which can be supplied to the rotating parts via an oil head
assembly. The regulating forces are transmitted through piston rod to the
cranks connected to the runner blade flanges. Each blade flange is fitted
with double acting seals. This arrangement prevents both oil leakage from
the hub and water leakage into the hub. A mechanical position indicator
attached to the control tube / Oil head assy. indicates runner blade pitch by
showing the IN-OUT position of the control tube relative to a graduated
scale mounted on the oil collector tank cover.
WARNING: Ensure proper connection of hydraulic hose pipe between hub
and OPU.
2.8 Turbine Shaft
The turbine shaft is of forged steel connecting the runner with the
generator. The upstream end of the shaft is connected to the hub body and
the downstream end is rigidly coupled to the drive end of the generator
shaft by means of a torque transmission type of coupling. The turbine shaft
is fitted with a replaceable P. Bronze Sleeve which provides a wearing
surface for the shaft stuffing box gland packing.
WARNING: Any connections made with turbine shaft, either directly or
indirectly, such as coupling, fasteners, flanges, etc., must be inspected for
slippage and loosening. Corrective actions be taken if required.
2.9 Oil Head Assembly
Its function is to control runner blade angle. This is provided with pressure
relief valves to release the leakage oil under pressure. It is important to
ensure that these pressure relief valves are properly set at the required
pressure and not tightened fully. Oil collector tank is provided to collect the
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leakage oil. M/s FAR Hydraulics rotating union is connected to the end of
control tube which allows the oil for opening or closing port as required.
WARNING: It is not advisable to run the turbine when the runner
blade servo motor is hunting.
2.10 Guide Bearing
Turbine guide bearing is water lubricated bearing fitted at the upstream of

the runner in guide ring which bolted to inner guide vane casing. Clean
filtered water is supplied to the bearing for lubrication and flushing. The
bearing is designed to take the radial load of the turbine. The bearing is
accessible from manhole provided at the upstream end of the inlet casing
for maintenance & inspection.
Warning: It is not advisable to run the turbine without cooling

water to the bearing
2.11 Hydraulic System: Ref. O&M manual provided by M/s Yuken India Ltd for
detailed information. The hydraulic system operates both the runner blade
servo motor, guide vane hydraulic actuator & generator brakes. Pressure
through out the system is continuously maintained at a pre-set level. This
system is provided with accumulator (Piston type) of sufficient size for
emergency shutdown of turbine. Solenoid operated Directional control
valves within the hydraulic system are electrically interconnected with the
electronic governor to operate and set the pitch of the runner blades as well
as to set the guide vane position.
Warning: The operating pressure of the system should not exceed

90 bars. Accumulator charging pressure should be 38 bars.
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2.12 Cooling Water System:
Cooling water pumps the water from the cooling water sump and supplies
to the turbine guide bearing, stuffing box & Bearing LOS heat exchanger.
Filtered water is provided continuously to the turbine guide bearing and to
the floating stuffing box gland. Water coming out from the Bearing LOS
heat exchanger is pumped out to the tailrace. A set of flow switches and
gate valves are provided in turbine guide bearing & Bearing LOS water
supply line. It is important to ensure the continuous supply of water to the
turbine guide bearing & Bearing LOS heat exchanger. It is not at all
advisable to run the turbine without cooling water supply to turbine guide
bearing & bearing heat exchanger. Frequent cleaning of strainers is
required to supply clean water. Failing to supply clean filtered water,
diminishes the life of turbine guide bearing.
WARNING: It is not advisable to run the turbine without cooling
water to turbine guide bearing & Generator LOS.
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2.13 Lubrication Oil system for Gear Box:
Lubrication Oil System to provide safe and reliable lubrication oil supply to
Thrust & Guide Bearing.
It consists of Lubrication oil storage tanks within the gear box with three
operating Pumps incorporated with two continuous duty AC Motors for
normal duty of operation one will be labelled as Main Motor and the other as
standby motor the priority can be reassigned after completion of their pre
assigned run hours and one Short time rated DC Motor powered by station
DC Battery system for Emergency backup duty of operation under both AC
Motors fails or the Station AC supply fails.
Built On pump takes over the oil supply once gear box reaches rated speed.
Suitable instrumentation are provided for proper operation.
WARNING: It is not advisable to run the LOS without cooling water

supply.
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CHAPTER 3 - ASSEMBLY OF COMPONENTS
3.1 Turbine:
The draft tube is assumed to be installed, fully embedded and the top
face of the suction cone is correct in the vertical and horizontal planes.
3.1.1 The suction cone is then handed over for concreting. Ensure
proper embedment with minimum distortion & misalignment.
Allow sufficient time for curing before runner chamber is erected.
3.1.2 Lower the runner chamber on the suction cone. Ensure top
flange face of runner chamber is correct in both vertical &
horizontal planes. Align the runner chamber with the given
centre line of the runner & maintain its top elevation as per
drawing. Check the elevation using precision levelling
instruments. Weld runner chamber with suction cone.
3.1.3 Clean the top flange of runner chamber. Lift the stay ring -
Operating gear assembly & place it on runner chamber by using
an EOT crane. Align the assembly with respect to the turbine
centre line & maintain its top elevation as per drawing. After
checking the alignment all the bolted joints are torque tightened
& foundation bolts are bolted to stay ring pedestals.
3.1.4 The runner chamber & stay ring assembly is then handed over
for concreting. Allow sufficient time for curing.
3.1.5 Construct a platform inside suction cone (for maintenance
purpose).
3.1.6 Assemble the blades & turbine shaft with the hub assembly. All
the bolted joints are torque tightened as per drawing values.
3.1.7 Lift the total rotating assembly by EOT crane & place it on the I-
beams constructed in the suction cone with proper supports.
Align the turbine shaft & runner blade assembly with respect to
runner chamber as per drawing. Check & ensure the verticality of
the shaft. After confirming the alignment of the blade with
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respect to runner chamber & the verticality of the shaft, the total
turbine shaft assembly is properly arrested in the position by
temporary supports.
3.1.8 Place the guide vane servo cylinder in position. Connect
regulating ring & servo cylinder. Ensure that the servo cylinder
rod is extended completely in guide vane closed position.
Operate the cylinder & check for smooth operation of cylinder &
proper guide vane openings.
3.2 Inner Top Cover & Gear Box :
3.2.1 Lift the inner top cover and place it on the outer top cover, align
it. After completion of alignment, the inner and outer cop covers
are bolted, torque tightened.
3.2.2 Clean the turbine shaft assembly. Loosely assemble stuffing box
and turbine guide bearing assembly in position on the turbine
shaft.
3.2.3 Complete the Gear Box installation as described in the Gear Box
O & M manual.
3.2.4 Align the gear box low speed shaft with turbine shaft & tighten
the flange bolts with torque wrench.
3.2.5 Assemble the Turbine guide bearing (Thordon) as explained in
the Bearing O & M manual.
3.2.6 Assemble the Stuffing box as per drawing.
3.2.7 Finally confirm the alignment of turbine shaft, guide bearing and
stuffing box assembly with proper clearances for free shaft
rotation as specified in the drawing. After proper alignment of
guide bearing and stuffing box, they are locked in position bolted
& doweling of guide bearing assembly to inner top cover as
mentioned in the drawing.
3.2.8 Push the complete assembly of control tube inside the gear box
low speed shaft bore. Lock the control tube assembly by
tightening the lock nut against the piston.
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3.3 Oil Head Assembly:
3.3.1 Secure the bushing for oil head assembly to gear box shaft.
3.3.2 Slide the Hydraulic union assembly & bolt it to control tube oil
head section.
3.3.3 Place the oil head cover / box in position.
3.3.4 Mount the indicator plate on the cover.
3.3.5 Connect oil hoses / piping from turbine OPU as mentioned in the
drawing.
LIMITED
CHAPTER 4 - STARTING / STOPPING PROCEDURE
4.0 Electrical:
CHECK LIST FOR TRANSFORMER

• Bochholz relay
• Oil level in conservator
• Colour of silica
• IR of winding and core
• BDV of oil
• OTI & WTI
For More Information refer O & M manual supplied by M/s CGL
CHECK LIST FOR SWITCH YARD

• Earthing switch Operation
• Isolator Operation
• Line Isolator Operation.
CHECK LIST FOR GENERATOR:

• AVR condition/excitation shall be in good condition
• DC supply for field flashing
• IR values
• Lubrication of bearings
• Check earth link for XLPE cables
• All the protective relays (86C/86B)faults are reset/normalised/maintained in
healthy condition
PLANT OPERATION PRIOR TO UNIT START/STOP
1. Switch on the 110V DC Feeder MCB’s of all the panels in Battery charger
panel.
2. After confirming the grid availability
Check the Line Voltage in all the 3 phases
LRMP
3. Before closing HT Breaker (Line Breaker) ensure for the following
 Line earth should be in open condition.
 Line Isolators should be in closed condition.
 HT Breaker spring should be charged.
 Local/Remote Switch in Remote.
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 Clear all the alarm/trip signals.
 Reset the 86L relay.
4. Close HT Breaker (Line Breaker) from LRMP.
TRMP
5. Before closing HT Side Trafo. Breaker (Trafo. Breaker) ensure for the
following
 Trafo. Isolator should be closed condition.
 HT Side Trafo. Breaker spring should be charged.
 Local/Remote Switch in Remote.
 Clear all the alarm/trip signals.
 Reset the 86 T relay.
6. Observe Transformer for healthiness. any abnormal soundness
7. Check the Generator Breaker is in Open condition
8. Close HV Side Trafo. Breaker from TRMP.
LTAC PANEL
9. Check the LV Side Breaker (EB Incomer is in OFF)
10.Check for Aux. Transformer healthiness.
11.Check the 33kV Isolator (HV Side Isolator of Aux. Trafo.) is closed.
12.Check the Phase & Neutral Voltage in all the 3 phases in EB incomer
13.There are 2 incoming MAIN supply in LTAC Panel
 EB Incomer
 DG Incomer
14.There are two mode operation in LTAC
 Manual
 Auto (Close/Open from DG Panel)
15. IF Operator select Auto mode operation
16. Select the Auto Mode in the Manual/Auto Selector Switch
Following operation will operate automatically thru PLC
 IF EB incoming supply will be healthy and voltages in all the phase
are within the limits EB MCCB will close.
 IF EB Incoming supply unhealthy or trips EB incomer MCCB will
trip and start DG incomer healthy, DG MCCB will close, IF EB
incomer supply will restores then DG breaker will open and EB
MCCB will close, DG will stop automatically after 1 min.
17. IF Operator Selects Manual mode operation
 Select the Manual Mode in the Manual/PLC Selector Switch.
 IF EB supply will be healthy and Check voltages in all the phase
are within the limits,
 Before closing EB MCCB ensure DG MCCB should be in off
condition.
 Close the EB Breaker by pressing EB Breaker Close Push button
 IF EB Incomer unhealthy, EB breaker trip
 Start the DG by pressing the DG Start PB
 Once DG incomer healthy and Check voltages in all the phase are
within the limits,
 Before closing DG MCCB ensure EB MCCB should be in off
Condition.
 Close the DG breaker by pressing DG Breaker , IF EB incomer
supply restores then OPEN DG breaker manually and follow the
above steps of manual operation for EB Incomer Close Operation.
Then Stop the DG set by pressing DG stop PB after 1 min idle run.
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4.1 START Procedure:

4.1.1 Make sure Intake gate is opened for respective unit to be started.
4.1.2 HMI screen Navigate to Manual mode screen, start the Auxiliary one
by one from LTAC Panel.
4.1.3 Reset the Alarm in the annunciator if any. Make sure there is no Alarm
in the Annunciator.
4.1.4 Prestart Condition to be ensured in the HMI before start of the
machine. Check if any prestart condition is not satisfied like Pressure,
Temperature and Oil levels for the auxiliary system present in the
plant. Check Prestart condition OK Indication on TGRMP.
4.1.5 Press all RESET buttons once.
4.1.6 Press SYSTEM RESET button available in the manual mode screen.
4.1.7 Press SYSTEM START button available on the Panel.
4.1.8 Make sure the guide vane is at zero position and Runner Blade is at
zero Position.
4.1.9 Close the Runner Blade up to position 15% by pressing button in the
manual mode screen.
4.1.10 Slowly open the guide vane pulse by pulse by pressing Button in the
manual mode screen maintaining a gradual speed raise.
4.1.11 At the RPM 387 Switch ON the Excitation through AVR ON PB, during
this time try to maintain the rated speed as it tends to go down and
cause trip Under Frequency from protection relay if RPM not
maintained.
4.1.12 Bring it to rated RPM, once the SPMD is on and try to regulate the
speed based on SPMD speed raise and lower signal indication from
SPMD.
4.1.13 When the voltage and frequency parameters are matched and SPMD
gives a synch permit signal and Breaker closes automatically and soon
the breaker Closes, OPEN THE GUIDE VANE UP TO BASE LOAD 313
KW which is very important.
4.1.14 Further to the operation based on the load mode & Position mode and
follow the cam relation chart available with you for efficiency and
smooth operation.
4.2 Manual MODE NORMAL STOP Procedure:

4.2.1 When decided to stop the machine, De load the machine to the base
load.
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4.2.2 Follow the CAM relation chart to de load the machine through Guide
Vane and Runner Blade push button which is present in Manual mode
screen.
4.2.3 Whenever Machine reaches the Base Load, Activate Emergency
button to trip the breaker and machine to stand still.
4.3 Procedure for starting the machine in AUTO MODE.

4.3.1 Make sure Intake gate is opened for respective unit to be started.
4.3.2 Place the Auto Manual selector switch in Auto position.
4.3.3 HMI screen Navigate to Auto Mode screen, start the auxiliary with
the button Auxiliary START.
4.3.4 Reset the Alarm in the annunciator if any. Make sure there is no
Alarm in the Annunciator.
4.3.5 Prestart Condition to be ensured in the HMI before the start of the
machine. Check if any prestart condition is not satisfied like
Pressure, Temperature and Oil levels for the auxiliary system
present in the plant.
4.3.6 Press System START button in the same auto mode page.
4.3.7 The behaviour is as observed.
4.3.7.1 The Runner blade closes till 15%.
4.3.7.2 The guide vane starts to open slowly till the rated RPM and
matches the frequency at a point and breaker closes and guide
vane open till base load when the breaker is closed.
4.3.8 Once it reaches base load. Switch to Load mode or position mode
present in the HMI for operating machine in respective control Mode.
4.3.8.1 Position Mode: Activate the button on the screen named as
Control Mode.
Enter the position set point of Guide Vane to which the machine
has to Operate and click Confirm the position mode, RB gets
adjusted to CAM relation automatically.
4.3.8.2 Control Mode: Activate the button on the screen which is
placed in Position Control mode.
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Enter the load set point value and click confirm button and load
reaches the set point.
4.3.8.3 Level Mode: In Level Mode Operator can set the Water level to
maintain the load and Guide Vane position will vary accordingly.
4.4 Normal Stop Operation for Auto Mode

4.4.1 When decided to stop machine, a normal stop, just click system stop
button on the screen Auto Mode which ever load it is.
4.4.2 It slowly reaches to base load by de-loading automatically and then
trip the breaker and machine & when machine reaches to 10% speed
apply the brake. Once the machine is stopped, after 15-20 minutes
all the auxiliary should be switched off.
To start the machine Next Time Repeat the steps following from 1 in the steps
mentioned in Start procedure for Automatic.
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CHAPTER 5 - MAINTENANCE PROCEDURE
General:
The turbine and generator are designed to function reliably for long
periods of time without maintenance. However, periodic inspection of the
following items is the best recommended practice.
5.1 Daily Inspection
5.11 Check continuous flow of water to turbine guide bearing and

stuffing box gland packing.
5.12 Check for vibration, noise and loose parts.
5.13 Check for cooling water pressure at delivery.
5.14 Check Leakage rate at stuffing box. If the leakage is more,
tighten the header ring uniformly to reduce the leakage.
5.15 Check for the water level in de-watering sump and
operation of de-watering pumps.
5.16 Check for leakage of valves, oil piping and take necessary
steps to stop the leakage.
5.17 Check for the oil level in turbine OPU tank.
5.18 Check for the hydraulic pressure at various points of turbine
OPU.
5.19 Check the generator rotor temperature.
5.20 Check for generator bearing temperature.
5.21 Check the oil level in generator DE & NDE Bearing.
5.22 Check the generator bearing temperature
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5.2 WEEKLY MAINTENANCE SCHEDULE
TURBINE:
5.2.1 Greasing at required places

5.2.2 cleaning of the equipment
GENERATOR:
5.2.3 Cleaning of the equipment and its auxiliaries

5.2.4 Flexible coupling has to be greased once in fifteen days
OPU AND BEARING LOS:
5.2.5 Clean the equipment.

5.2.6 Check the Nitrogen pressure if less refill (once in 30 Days)
5.2.7 Test the oil contamination level if required start the online filtering
5.2.8 Check the oil level if required fill / top up the oil
COOLING WATER SYSTEM & FIRE FIGHTING SYSTEM:
5.2.9 Clean the equipments

5.2.10 Check the pressure if found any choking in the filters clean the
same
5.2.11 Drain the filter and clean it
BATTERY:
5.2.12 Clean the equipments, apply petroleum jelly wherever is necessary

and check the terminal tightness
TRANSFORMERS: (only at the shutdown period)
5.2.13 Clean the equipment’s, apply petroleum jelly wherever is necessary

and check the terminal tightness
5.2.14 Check the Silica gel condition at the Breather clean it or replace if
necessary.
LIMITED
5.3 Standard Schedule for Maintenance of Power Transformers
5.3.1 Daily/ each shift
5.3.1.1Checking of oil level

5.3.1.2Checking of Silica Gel in the Breather
5.3.1.3Recording of OTI and WTI Temperature.
5.3.1.4Checking of oil leakage in the transformer
5.3.2 Monthly/ shutdown
5.3.2.1Cleaning of Bushings
5.3.2.2Checking / Replacement of silica gel
5.3.2.3Release Air form the Main Tank , Ensure oil that comes out through
air release valve
5.3.2.4Inspection of vent holes ( vent holes should not be blocked)
5.3.2.5Checking of insulation resistance of winding
5.3.2.6Checking of Temperature /Bucholtz relay alarm operation
5.3.2.7Record / Checking of oil level in Bucholtz relay
5.3.3 HALF YEARLY
5.3.3.1Testing of BDV and HV Test of oil from main tank & Conservator
5.3.3.2Checking of Bucholtz relay for gas collection
5.3.3.3Testing of Insulation Resistance of the winding
5.3.3.4Checking of earthing resistance of the Transformer
5.3.4 YEARLY
5.3.4.1Calibration of Temperature indicators

5.3.4.2Testing of oil for acidity
5.3.4.3Testing of oil for complete analysis test.
5.3.4.4Checking of Bucholtz relay by air injection for getting alarm
5.3.4.5Tap changer overhaul- checking of contacts , oil acidity tests &
filtering / changing of oil if results not satisfactory
LIMITED
5.3.4.6 Overhaul of Transformer if necessary
5.4 Monthly Inspection
5.4.1 Check the cleanness of cooling water and clean the strainers as
and when required.
5.4.2 Check the adequacy of grease in ball bearing of regulating ring
assembly. If required apply it through the grease nipples
provided in the retaining plate.
5.4.3 Check the grease lubrication of servo motor foot mounting
bracket and at the clevis pin and apply grease if required.
5.4.4 Check hydraulic oil level in the sump tank for both turbine OPU &
Bearing LOS. If required, add clean, filtered oil to maintain
the level of oil as per manufacturer’s recommendations.
5.4.5 Check the cleanness of oil and clean the filters and strainers
both in turbine OPU & Bearing LOS
5.4.6 Check the lubrication Oil level in generator bearings.
5.5 Annual Inspection :
Annual inspection is recommended for effective maintenance and to

take preventive action of the generating equipment.
5.5.1 Shut down the turbine unit and lock-out the control stations.
5.5.2 Close the intake and tail race gate.
5.5.3 De-water the turbine hydraulic passage.
5.5.4 Remove the man hole covers in the draft tube and inlet casing.
Remove the inlet casing end cover and inspect the following
a) Runner Blade tip clearances when blades are in fully closed
condition.
b) Runner blade condition and its securing to crank.
c) Guide vane condition and clearances.
d) Turbine guide bearing condition and clearances.
LIMITED
5.5.5 Check that all the guide vanes are touching nose to tail when
servo motor is in closed position.
5.5.6 Check guide vane operating mechanism for play and smooth
movement of regulating ring.
5.5.7 Replace gaskets in manhole covers using new gaskets.
5.5.8 Inspect stuffing box packing and adjust glands or change with
new packing if required.
5.5.9 Inspect all gaskets, seals and ‘O’ rings and replace them
wherever required.
5.5.10 Drain Bearings lube oil, clean the tank and fill it with the new
filtered oil.
5.5.11 Inspect all auxiliary pumps, motors and valves, tighten loose
connections.
5.5.12 Drain oil from hydraulic system and thoroughly clean the oil
tank to remove dirt, sediments, sledges, etc.
5.5.13 Clean or replace all oil/water filters.
5.5.14 Carry out general cleaning of all equipment and piping.
5.5.15 Clean the heat exchangers to remove the dust, dirt,
corrosion, etc., for effective heat transfer.
5.5.16 Fill the hydraulic system with new oil and bleed as necessary.
5.5.17 Touch up paint for rust prevention as needed.
5.5.18 Put the turbine unit back to service.
5.5.19 Keep permanent record of condition found and all works
done, including parts installed, quantity and type of hydraulic
oil and lubricant added.
LIMITED
NOTE:
1. The first fill of oil should be changed after 500 hours of operation
and then after every 4000 hours of working.
2. Oil should always be filled through the filter/breather provided on
the tank.
3. ‘O’ rings and seals should be applied with hydraulic oil/grease at the
time of assembly.
4. Clean the filters by soaking in trichloroethylene or other suitable
solvent for 5 to 10 minutes and blow dry air from the inside out
using compressed air.
LIMITED
CHAPTER 6 - Do’s & Don’ts
6.1 Proper functioning of the hydraulic system requires the very high
cleanness level of hydraulic oil which is to be maintained at all times.
Hence, filter all hydraulic oil through a 10 micron filter before adding to
the system. Oil should always be filled through the filter/breather
provided on the tank.
6.2 Continuously clean cooling water supply to the turbine guide
bearing should be ensured. It is not advisable to run the unit
without cooling water supply which reduces the life of turbine
guide bearing.
6.3 Ensure the recommended generator lubricating oil pressure and
flow are maintained at all times, failing which diminishes the life of
bearings.
6.4 For any unusual sounds and vibration of the operating equipment,
stop the unit and check properly.
6.5 Before opening the intake and draft tube gates, ensure that the
valves in de-watering pit are closed completely.
6.6 When working with OPU, oil piping, guide vanes, runner blades,
ensure that the OPU pressure is completely relieved by discharging
the accumulator.
6.7 Do not rest the turbine drive shaft in the floating stuffing box. The
floating stuffing box is not designed to be used as a support for the
shaft.
6.8 Make sure that the drain plugs in front bearing shaft and hub body
are installed properly before closing the manhole covers.
6.9 Make sure that the pressure relief valves in oil head assembly are
tightened to required position/pressure and not tightened fully.
6.10 Ensure before Starting Butterfly valve mechanical lock should be
disengaged and while during shutdown/maintenance work lock
should be engaged
LIMITED
6.11 Always check all the pre-start sequences should be satisfied before
System start
6.12 Draw out the Generator Breaker when maintenance works on
generator
6.13 Ensure before closing of the HT Breaker all the faults/alarms
should be cleared
6.14 Do not close the Generator Breaker When the Unit was offline/
shutdown condition.
6.15 Do not switch on the DC motor while Unit is Shut down / Stand
still
6.16 Do not charge the line while unit is under maintenance / servicing
and while closings of the beaker make sure there is no person
working on line.
6.17 Don not work on TOPU with pressure, release all pressure by
opening accumulator / drain valve
LIMITED
CHAPTER 7 - GENERAL INFORMATIONS
7.1 Clearances.
7.2 Weights.
7.3 Tightening Torque’s.
7.4 CAM Relation between guide vane & runner blade
7.5 List of drawings.
7.6 Parameters to be set / ensured
7.1 CLEARANCES
1. Between Runner chamber & Runner Blade : 1.25 to 1.5mm

2. Thordon Bearing Clearances: Min. 1.00 mm. Max. 1.23 mm
3. Operating gear assembly
a. Clearance at Guide vane top: Min.: 0.70 mm Max. : 1.2 mm
b. Clearance at Guide vane bottom: Min.: 0.6 mm Max. : 1.2 mm
c. Bedding clearance : 0 - 0.3 mm
4. Between turbine shaft & Gear box shaft : 10 mm
5. Between Gear box shaft & generator Shaft : 7.5 mm
IMPORTANT: It is very important to maintain the clearances

mentioned above for long trouble free life
LIMITED
7.2 WEIGHTS OF MAJOR COMPONENETS
Sl Weight
No. Assembly/Subassembly Length Breadth Height in Kg
1 DRAFT TUBE ASSLY-HFK 5561 3272 4437 5300
2 RUNNER CHAMBER ASSLY-HFK 1816 1816 488 770
INLET CASING AND OPERATING GUIDEVANE
3 ASSEMBLY 2580 2580 2262 10110
STUFFING BOX ASSEMBLY WITH
4 WATERBOX-HFK 920 920 320 300
5 TURBINE GUIDE BEARING ASSEMBLY-HFK 555 555 690 200

6 ROTATING ASSEMBLY-HFK 1600 1600 5487 4150
7 TURBINE OIL PUMPING UNIT 1943 1112 2388 1400
OIL PIPING SYSTEM WITH PIPE AND
8 FITTINGS 280
9 OIL HEAD ASSY 330 330 534 135
10 HYDRAULIC UNION 200 200 200 110
EOT / HOT CRANE WITH FOUNDATION
11 BOLTS,SOLE PLATES 15920 4761 2600 16478
12 EMBEDDED PIPE & FITTINGS 200
13 GEAR BOX WITH ACCESSORIES 4423 2085 2340 8260
14 FLEXIBLE COUPLING 405 405 358 153.8
15 RIGID COUPLING 570 570 500 675
16 COOLING WATER SYSTEM 280
17 DEWATERING SYSTEM 200
18 DRAINAGE SYSTEM 200
19 BRAKE ASSEMBLY 350 350 940 500
20 GENERATOR & ACCESSORIES 3994 2669 2245 21000
TOTAL WEIGHT OF ALL EQUPEMENTS IN KG 1,87,840

This Weights for 1 unit Only
LIMITED
7.3 TIGHTENING TORQUE VALUES
Bolt Tightening
Sl.No Description
Size Torque (N-m)
1 Anchor frame to Inlet casing M30 1260

2 Front bearing shaft - Hub body
M16 221
bolts.
3 Rigid coupling bolts (Torque M20 547
transmission type)
4 Turbine shaft - Hub body bolts M20 435
5 Runner blade securing bolts M24 750
6 Generator Foundation M30 1260
M20 368
7 Gear box Foundation bolts M20 520
Important: It is very imp. to tighten the bolts with tightening torque

mentioned above
Tightening torque values mentioned below are for general use on final
assembly where the required tightening torque for the most commonly
used bolt types is not specified on the relevant drawings.
LIMITED
Tightening torque’s for P8.8 grade bolts
The torque figures stated above are for use with hand operated torque
wrenches.
For power operated torque wrenches the torque figures stated should be
reduced by 25%
LIMITED
7.4 CAM RELATIONS
CAM relation between Guide Vane and Runner Blade position for rated head.
Note: The head mentioned below is net head, Deduct friction losses from gross
head.
Head = 23 Head = 22.5 Head = 22

%GV %RB %GV %RB %GV %RB
27.27 5.57 27.27 5.57 27.27 5.57
36.36 13.06 36.36 12.40 36.36 12.71
45.45 20.49 45.45 20.23 45.45 20.23
54.55 28.74 54.55 30.29 54.55 30.23
63.64 40.00 63.64 40.00 63.64 39.00
72.73 48.97 72.73 48.66 72.73 47.97
81.82 57.34 81.82 58.17 81.82 57.91
90.91 69.83 90.91 67.86 90.91 68.26
100.00 79.46 100.00 78.57 100.00 77.31
Head = 21.35 Head = 21 Head = 20.5

%GV %RB %GV %RB %GV %RB
27.27 5.37 27.27 4.86 27.27 4.74
36.36 12.51 36.36 12.17 36.36 11.91
45.45 20.00 45.45 20.00 45.45 19.77
54.55 29.14 54.55 28.57 54.55 28.57
63.64 38.57 63.64 37.89 63.64 36.80
72.73 47.43 72.73 46.94 72.73 46.07
81.82 56.57 81.82 56.63 81.82 53.57
90.91 66.57 90.91 66.00 90.91 64.77
100.00 76.86 100.00 76.06 100.00 75.51
Head = 20 Head = 19.5

%GV %RB %GV %RB
27.27 4.14 27.27 4.14
36.36 11.91 36.36 11.29
45.45 19.23 45.45 19.23
54.55 28.00 54.55 27.46
63.64 36.80 63.64 36.26
72.73 46.57 72.73 45.31
81.82 55.26 81.82 54.69
90.91 64.29 90.91 63.80
100.00 74.69 100.00 73.86
LIMITED
7.5 LIST OF DRAWINGS
SL.No. Description Drawing Revisio

No. n
TURBINE DRAWINGS
1 Draft tube Assembly. 3983101 A
2 Inlet Casing Assembly. 3983301 D
3 Runner chamber Assembly. 3983401 -
4 Stuffing box Assembly. 3983501 B
5 Operating Gear assembly 3983601 D
6 Front bearing shaft assembly 3984401 -
7 Hub Assembly 3984101 -
8 Turbine shaft assembly 3984201 A
9 Control Tube Assembly 3984501 -
10 Oil head Assembly. 3984301 A
11 Front bearing Assembly 3983701 A
SYSTEM DRAWINGS
1 Station arrangement (Plan &
3980201 F
Elevation)
2 Foundation Details 3980202 B
3 Cooling water system - Piping 3987101 -
Layout
4 De-watering System - Piping 3987301 -
Layout
5 Drainage System 3987401 -
6 Oil Piping System 3987201 -
LIMITED
7.6 PARAMETERS TO BE SET / ENSURED
1. Turbine - OPU
Pressure switch setting
P1 Accumulator Low PS1 Alarm

P2 Accumulator High PS2 Trip
P0 Nitrogen charging
Pressure
Pump setting
a. Pump flow : 23 LPM
b. Pump pressure : 80 bar
Pressure relief valve

a. Relief valve setting : 80 bar
Flow switch
a. Oil level low alarm
Pressure line filter

a. Pressure line Filter clogging indication.
Flow control valves:

a. Guide vane Flow control valves : Open = 10 sec. & Close = 10 sec and
Emergency = 8 sec
b. Runner Blade Flow control valves : Open = 15 sec. & Close = 15 sec
3. Cooling water System:
a. Flow switch for Thordon Bearing : Full flow at 90 LPM

b. Flow switch for Gear Box LOS : Full flow at 250 LPM
c. Flow switch for Stuffing box : Full flow at 15 LPM
4. Turbine:
a. Runner Blade Servo cylinder stroke: 60 mm.

b. Runner Blade Angle: +15 deg to –15 deg.
c. Guide vane servo cylinder stroke: 235 mm.
d. Guide vane angle: 56 Deg.
LIMITED
CHAPTER 8 - SAFE OPERATING CONDITIONS
The operation of the turbine is not safe under following

conditions
Turbine:
1. Max. Head more than 23.0 mtrs.

2. Min. Head less than 19.5 mtrs
3. Min. Tail water level less than 1794 (above MSL.)
4. Max. generator output > 2600 kW
5. Upstream gate partially open.
6. Downstream gate partially open.
7. Leakage in turbine passage.
8. Foreign body entrapped between guide vanes / Runner blades
9. Guide vane slipped.
10. Stuffing box leaking heavily.
11. Shrink disc coupling slipped.
12. Any bolted joint in loose condition.
13. Heavy leakage at oil head pressure relief valve.
14. Runner blade servo motor hunting.
Turbine OPU: (Refer O&M manual supplied M/s YUKEN India Ltd. for
more details)
1. Sump tank temperature > 650C

2. Pressure relief valve setting > 80 Bar.
3. Oil pumps not operative.
4. Line filter clogged.
5. Pressure switches malfunctioning.
6. Accumulators charging pressure less.
7. Accumulator bladder damaged.
8. Shut down solenoid stuck
9. Pilot operated check valves chattering.
LIMITED
Generator: (Refer O&M manual supplied by M/s Crompton Greaves Ltd.
for more details)
1. Excessive vibrations
2. Abnormal sound.
3. Generator bearing temperature high.
Cooling Water System:

1. Both the strainers clogged.
2. Cooling water pumps not operative.
3. Flow switch to Thordon bearing showing “ No flow”
4. Flow switch to Generator LOS Heat exchanger showing “ No flow”
5. No flow to Stuffing box.
6. Out let pipes from generator bearings not delivering water in to tail
race
7. Heavy leakage in cooling water piping.
Brake:
1. Brake in engaged condition.
Oil Piping System:

1. Excessive vibrations in oil pipe lines.
2. Leakage in oil piping.
De-Watering System:
1. De-watering pumps not operative.
2. Water level sensors not operative (If provided)
LIMITED
CHAPTER 9 - FAULT DIAGNOSIS
The following chart provides a guide to fault diagnosis with probable causes
and proposed rectification actions
Note: For detailed fault diagnosis refer individual manuals for respective
equipment’s.
Defect Probable cause Rectification

Guide vanes slow Low oil pressure Check setting of pressure
to operate relief valve in OPU
Piston seal leaking Replace servo motor seals
Spongy operation Air in servo motor Bleed the hydraulic
of GV servo motor system.
Jerky operation of Air in servo motor Bleed the hydraulic
servo motor system.
Tight servo motor Replace seals & bearings.
seals/bearings
Noisy operation of Loose mounting Check & rectify mounting
servo motor
Scored servo Foreign material in Remove/replace
motor rod bearing / gland seal bearing/seal
Runner blade will Obstruction in runner Clear the obstruction
not cycle chamber
Runner blade jammed Clear the obstruction
Low oil pressure Check performance of OPU
Oil head defective Check & replace
Rotating union / Gasket Check & replace
defective
Runner will not Obstruction in runner Clear the obstruction
rotate chamber
Turbine-Generator mis- Check & correct the mis
aligned alignment
No blade tip to Runner Check the Runner blade
chamber clearance clearance
Excessive vibration Operation outside “Safe Check the operating
operating conditions.’ parameters
LIMITED
Guide vanes have slipped Check for guide vane slip.
Obstruction in hydraulic Check & clear the
passage obstruction
Bearing failure Check & replace bearings
Turbine mis aligned Check for alignment
Excessive noise Operation outside “Safe Check the operating
operating conditions.’ parameters
Guide vanes have slipped Check for guide vane slip.
Loose parts of fasteners Check for loose / failed
fasteners
Stuffing box Lack of cooling water Check for cooling water
assembly over supply
heating
Gland packing too tight Check & correct
Lantern ring incorrectly Check & correct
installed accordingly
Packing extruded/worn Check & replace
Oil head leaking Hub body seal fail Check & replace
Control tube seals fail Check & replace
Fitting/connectors leaking Check & replace
Guide vane servo Faulty signal from Check & correct
motor hunting governor to proportional
valves
Feed back sensor faulty Check & correct
Proportional valve Check & correct
malfunctioning
Piston seal leaking Check & replace the seals
Runner blade Faulty signal from Check & correct
servo motor governor to proportional
hunting valves
Feed back sensor faulty Check & correct

Proportional valve Check & correct
malfunctioning
Piston seal leaking Check & replace the seals
Cooling water flow Clogging of strainers Clean the strainers
switch showing ‘no
flow”
Water path obstructed Clear the water path.
Pump inoperative Check & replace the pump
Flow switch Check & replace
malfunctioning
Motor running in reverse Check & correct
direction
LIMITED
CHAPTER 10 - HEALTH & SAFETY AT WORK
The customer and all concerned with operation of the installation must
observe directions and recommendations generally as follows.
1) The equipment must be operated at all times under conditions within the
parameters defined in this manual.
2) The installation must be maintained as specified in this manual.
3) Operation & maintenance of the equipment must be by competent operators &
engineers conversant with the specified operating procedures.
4) Safety guards around moving parts must not be removed except during
maintenance.
5) Power supplies must be isolated before opening the enclosures or cubicles
housing electrical equipment.
6) Whilst maintenance work is in progress, safe and proper access to working
areas must be provided.
7) Suitable lifting arrangements must be used for handling dismantled parts
during maintenance
8) When equipment is stationary, working parts may be under load, so that care
must be taken before dismantling any part, that such loads are relieved by
appropriate support of adjacent parts.
9) Before breaking any hydraulic pipelines or disconnecting any components,
pressurised fluids must be safely vented.
10)Before equipment is put back to work all parts should be checked to see that
they are correctly assembled, all tools and other equipment are removed and
clear of machinery and all guards are replaced correctly.
11)Check electrical equipment, operation.
12)Check hydraulic equipment, operation.
13)Check equipment overall for correct operation.
As water control equipment is installed in or adjacent to open water ways, the
hazards associated with such conditions must be considered and river traffic
must be considered and the user should provide appropriate safeguards,
protection and rescue facilities for plant operators and others involved.
LIMITED
14)The user must comply with all requirements of Statutory Regulations applying
to the installation.
15)Hydraulic mineral oil has no significant health hazards when properly used and
in the application for which it is designed. Frequent and/ or prolonged skin
contact may give rise to skin irritations and it is recommended that protective
gloves are worn.
First Aid
1. Ingestion: Do not induce vomiting because of risk of operation. Give 300 ml

of milk. Seek medical advice.
2. Skin contact: Mildly irritating. Remove by wiping. Wash with soap and water.
3. Eye contact: Mildly irritating. Flush with copious amounts of warm water. Seek
medical advice if necessary.
4. Aspiration: If there is any suspicion of aspiration in to the lungs (for example
during vomiting) admit to hospital immediately.
5. Inhalation: Remove from exposure in to fresh air if necessary gives artificial
respiration or oxygen. Seek medical advice.
CAUTION: Protect the environment by not disposing of used oils to

drains, soil/water.
LIMITED
CHAPTER 11 – TOOLS & TACKLES
Refer the list below for the Tools & Tackles are recommended to be held
by the operators of the equipment covered in this manual.
Sl.No Item Qty

.
1 Dial Gauge with magnetic Base 8 No’s
2 Inside Micrometre 1 No
3 Outside Micrometre 1 No.
4 Ring Spanners & Double end open jaw spanners 1 Set, Each
5 Single end Open jaw & Single end ring Spanners 1 Set, Each
6 Box Spanners 1 Set
7 Circlip Opener (Inside & Outside) 1 No. Each
8 Hammers 1 No. Each
9 Pistol Drilling Machine 1 No.
10 Shim Cutter 1 No.
11 Die Set With Wrench 1 No. Each
12 Chain Pipe Wrench 1 No. Each
13 Screw Pipe Wrench 1 No
14 Allen Keys 1 Set
15 Insulated Cutting Pliers 1 No. Each
16 Nose Pliers 1 No. Each
17 Hacksaw Frame 1 No
18 Rough & Smooth flat, Round, Half Round & 1 No. Each
Triangular files
19 Centre Punch 5"& Letter Punch 1/4" 1 No. Each
20 Chisels 1 No. Each
21 Bench Vice 1 No
22 Screw Drivers 1 No. Each
23 Nylon slings - 2mtrs long 2 Nos, Each
24 "D'' Shackles 2 Nos, Each
25 Feeler Gauge 1 Set, Each
26 Torque wrench 1 No
LIMITED
Sl.No Item Qty
.
27 Eye bolts 2 sets
28 Vibration meter 1 No
29 Hydraulic torque wrench 1 No
30 Socket inserts M36, M39, M42 & M45 2 sets
31 Pawl 1 No
32 Hydraulic Power Pack 1 No
LIMITED
CHAPTER 12 – SPARES
NOTE: Spares list provided below is for FULL project For Turbine
Draft Tube Assembly

• Gasket - ID 620 x OD 720 x 3 Thk. - 1 No
Inlet Casing Assembly

• Thrust Washer - OD 54 x ID 30 x 1.5 Thk - 4 No’s
• Split Pin - Dia 4 x 45 Lg - 2 No’s
• 'O' Ring Cord - Dia.8 x ID 2320 - 1 No
• Machined Washer - To Suit M24 - 10 No’s
• 'O' Ring Cord - Dia.6 x ID 660 - 1 No
Runner Chamber Assembly

• 'O' Ring Cord - Dia. 8 x ID 1596 - 2 No’s
• 'O' Ring Cord - Dia. 8 x ID 1640 - 1 No
Stuffing Box Assembly

• Gland Packing - Stoplik Style 99 ID 280 x 20 Sq – 1 Set
• 'O' Ring Cord - 'Dia. 5 x ID 820 - 1 Set
• 'O' Ring Cord - 'Dia. 5 x ID 476 - 1 Set
• Labyrinth Seal - Refer Drawing - 1 Set

LIMITED
• Lip Seal -ID 255 x OD 285 x 20Thk(Split). - 1 Set
Operating Gear Assembly

• Guide Vane - Refer Drawing – 4 No’s
• Dowel-1 - Dia 20 (m6) x 80 Lg - 2 No’s
• Dowel-2 - Dia 10 (m6) x 30 Lg - 1 No
• Hex. Nut (Left hand) - M16 x 2P - 5 No’s
• Hex. Nut (Right hand) - M16 x 2P - 5 No’s
• Thin Nut(Hex) - M16 x 2P - 5 No’s
• Machined Washer - OD 65 x ID 47 x 3 Thk - 2 No’s
• Split Pin - Dia 4 x 60 Lg - 4 No’s
• 'O' Ring Cord - Dia. 5.7 x ID 49.3 - 48 No’s
• 'O' Ring Cord - Dia. 3 x ID 79.5 - 24 No’s
• Conical Head Grease Nipple - M10 x 1P - 1 No
• Thrust Washer - OD 74 x ID 48 x 2 Thk. - 2 No’s
• Machined Washer - M42 x 10 THK - 1 No
• Socket Grub Screw - M6 x 10 Lg - 2 No’s

LIMITED
Operating Gear Assembly

• Quad Ring X Seal - Refer Drawing – 4 No’s
• 'O' Ring Cord - Dial 3 x ID 141.5 - 1 No
• 'O' Ring Cord - Dia 3.0 x ID 57.5 - 1 No
• 'O' Ring Cord - Dia 5.7 x ID 415.3 - 1 No
• 'O' Ring Cord - Dia 5.7 x ID 450 - 1 No
• Piston Rod Seal - Refer Drawing – 1 No
• Piston Seal - Refer Drawing – 2 No’s
Turbine Shaft Assembly

• Shaft Sleeve for Turbine Shaft - Refer Drawing – 1 Set
• 'O' Ring - C/S Dia 5.7 x ID 269.3 - 2 No’s
Oil Head Assembly

• 'O' Ring - Dia. 3 x ID 40 - 1 No
• 'O' Ring - Dia. 2.4 x ID 16.4 - 1 No
• Super mono seal, Type 10,000 - ID 210 x OD 230 x 19 - 1 No
• Super wiper seal-Type 5000 - ID 210 x OD 225 x 6.5 x 11.25 - 1 No

LIMITED
Front Bearing Shaft Assembly

• 'O' Ring - Dia. 5.7 x ID 119.3 - 1 No
Control Tube Assembly

• 'O' Ring - Dia. 3 x ID 23 - 1 No
• 'O' Ring - Dia. 3 x ID 50 - 1 No
• 'O' Ring - Dia. 3 x ID 21.5 - 1 No

LIMITED
To obtain any assistance or support please contact:
B FOURESS (P) LIMITED.

Plot No.7 , Post Box. No. 11
K.I.A.D.B Industrial Area.
HOSKOTE :562114
Bangalore (Rural)
Phone : 080-27971641 to 646
Fax No : 080-27971455
email : info@bflhydro.com
For the attention of:
Mr. B.S Murali

Chief - Erection & Commissioning

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PROJECT: LOWER ALEO HEP

(2x2.0MW + 30% COL)

CUSTOMER: M/s Baragarh Hydro Power Co. Pvt Ltd

OPERATION & MAINTENANCE MANUAL TURBINE

B Fouress (P) Limited – India

PROJECT NAME : LOWER ALEO HEP

CUSTOMER : M/s Baragarh Hydro Power Co. Pvt Ltd

SUPPLIER : M/s. B Fouress (P) Limited

The items covered are:

Salient Features of Lower Aleo Project

Chapter 3 – Assembly of Components

Chapter 4 – Starting / Stopping Procedure

Chapter 5 - Maintenance procedure

Chapter 6 - Do’s & Don’ts

Chapter 7 - General Information.

Chapter 8 - Safe Operating conditions

Chapter 9 - Fault Diagnosis.

Chapter 10 - Health & safety at work

Chapter 11 – Tools & Tackles

Chapter 12 – Spares for Turbine

Manufacturer M/s. B Fouress (P) Limited.

1.2 Turbine OPU

Supplier M/s Yuken India (P) Ltd

Supplier M/s. Crompton Greaves Ltd.

1.4 Flexible Coupling (Between Gear box and Generator)

Make M/s. Esco Couplings & Transmissions

1.5 Rigid Coupling (Between Turbine & Gearbox)

Make M/s. Elecon Peripherals Ltd.

1.6 Cooling Water Pump

Make M/s. Kirloskar Ltd

1.7 De-watering Pump

Make M/s. Lubi Industries LLP.

1.8 Drainage Pump

Make M/s KIRLOSKAR

1.9 Turbine Bearing (Front Bearing)

Make M/s Thordon Bearing

1.10 Duplex Filter

Make M/s AOF Filtration Systems (P) Ltd

1.11 EOT Crane

Make M/s TECHNO INDUSTRIES

1.12 GEAR BOX with LOS

Supplier M/s. Elecon

The turbine is of horizontal shaft of S-type Kaplan, with movable guide

2.2 Inlet Casing

2.3 Guide vane Operating Assembly

Guide vane operating assembly consists of outer casing, inner casing,

WARNING: Ensure proper connection of hydraulic hose pipe between

2.4 Runner Chamber Assembly:

Runner chamber is fabricated from Stainless steel. It comprises of two

2.5 Draft Tube:

2.6 Shaft Seal

2.7 Hub and Runner

regulating servo motor will be operated at an oil pressure of about 50 - 80

2.8 Turbine Shaft

2.9 Oil Head Assembly

2.10 Guide Bearing

Turbine guide bearing is water lubricated bearing fitted at the upstream of

Warning: It is not advisable to run the turbine without cooling

Warning: The operating pressure of the system should not exceed