Professional Documents
Culture Documents
CRHT VI
March 14, 2016, Turbine Testing Lab, Kathmandu University, Dhulikhel, Nepal
Paper no. CRHT2016-04
Abstract
Preventive maintenance is one of the techniques to improve the equipment life and avoid unplanned maintenance
activities in hydropower stations. The plant outage of hydropower stations can be reduced to some extend by
adopting the preventive maintenance technique. This paper elaborates the maintenance technique adopted in some
of hydropower stations in Nepal. The paper also illustrates the preventive maintenance software build for
hydropower stations, aiming to explore the application of the software in hydropower stations to reduce the forced
outage of the machine.
Keywords: Preventive maintenance, force outage, SAJILO Hydro preventive maintenance software
1. Introduction
The reliable operation of hydropower plants with minimum O&M cost is key consideration for long rung
sustainability of hydropower development. The economic operation of an electric utility system requires
the simultaneous solution of all aspects of the operation scheduling problem in the face of system
complexity, different time-scales involved, uncertainties of different order, and dimensionality of
problems [1]. An effective maintenance strategy is essential in delivering safe and reliable electric power
to customers economically [2]. The reliability of system operation and production cost in an electric
power system is highly affected by the maintenance outage of generating facilities [3].
Experience of running hydropower station reveals that even after detailed project planning/quality control
measures taken at various stages from inception to commissioning several unforeseen problems do take
place during the operation and maintenance resulting in forced outages/low generation and load shedding
etc. causing misery to the consumers and undesired set back to the overall economy [4]. Sediment
induced turbine wear in hydraulic machinery is probably the most serious problem in operation and
maintenance of hydropower projects in Himalayan region [5]. Besides damage of underwater components
numbers of operation and maintenance problems are encountered due to sedimentation. This consequently
leads to outages of the unit, resulting loss in generation, with consequent loss of revenue.
Experience shows that most of run-off rivers hydropower projects in Nepal have been suffered prolonged
forced outage because of frequent shutdown of the machine due to problems come across during
operation of the machine. Corrective maintenance scheduling has been in practice to solve the operational
problems in hydropower stations. The time and cost of corrective maintenance is always in higher side
and may affect the allocated maintenance budget of the plant and affect the plant performance as the
pattern of equipment failure is uncertain.
Nepal Electricity authority is the leading government organization to generate, transmit and distribute
adequate, reliable and affordable power by planning, constructing, operating and maintaining all
generation, transmission and distribution facilities in Nepal's power system both interconnected and
isolated. The total energy generation of fiscal year of 2013 has registered 2,350 GWh whereas the total
outage hour of the plants during the fiscal year is 133,684.07 hours [6]. Outages of the plants, such as
planned outage and force outage are an excellent indicator for performance of the plant.
The planned outage is determined by the provisions made for inspections and repair work of the damaged
components necessary to upgrade the plant performance. Some unforeseen problems are encountered
during operation of machine which leads to increase the force outage of the plant. The force outage
illustrates the real condition of the plant and machine.
The hydropower development companies are continuous focus on rise of cost for hydroelectric plants and
electric energy. It is natural to be maintaining those high-value assets through maintenance, and operation
with correct methods, for save it from rapid deterioration and increase the long term life span. In 1954
the Japanese scientists and engineers discovered the preventive maintenance [7]. Preventive and
corrective maintenance scheduling have been implemented in hydropower stations. Preventive
maintenance is defined as the maintenance carried out at predetermined intervals or according to
prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning
of an item [8] whereas corrective maintenance is defined as the maintenance carried out after fault
recognition and intended to put an item into a state in which it can perform a required function [9].
Maintenance scheduling is necessary to ensure quality and reliable operation of equipment to minimize
the force outage of the plant. Preventive maintenance program can be considered to attain maximum plant
availability and equipment reliability, and to reduce forced outages. The program also helps to reduce the
unexpected failures during operation of machine of hydropower stations. Preventive maintenance covers
inspection, replacement, repair of any piece of equipment or component based on time and set parameters.
It even includes painting, lubrication, cleaning, adjusting and minor component replacement to extend the
life of equipment. Its main purpose is to minimize costly break down and unplanned shutdowns of the
units.
The paper describes the loss of energy generation of hydropower stations and the performance of the plant
due to force outage of the machine. Total generation at Modi Khola power station was at its lowest since
its commissioning because of long shut down for maintenance of a cooling system failure caused by
sediment.
Similarly, the balancing pipe of head cover at Kaligandaki was replaced because of damage in pipe,
requiring tunnel dewatering due to malfunction of main inlet valve. Some reasons for force outage of the
Modi Khola HEP are identified such as increase temperature in turbine bearing temperature, leakage in
shaft seal and vibration of the machine. There are several reasons behind the force outages at the plant,
such as ineffective maintenance plan, a lack of awareness of preventive maintenance techniques,
unsystematic management and storage of spare parts, poor documentations and drawings, lack of proper
record- keeping of past maintenance of the machine components.
The availability of equipment, such as electro mechanical and hydro mechanical equipments for power
generation depends on their quality, errection and alignment of the components and the experience of the
plant operator. Besides these, implementation preventive maintenance program can minimize the loss of
generation to some extent by considering the operational problems before it occurs.
5. Conclusion
Operation and maintenance includes the activities required to run a Hydropower stations. The cost
associated with maintenance work has significant effect on total operational costs of the hydropower
plant, hence proper operation and maintenance planning is vital for sustainability of the hydropower
projects. Operating conditions are required to be monitored and recorded as it contains the information of
causes of failures and faults which help to determine the performance of the plant and to make the
strategies for long term maintenance plan. SAJILO hydro preventive maintenance software can be used as
maintenance scheduling tool for hydropower stations to organize the maintenance activities and to
maintain the track records of the equipment.
Acknowledgement
Authors would like to thank Mr. Chandan Bachhar for his contribution in making programme to prepare
the SAJILO hydro preventive maintenance software.
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