pdf.usaid.govpdf.usaid.gov/pdf_docs/pa00mvnp.pdf · kajaki hydroelectric power plant (hpp)...

Engineering Support Program (ESP) Contract No. AID-306-C-16-00010

OPERATION AND MAINTENANCE SUSTAINABILITY PLAN

KAJAKI HYDROELECTRIC POWER PLANT (HPP)

SECTION 8

ANCILLARY PLANT

HELMAND PROVINCE

AFGHANISTAN

MAY 2017

Kajaki Hydroelectric Power Plant (HPP) Engineering Support Program (ESP) Operation & Maintenance (O&M) Plan Contract No. AID-306-C-16-00010

i Section 8: Ancillary Plant

TABLE OF CONTENTS 8.0 Ancillary Plant .................................................................................................................................. 1

8.1 Medium Voltage Switchgear ......................................................................................................... 1

8.1.1 Introduction ................................................................................................................................... 1

8.1.2 Scope and Supply of Technical Description ........................................................................... 1

8.1.3 Preparations Before Start .......................................................................................................... 3

8.1.4 Operation ...................................................................................................................................... 3

8.1.5 Maintenance ................................................................................................................................... 3

8.1.6 Spare Parts ..................................................................................................................................... 4

8.1.7 Drawings and Data Sheets ......................................................................................................... 5

8.2 Draft Tube Gantry Crane ........................................................................................................... 13

8.2.1 Description .................................................................................................................................. 13

8.2.2 Layout ........................................................................................................................................... 14

8.2.3 Maintenance Plan ........................................................................................................................ 19

8.3 Penstock and Tunnel.................................................................................................................... 20

8.3.1 Description .................................................................................................................................. 20

8.3.2 Inspection ..................................................................................................................................... 26

8.3.3 Inspection and Maintenance Frequency ................................................................................ 27

8.4 Draft Tube Bulkheads .................................................................................................................. 28

8.4.1 Introduction ................................................................................................................................. 28

8.4.2 Description .................................................................................................................................. 31


8.5 Trashrack ........................................................................................................................................ 37

8.5.1 Introduction ................................................................................................................................. 37

8.5.2 Description .................................................................................................................................. 37

8.5.3 Maintenance PLan ...................................................................................................................... 43

8.6 Intake Gate ..................................................................................................................................... 44

8.6.1 Introduction ................................................................................................................................. 44

8.6.2 Description .................................................................................................................................. 44


8.7 List of Manufacturers ................................................................................................................... 52

8.8 High Voltage Power Transformers .......................................................................................... 54

8.8.1 Introduction ................................................................................................................................. 54

8.8.2 Scope of Supply and Technical Description ......................................................................... 54

8.8.3 Preparations Before Start ........................................................................................................ 55

8.8.4 Operation .................................................................................................................................... 55


ii Section 8: Ancillary Plant

8.8.5 Maintenance ................................................................................................................................. 55

8.8.6 Spare Parts ................................................................................................................................... 58

8.8.7 Drawings and Data Sheets ....................................................................................................... 58

8.9 Turbine Governors: Units 1, 2, and 3 ..................................................................................... 60

8.9.1 Introduction ................................................................................................................................. 60

8.9.2 Technical Description and Operation ................................................................................... 60

8.9.3 Maintenance and Repairs .......................................................................................................... 71

8.9.4 Spare Parts & Special Tools ..................................................................................................... 72

8.9.5 Drawings ...................................................................................................................................... 72

8.10 Main Inlet Valve ............................................................................................................................. 74

8.10.1 Introduction ................................................................................................................................. 74

8.10.2 Description .................................................................................................................................. 74


TABLE OF TABLES Table 1: Supplier Information ............................................................................................................................. 1

Table 2: Main Data for Medium Voltage Switchgear .................................................................................... 2

Table 3: Cubicle Functions and Reference Drawings ................................................................................... 2

Table 4: Recommended Inspection and Maintenance Activities for Unit 2 ............................................ 3

Table 5: Spare Parts Provided ............................................................................................................................ 4

Table 6: Drawings ................................................................................................................................................. 5

Table 7: Suppliers Address .............................................................................................................................. 12

Table 8: Summary of Maintenance .................................................................................................................. 49

Table 9: Preventative Maintenance Plan ........................................................................................................ 51

Table 10: Supplier Information ........................................................................................................................ 54

Table 11: Main Data for High Voltage Transformers ................................................................................. 54

Table 12: Recommended Inspection and Maintenance Activities for Transformers .......................... 56

Table 13: Spare Parts Provided ........................................................................................................................ 58

Table 14: Drawings ............................................................................................................................................. 59

Table 15: Suppliers Address ............................................................................................................................ 59

Table 16: Supplier Information ........................................................................................................................ 60

Table 17: Oil Pressure Unit, Main Data & Dimensions ............................................................................. 61

Table 18: Electronic PID Governor, Main Parameters .............................................................................. 62

Table 19: Summary of Maintenance Intervals ............................................................................................... 72

Table 20: Drawings ............................................................................................................................................. 72


iii Section 8: Ancillary Plant

TABLE OF FIGURES Figure 1: 9-Ton Gantry Crane ......................................................................................................................... 13

Figure 2: Gantry Crane ...................................................................................................................................... 14

Figure 3: North Elevation View of Draft Tube and Crane ........................................................................ 15

Figure 4: Bulkhead Lifting Beam Drawing ...................................................................................................... 16

Figure 5: Lifting Beam with Release Toggle and Rope ................................................................................ 17

Figure 6: Draft Tube Bulkhead Dogging Device .......................................................................................... 18

Figure 7: Penstock Access ................................................................................................................................. 21

Figure 8: Penstock Details Showing Walkway ............................................................................................. 22

Figure 9: Tunnel and Penstock Layout ........................................................................................................... 23

Figure 10: Exposed Penstock Details ............................................................................................................. 24

Figure 11: Penstock Details Trifurcation ....................................................................................................... 25

Figure 12: North Elevation of Powerhouse .................................................................................................. 29

Figure 13: Photo Bulkhead A, with Lifting Beam ......................................................................................... 30

Figure 14: Bulkhead Type A .............................................................................................................................. 32

Figure 15: Bulkhead Type B .............................................................................................................................. 33

Figure 16: Draft Tube Bulkhead ...................................................................................................................... 34

Figure 17: Wedges and Seals ............................................................................................................................ 35

Figure 18: Power Intake Trashrack Layout ................................................................................................... 38

Figure 19: Trashrack Plan and Elevation ........................................................................................................ 39

Figure 20: Trashrack Elevations and Details ................................................................................................. 40

Figure 21: Underwater Inspection of Trashrack (1) ................................................................................... 41

Figure 22: Underwater Inspection of Trashrack (2) ................................................................................... 42

Figure 23: Intake Gate General Arrangement Drawing ............................................................................. 45

Figure 24: Detailed Intake Gate Drawing ...................................................................................................... 46

Figure 25: Intake Gate Wheel Lubrication Drawing ................................................................................... 47

Figure 26: General Configuration of Intake Gate ........................................................................................ 48

Figure 27: Intake Gate Seals ............................................................................................................................. 51

Figure 27: Turbine Oil Pressure Unit Layout ............................................................................................... 63

Figure 28: Oil Pressure Schematic Diagram ................................................................................................. 64

Figure 29: Turbine Governor Layout ............................................................................................................. 65

Figure 30: Governor Arrangement Drawing Step Motor PLC ............................................................ 66

Figure 31: Governor Electric Cubicle Layout .............................................................................................. 67

Figure 32: Governor PLC Control Cubicle .................................................................................................. 68

Figure 33: Governor Pump Control Cubicle ............................................................................................... 69


iv Section 8: Ancillary Plant

APPENDICES Appendix 8.1-A: Installation Method Statement

Appendix 8.1-B: Switchgear Wiring Diagram

Appendix 8.1-C: Instruction Book

Appendix 8.1-D: Drawings

Appendix 8.1-E: Commissioning

Appendix 8.6-A: Intake Hoist Gate Final Inspection Report

Appendix 8.8-A: Operations Manual GSU Transformer

Appendix 8.8-B: Transformer O&M Manual

Appendix 8.8-C: Transformer Sprinkler System

Appendix 8.8-D: Transformer Transportation

Appendix 8.8-E: Transformer Installation

Appendix 8.9-A: Governor Operation and Maintenance Manual


1 Section 8: Ancillary Plant

8.0 ANCILLARY PLANT

8.1 MEDIUM VOLTAGE SWITCHGEAR

8.1.1 INTRODUCTION

This manual is divided into Sections, with each Section further divided, when required, to describe the operation and/or maintenance of individual parts of major components of plant which allows the Kajaki Hydropower Plant (hereinafter Kajaki HPP or the Plant) as a whole to operate reliably. The Sections and related subsections and Appendices to each have been made as simple and easy to understand as is possible while at the same time providing the information necessary for safe and sustainable operation and maintenance (O&M).

An obvious condition for the safe running of the switchgear is that it is only operated by qualified personnel. The users manual is an important aid which operational personnel are obliged to make themselves familiar with. The users manual should therefore be kept easily accessible for the operators.

It is the duty of the operator in charge to ensure that unqualified personnel do not gain access to the machinery.

CONTACT ADDRESS OF SUPPLIER

Table 1: Supplier Information Supplier Name Address Phone Email

Germany

8.1.2 SCOPE AND SUPPLY OF TECHNICAL DESCRIPTION

SCOPE OF SUPPLY

The medium voltage switchgear is a PIX High air-insulated switchgear device made by Schneider Electric. It serves Units 1, 2 and 3, two station service transformers and 13.8kV feeders for local distribution.

SUPPLIER INFORMATION

Schneider Electric SE is a French multinational corporation that specializes in energy management and automation solutions, spanning hardware, software, and services. The company is headquartered in Rueil-Malmaison and has also offices throughout the world.

Schneider Electric is the parent company of Square D, Pelco, APC and others.

As of 2016, the company has 20,000 patents either active or in application worldwide; the company has over 160,000 employees in approximately 100 countries worldwide.

Schneider Electric has had its head office in the Trianon site in Rueil-Malmaison, France since 2000. The current headquarters, also located in Rueil Malmaison and known as the Hive, previously housed Schneider subsidiary Tlmcanique, while the parent company occupied a site in Boulogne-Billancourt.



MAIN DATA AND CHARACTERISTICS

Main Data

Main specifications, data and parameters for the medium voltage switchgear are provided in the vendors O&M Manual included in Appendix 8.1-A and summarized in Table 2.

Table 2: Main Data for Medium Voltage Switchgear Rated voltage 12 kV

Rated lightning impulse withstand voltage 75 kV

Rated normal current 4000 A

Rated peak withstand current < 130 kA

Rated short-circuit breaking current < 50 kA

Declaration of Conformity

The medium voltage switchgear complies with IEC standard 62271-200 and other IEC standards, as detailed in Section 2.4 of the manufacturers technical manual, included in Appendix 8.1-A.

DESCRIPTION OF COMPONENTS

General Information

The medium voltage switchgear is made up of eight cubicles, labeled K01 through K08. The functions and reference drawings for each cubicle are listed in Table 3. The reference drawings are included in Appendix 8.1-B.

Table 3: Cubicle Functions and Reference Drawings Cubicle Function Reference Drawing

K01 Busbar metering 0-SB-E-A1-6602

K02 Station Service 2 0-SB-E-A1-6502

K03 Station Service 1 0-SB-E-A1-6502

K04 Local Distribution 0-SB-E-A1-6502

K05 Power Transformer Supply 4-SB-E-A1-6402

K06 Unit 3 3-SB-E-A1-6302

K07 Unit 2 2-SB-E-A1-6202

K08 Unit 1 1-SB-E-A1-6102

MANNER OF OPERATIONS

The medium voltage switchgear can be operated using either local or remote operation. Operating instructions are provided in Section 10 of the manufacturers technical manual, included in Appendix 8.1-A.

INSTRUMENTS

The medium voltage switchgear is made up of eight cubicles, labeled K01 through K08. The functions and reference drawings for each cubicle are listed in Table 3. The reference drawings are included in Appendix 8.1-B.



8.1.3 PREPARATIONS BEFORE START

Commissioning and startup instructions are provided in Appendix 8.1-D.

8.1.4 OPERATION

OPERATING MODES

The medium voltage switchgear can be operated using either local or remote controls.

START-UP, NORMAL OPERATION

Operating instructions for the medium voltage switchgear are provided in Section 10 of the manufacturers technical manual, included in Appendix 8.1-A.

DANGERS AND PREVENTATIVE MEASURES

The medium voltage switchgear cabinet contains high voltage sources and should only be opened or operated by qualified personnel.

Interlocks are built into the medium voltage switchgear as described Section 10.4 of the manufacturers technical manual A.

8.1.5 MAINTENANCE

MAINTENANCE PLAN

To ensure that the equipment functions satisfactorily over a longer period of time, check-ups and maintenance must be carried out at regular intervals. A list of the recommended inspection and maintenance activities for the medium voltage switchgear is shown in Table 4,

Table 4: Recommended Inspection and Maintenance Activities for Unit 2 Activity Interval

Visual inspection Daily

Replace fuses As needed

Replace earthing switch 1000 actuations of a switch

Clean and grease drives and movable main current contacts 12 years

Check releases and blocking coils for proper function 12 years

INSPECTION/EVALUATION

Visual Inspection

The medium voltage switchgear should be inspected daily. The inspection should verify:

Cooling fans are operating Cooling fans intakes are free of dust Cabinet doors are locked Cabinet is free of condensation or contamination

The medium voltage switchgear should be cleaned as needed using a dry, lint-free cloth.

DANGER: The switchgear cabinet contains high voltage power sources. Maintenance of the medium voltage switchgear should only performed by qualified personnel.



PROCEDURES FOR BASIC MAINTENANCE

Basic servicing consists of preventative maintenance and aims to avoid operational disturbances and to correct faults which over time could necessitate larger scale repairs. This usually only requires minor dismantling and can be incorporated into maintenance routines.

Instructions for disassembly and internal access to the medium voltage switchgear are included in in Section 4 of the switchgear technical manual, included in Appendix 8.1-A.


During reassembly, screws should be tightened to the specifications stated in Section 12.3 of the switchgear technical manual, included in Appendix 8.1-A.

Replace Fuses

The high voltage fuses should be replaced after a failure, as described in Section 11.8 of the switchgear technical manual, included in Appendix 8.1-A.


PROCEDURES FOR MORE COMPREHENSIVE MAINTENANCE

Larger scale servicing of the medium voltage switchgear requires a more complete understanding of the equipments construction and a more extensive selection of tools and lifting equipment than is included in the supply to cover daily maintenance.


Replacing Earthing Switches

The earthing switches should be replaced after 1000 actuations. This work should be performed by the manufacturers service personnel.

Clean and Grease Drives and Movable Main Current Contacts

The sliding contact surfaces, accessible friction points, bearings, joints, and drives should be lubricated every 12 years, as described in Section 11.7 of the switchgear technical manual.

The lubricant to be used is described in Section 12.1 of the switchgear technical manual, included in Appendix 8.1-A.

WARNING: The drives must not be disassembled for service and maintenance work.

Check Releases and Blocking Coils

The proper function of the releases and blocking coils should be checked every 12 years. This work should be performed by the manufacturers service personnel.

8.1.6 SPARE PARTS

LIST OF SPARE PARTS

Spare parts provided for the medium voltage switchgear are listed in Table 5.

Table 5: Spare Parts Provided Qty Name/dimension Drawing No. Part No. Supplier

1 Circuit breaker 3700 A 4-SB-E-A1-6402 52-L



Qty Name/dimension Drawing No. Part No. Supplier

1 Circuit breaker 2550 A 1-SB-E-A1-6102 52-G1

1 Circuit breaker 1250 A 0-SB-E-A1-6502 52-A(B)

2 Switchgear current transformer

4 FUSE 67037.003

8 Switchgear voltage transformer

2 Replacement light bulb

2 2x50 Ampere Molded Case Circuit Breaker (MCCB)

2 2x32 A MCCB

2 2x16 A MCCB

2 2x25 A MCCB

2 2x63 A MCCB

2 3x63 A MCCB

2 3x32 A MCCB

2 3x20 A MCCB

2 2x10 A MCCB

8.1.7 DRAWINGS AND DATA SHEETS

LIST OF DRAWINGS

Drawings showing the medium voltage switchgear are included in Appendix 8.1-B

Table 6: Drawings Index Name Drawing No. Rev.

1 ELECTRICAL LEGEND & ABBREVIATIONS 0-SB-E-A1-6001 0

2 15 kV (13,8) SCHEMATIC DIAGRAMS, GENERAL SINGLE LINE DIAGRAM 0-SB-E-A1-6010 2

3 ELECTRICAL POWER PLAN, EQUIPMENT LAYOUT 0-SB-E-A1-6025 2

4 15 kV (13,8) SCHEMATIC DIAGRAMS, STEP UP TRANSFORMER CUBICLE, FULL LINE DIAGRAM 4-SB-E-A1-6402 2

5 15 kV (13,8) SCHEMATIC DIAGRAMS, SERVICE STATION, LOCAL DISTRIBUTION SWITCHGEARS, FULL LINE DIAGRAM

0-SB-E-A1-6502 2

6 15 kV (13,8) SCHEMATIC DIAGRAMS, UNIT-1 SWITCHGEAR, FULL LINE DIAGRAM 1-SB-E-A1-6102 2


8 ELECTRICAL SINGLE LINE DIAGRAMS, STATION SERVICE LV SINGLE LINE FOR UNIT 2 2-SB-E-A1-6241 2

9 ELECTRICAL SINGLE LINE DIAGRAMS, STATION SERVICE LV SINGLE LINE FOR UNIT 2 2-SB-E-A1-6242 2



Index Name Drawing No. Rev.

10 ELECTRICAL SINGLE LINE DIAGRAMS, 220 V. DC DISTRIBUTION PANEL 2-SB-E-A1-6251 2


12 ELECTRICAL SCHEMATIC DIAGRAMS, BUS-BAR VOLTAGE SWITCHGEAR 0-SB-E-A1-6602 2

13 COVER SHEET E15038, 35-00_1 6

14 CONTENT LIST E15038, 35-00_2 6

15 SINGLE LINE DIAGRAM 1 E15038, 35-00_3 6

16 SINGLE LINE DIAGRAM 2 E15038, 35-00_4 6

17 FRONT VIEW E15038, 35-00_5 6

18 FOUNDATION PLAN 1 E15038, 35-00_6 6

19 FOUNDATION PLAN 2 E15038, 35-00_7 6

20 SECTION VIEW, LOCAL DISTRIBUTION E15038, 35-00_8 6

21 SECTION VIEW, POWER TRANSFORMER SUPPLY E15038, 35-00_9 6

22 SECTION VIEW, GENERATOR 1,2,3 E15038, 35-00_10 6

23 COVER PAGE G15038.35_1 8

24 TABLE OF CONTENTS G15038.35_2 8







31 COVER PAGE G15038.35-05_1 8

32 MAIN CIRCUIT CONNECTION G15038.35-05_2 8

33 DC & AC DISTRIBUTION G15038.35-05_3 8

34 CONTROL PANEL G15038.35-05_4 8

35 INDICATION CIRCUIT DIAGRAM G15038.35-05_5 8

36 SIGNALS TO REMOTE CONTROL G15038.35-05_6 8

37 MTX POSITION CONTACTS G15038.35-05_7 8

38 COMMUNICATION & INPUT CONTACTS G15038.35-05_8 8

39 G1503835.05-X1 G15038.35-05_9 8

40 G1503835.05-X4 G15038.35-05_10 8

41 G1503835.05-X4 G15038.35-05_11 8

42 G1503835.05-X101 G15038.35-05_12 8

43 G1503835.05-X105 G15038.35-05_13 8

44 COVER PAGE G15038.35-07_1 8







48 C.B. CONTROL G15038.35-07_5 8

49 C.B. CONTROL G15038.35-07_6 8

50 RELAY CONNECTIONS G15038.35-07_7 8

51 SEPAM WIRING DIAGRAM G15038.35-07_8 8

52 CONTROL PANEL G15038.35-07_9 8

53 CONTROL PANEL G15038.35-07_10 8




57 EARTHING SWITCH & POSITION G15038.35-07_14 8

58 C.B. WIRING DIAGRAM G15038.35-07_15 8

59 G1503835-07-X1 G15038.35-07_16 8

60 G1503835.07-X2 G15038.35-07_17 8

61 G1503835-07-X4 G15038.35-07_18 8

62 G1503835-07-X4 G15038.35-07_19 8

63 G1503835-07-X4 G15038.35-07_20 8

64 G1503835.07-X11 G15038.35-07_21 8

65 G1503835.07-X101 G15038.35-07_22 8

66 G1503835.07-X101 G15038.35-07_23 8

67 COVER PAGE G15038.35-06_1 8




71 C.B. CONTROL G15038.35-06_5 8

72 C.B. CONTROL G15038.35-06_6 8



75 CONTROL PANEL G15038.35-06_9 8

76 CONTROL PANEL G15038.35-06_10 8




80 EARTHING SWITCH & POSITION G15038.35-06_14 8





82 G1503835-06-X1 G15038.35-06_16 8

83 G1503835.06-X2 G15038.35-06_17 8

84 G1503835-06-X4 G15038.35-06_18 8

85 G1503835-06-X4 G15038.35-06_19 8

86 G1503835-06-X4 G15038.35-06_20 8

87 G1503835.06-X11 G15038.35-06_21 8

88 G1503835.06-X101 G15038.35-06_22 8

89 G1503835.06-X101 G15038.35-06_23 8

90 COVER PAGE G15038.35-08_1 8




94 C.B. CONTROL G15038.35-08_5 8

95 C.B. CONTROL G15038.35-08_6 8



98 CONTROL PANEL G15038.35-08_9 8

99 CONTROL PANEL G15038.35-08_10 8




103 EARTHING SWITCH & POSITION CONTACTS G15038.35-08_14 8


105 G1503835-08-X1 G15038.35-08_16 8

106 G1503835.08-X2 G15038.35-08_17 8

107 G1503835-08-X4 G15038.35-08_18 8

108 G1503835-08-X4 G15038.35-08_19 8

109 G1503835.08-X11 G15038.35-08_20 8

110 G1503835.08-X101 G15038.35-08_21 8

111 G1503835.08-X101 G15038.35-08_22 8

112 COVER PAGE G15038.35-01_1 8




116 FAN STARTER TEMP.CONT. G15038.35-01_5 8

117 C.B. CONTROL G15038.35-01_6 8

118 C.B. CONTROL G15038.35-01_7 8







122 CONTROL PANEL G15038.35-01_11 8







129 G1503835-01-X1 G15038.35-01_18 8

130 TERMINAL DIAGRAM=KF01-X1 G15038.35-01_19 8

131 G1503835.01-X2 G15038.35-01_20 8

132 G1503835-01-X4 G15038.35-01_21 8

133 G1503835-01-X4 G15038.35-01_22 8

134 G1503835.01-X11 G15038.35-01_23 8

135 G1503835.01-X101 G15038.35-01_24 8

136 G1503835.01-X101 G15038.35-01_25 8

137 G1503835.01-X105 G15038.35-01_26 8

138 COVER PAGE G15038.35-02_1 8

139 MAIN CURCUIT CONNECTION G15038.35-02_2 8




143 C.B. CONTROL G15038.35-02_6 8

144 C.B. CONTROL G15038.35-02_7 8



147 CONTROL PANEL G15038.35-02_10 8

148 CONTROL PANEL G15038.35-02_11 8

149 CONTROL PANEL G15038.35-02_12 8

150 CONTROL PANEL G15038.35-02_13 8









156 G1503835-02-X1 G15038.35-02_19 8

157 G1503835.02-X2 G15038.35-02_20 8

158 G1503835.02-X2 G15038.35-02_21 8

159 G1503835.02-X2 G15038.35-02_22 8

160 G1503835.02-X2 G15038.35-02_23 8

161 G1503835-02-X4 G15038.35-02_24 8

162 G1503835-02-X4 G15038.35-02_25 8

163 G1503835-02-X4 G15038.35-02_26 8

164 G1503835.02-X11 G15038.35-02_27 8

165 G1503835.02-X101 G15038.35-02_28 8

166 G1503835.02-X101 G15038.35-02_29 8

167 G1503835.02-X105 G15038.35-02_30 8

168 COVER PAGE G15038.35-03_1 8





173 C.B. CONTROL G15038.35-03_6 8

174 C.B. CONTROL G15038.35-03_7 8



177 CONTROL PANEL G15038.35-03_10 8

178 CONTROL PANEL G15038.35-03_11 8

179 CONTROL PANEL G15038.35-03_12 8

180 CONTROL PANEL G15038.35-03_13 8






186 G1503835-03-X1 G15038.35-03_19 8

187 G1503835.03-X2 G15038.35-03_20 8

188 G1503835.03-X2 G15038.35-03_21 8

189 G1503835.03-X2 G15038.35-03_22 8

190 G1503835.03-X2 G15038.35-03_23 8

191 G1503835-03-X4 G15038.35-03_24 8

192 G1503835-03-X4 G15038.35-03_25 8




193 G1503835-03-X4 G15038.35-03_26 8

194 G1503835.03-X11 G15038.35-03_27 8

195 G1503835.03-X101 G15038.35-03_28 8

196 G1503835.03-X101 G15038.35-03_29 8

197 G1503835.03-X105 G15038.35-03_30 8

198 COVER PAGE G15038.35-04_1 8





203 C.B. CONTROL G15038.35-04_6 8

204 C.B. CONTROL G15038.35-04_7 8



207 CONTROL PANEL G15038.35-04_10 8

208 CONTROL PANEL G15038.35-04_11 8

209 CONTROL PANEL G15038.35-04_12 8

210 CONTROL PANEL G15038.35-04_13 8






216 G1503835-04-X1 G15038.35-04_19 8

217 G1503835.04-X2 G15038.35-04_20 8

218 G1503835.04-X2 G15038.35-04_21 8

219 G1503835.04-X2 G15038.35-04_22 8

220 G1503835.04-X2 G15038.35-04_23 8

221 G1503835.04-X2 G15038.35-04_24 8

222 G1503835.04-X2 G15038.35-04_25 8

223 G1503835-04-X4 G15038.35-04_26 8

224 G1503835-04-X4 G15038.35-04_27 8

225 G1503835-04-X4 G15038.35-04_28 8

226 G1503835.04-X11 G15038.35-04_29 8

227 G1503835.04-X101 G15038.35-04_30 8

228 G1503835.04-X101 G15038.35-04_31 8

229 G1503835.04-X105 G15038.35-04_32 8



SUPPLIERS ADDRESS

Contact information for the major system suppliers are listed in Table 7.

Table 7: Suppliers Address Component Type Supplier

Medium voltage switchgear

Medium voltage switchgear Trucks

,

Germany



8.2 DRAFT TUBE GANTRY CRANE

8.2.1 DESCRIPTION

The electric, 9 ton, draft tube bulkhead crane traverses the downstream deck to serve three generating units as shown in Figures 1 and 2.

The crane moves along rails at different elevations as shown in Figure 1. The outside/downstream rails are on the downstream deck at EL 974. The inside/upstream rails are at the height of the powerhouse crane rails, El. 980.

The wheels are not powered; the crane is pulled/towed from one location to the other. At each location there is a crane positioner and embedded stop. A rod lowers from the wheel rail to a receptacle set in the downstream deck to prevent crane movement over the draft tube during operation.

Information about the electric hoist for the crane is unavailable.

Figure 1: 9-Ton Gantry Crane



Figure 2: Gantry Crane

8.2.2 LAYOUT

The north elevation view, Figure 3 shows rectangular openings in the powerhouse wall for draft tubes, two per unit. On the right side, looking upstream, of the unit pair there is a circular opening above the right draft tube for each unit. The circular opening is for the pressure relief valve discharge. When a unit shuts down rapidly, such as due to a line fault, the relief valve opens, and then closes slowly, to minimize water hammer effects. In order to prevent tailwater entering the powerhouse, both the draft tube openings and the bypass valve opening must be sealed closed.

Dewatering the draft tube of any one unit requires deployment of two draft tube bulkheads. The bulkheads are two different sizes. The tall bulkhead (Type A) closes the draft tube plus valve opening. The short bulkhead (Type B) closes only over the draft tube. There is only one set of bulkheads for dewatering one unit at a time.

In order to load and unload a draft tube bulkhead, the crane uses a lifting beam that is manually disengaged by a rope from the deck after the bulkhead is set. When retrieving bulkheads, the lifting hook is pushed open by contact between the outside of the hook and the bulkhead-lifting pin. Details and a photo of this operation are shown on Figures 4 through 6.

During normal storage, draft tube bulkheads are dogged below deck in the slots.



Figure 3: North Elevation View of Draft Tube and Crane



Figure 4: Bulkhead Lifting Beam Drawing



Figure 5: Lifting Beam with Release Toggle and Rope



Figure 6: Draft Tube Bulkhead Dogging Device



8.2.3 MAINTENANCE PLAN

MANUFACTUERS INFORMATION SUMMARY

No information available.

DRAWINGS

No manufacturers drawing of the moving equipment is available.

PREVENTATIVE MAINTENANCE

Inspection and maintenance are performed to ensure the functional capacity of the system both for scheduled maintenance and for unscheduled situations. Periodically exercising the crane may be required if the draft tube bulkheads are not used regularly. There is little opportunity for impact damage, but typically, corrosion damage occurs in the period between uses. Damage caused by lightning strikes are also possible on the crane. Damage to electrical wire is possible from traffic and rodents.

Inspection consists of:

Visual observation of the stationary crane, Visual and audio observation during operation/exercise, and Oil sample testing.

The crane should be inspected for corrosion, loss of coating, deformation, out of plumb, and cracks particularly at welds. The wheels and rails should be inspected for rust. All bearing surfaces should be lubricated. Wire rope should be inspected for rust and broken strands. Inspect the wire rope drum to ensure rope is laying properly.

During (manual) motion, the wheel-rail contact should be observed/listened to for rough running both rails. The staking points (lower surface) should be cleaned out to ensure the rod fits correctly.

During crane lifting operation, observations should be made from the drum location regarding hoist motor and bearing noise and wire rope condition.

To collect an oil sample from the hoist gearbox, the sample should be collected after 10 minutes of crane operation. This ensures that the sample represents the oil in the gearbox, including any loose particles that may have settled since the last operation.

Maintenance includes lubrication of all moving parts and painting of metal surfaces that could rust that are not designed to be lubricated. Any physical damage must be repaired and debris from any source should be cleaned away.

Sampling/Lubrication includes:

For hoist drum drive, sample the oil to be tested for particles/pollution. Replace oil if it is found to be contaminated.

Lubricating rotating parts. In particular wheels for the trolley and bearings for the hoist drum and sheaves should be appropriately lubricated.

The power cable support should be checked for any sign of fraying or damage to the power cable.

The lifting beam is part of the crane operation. The engaging hook is weighted to allow engagement. In order to disengage the lifting beam from the bulkhead, the rope attached to the hook arm is pulled. The same general maintenance applies. Areas that do not move and are corroding should be cleaned and repainted. Contacting surfaces that slide should be greased.



8.3 PENSTOCK AND TUNNEL

8.3.1 DESCRIPTION

The tunnel and penstock used for power generation utilizes one of the two original diversion tunnels created during the original construction of the dam. A power intake structure was constructed about 30 meters above the diversion tunnel, at centerline El. 997.5, and a 7 m diameter concrete-lined shaft with elbows connects to the original unlined 10-meter nominal diameter diversion tunnel. A concrete plug was constructed upstream of this connection point. From the connection point the unlined tunnel is 292.5 meters in length where a second concrete plug was constructed. The downstream tunnel plug is 22 meters in length and encases two steel penstocks; a 3.6 m diameter penstock which conveys water to the existing powerhouse, and a 4.9 meter diameter penstock for a future powerhouse expansion. The 4.9 m penstock is sealed with a steel bulkhead. The 3.6 m penstock is supported on ring girders for about 90 m to the tunnel exit, then becomes a buried penstock for about 44 m to a manifold (where the piping is divided into three or trifurcates) with three 2.438 m diameter wye branches. The buried penstock and manifold are encased in concrete. Centerline elevation of all three wye branches at the powerhouse is El. 962.0.

The penstock within the tunnel downstream of the tunnel plug is in 13-meter sections of pipe on pipe supports with dresser-type couplings. This exposed portion of the penstock can be accessed upstream of the powerhouse as shown in Figure 7. The 3.6 m diameter penstock can be inspected via a walkway as shown in Figure 8.

The unlined tunnel comprises the greatest length of the entire power conduit (Figure 9). When the intake gate is closed and the tunnel is dewatered, the unlined tunnel section can be inspected via a 20-inch diameter manhole access in the exposed penstock as shown in Figure 10.

The invert of the buried penstock section slopes down at a rate of 4H: 1V in places (Figure 11). Access through this section will be more difficult due to the slope.



Figure 7: Penstock Access



Figure 8: Penstock Details Showing Walkway



Figure 9: Tunnel and Penstock Layout



Figure 10: Exposed Penstock Details



Figure 11: Penstock Details Trifurcation



8.3.2 INSPECTION

DEWATERING FOR INSPECTION

The penstock shall be dewatered prior to the interior inspection. No dewatering or tunnel/penstock filling procedures have been located from the original design. Absent such procedures, dewatering requires closure of the intake gate under balanced pressure with all turbine/generator units shutdown, locked out and tagged out. A penstock dewatering valve normally located in the invert upstream of any of the turbine scroll cases shall be opened.

To minimize the risk of rock displacement in the left abutment the rate of reduction of water pressure within the unlined tunnel shall be limited to 0.3 meter per minute when the static water level within the tunnel is above El. 970. No limitation of the dewatering rate is required below El. 970.

Inspection of the power conduit will involve the following:

1. Exterior of the 3.6 m diameter steel penstock. The accessible exterior surfaces of the penstock and shall be visually examined. Photographs and notes shall be taken of worn or damaged exterior coatings and any other unusual observations such as leakage, offsets or deformation at couplings, cracked welds, corroded and settled ring girder supports, or deterioration of the access walkway and supports.

2. Interior surfaces of the penstock and manifold. Photographs and notes shall be taken of worn or damaged interior linings, and any other unusual observations such as cracked welds or offsets of pipe ends at couplings.

3. Unlined tunnel. Photographs, video and notes shall be taken of the dewatered tunnel surface including the tunnel invert, walls and crown for general condition and for any unusual voids in the rock, roughness of angled rock surfaces at voids to judge the relative age of the void, documenting the location and rate of flow from seepage and leaks into the tunnel, and documenting the size and location of loose rock within the tunnel.

TUNNEL AND PENSTOCK FILLING

No filling procedure has been located from the original design. Absent such procedure, filling of the tunnel and penstock should be generally as follows:

With the butterfly valves and wicket gates closed for each turbine/generator unit, raise the intake gate 30 mm. Fill the tunnel and penstock until there is no differential pressure across the intake gate. This may take several hours. Once the pressure is balanced across the intake gate, normal operations for power generation can proceed.

EMERGENCY CLOSURE OF INTAKE GATE

There may never be a need to close the intake gate under flowing conditions. In the event that a turbine/generator unit experiences a runaway condition, the turbine wicket gates and turbine shutoff valve (butterfly valve) should automatically close, or can be closed manually.

It is not known whether the intake gate was designed to close under flowing conditions. If it was not designed for such conditions, closure of the intake gate under flowing conditions may cause damage to the gate and appurtenant structures. If the gate becomes damaged and cannot be raised or lowered when the gate is partially obstructing the flow path to the intake, then the available flow to the turbines will be diminished. If this occurs, underwater divers may be required to release the intake gate from its stuck position.



8.3.3 INSPECTION AND MAINTENANCE FREQUENCY

MONTHLY INSPECTION

A visual inspection of accessible exterior portions of the exposed penstock shall be performed. Photographs and notes shall be taken to document the observed conditions.

ANNUAL INSPECTION

The interior and exposed exterior surfaces of the penstock and manifold shall be visually examined. Photographs and notes shall be taken of worn or damaged interior linings, exterior coatings, and any other unusual observations such as offsets, cracked welds, corroded ring girder supports, or deterioration of the access walkway and supports.

The penstock shall be dewatered prior to the interior inspection. Dewatering requires closure of the intake gate.

5-YEAR INSPECTION

Inspection of the unlined tunnel, and of the concrete-lined shaft if accessible. Photographs and notes shall be taken to document the observed conditions

The penstock shall be dewatered prior to the interior inspection. Dewatering requires closure of the intake gate.



8.4 DRAFT TUBE BULKHEADS

8.4.1 INTRODUCTION

This users manual has been divided into sections and the descriptions have been made simple and easy to understand while at the same time providing the information necessary for safe operation and maintenance.

LAYOUT

Draft tube bulkheads are normally stored in the existing slots on dogging devices.

The north elevation view, Figure 12 shows rectangular openings in the powerhouse wall for draft tubes, two per unit. Looking upstream, on the right side of the unit pair there is a circular opening above the right draft tube for each unit. The opening is for the Pressure Relief Valve (PRV) discharge. When a unit shuts down rapidly, typically due to a line fault, the PRV opens, and then closes slowly, to minimize water hammer effects. In order to allow servicing of the pressure relief valve both the draft tube openings and the PRV opening must be closed.

The elevation view in Figure 12 shows two different heights of lintel. For this reason, there are two types of draft tube bulkheads. The tall (A) bulkhead, Figure 14, closes the draft tube plus valve opening. The short (B) bulkhead, Figure 15, closes only over the draft tube. There is one pair of bulkheads to handle all three units, therefore only one unit can be serviced at any one time.



Figure 12: North Elevation of Powerhouse



Figure 13: Photo Bulkhead A, with Lifting Beam



8.4.2 DESCRIPTION

STRUCTURE

Bulkheads are a welded fabrication shown in Figure 14 and Figure 15.

The A bulkhead is 6.9 m tall x 3.2m wide x 0.35 m thick The B bulkhead is 2.3 m tall x 3.2 m wide x 0.35m thick

They have similar seals, lift points, guides, and wedges.

NORMAL OPERATION

Draft tube bulkheads (also called gates) prevent tailwater from entering the draft tubes and powerhouse. This feature is used when turbine equipment that is normally underwater needs to be inspected or serviced. This includes the turbine, draft tube and pressure relief valve.

The draft tube bulkheads shall only be lowered into the closed position when the turbine/generator unit is not operating. In this condition the draft tube bulkhead gates are closed under balanced water pressure. Lockout/tagout procedures for the unit being serviced shall be implemented before lowering any bulkhead into the closed position.

Down time associated with draft tube dewatering should be minimized as much as possible, but dictated by the O&M manual for the turbines.

GUIDES AND SEALING

The general arrangement of bulkhead and embedded guides and seals is shown in Figure 16.

Since the volume protected by the bulkheads is pumped out causing a pressure differential on the bulkhead, it is desirable to start with a tight seal. Even though the bulkhead rubber seals (J-Bulb) become efficient under pressure, differential pressure to increase cause sealing accumulates slowly if the bulkhead does not seal fairly tightly during setting. Therefore, a wedge system is used so that at closure the bulkhead seals are compressed against the embedded frame as shown in Figure 17.



Figure 14: Bulkhead Type A



Figure 15: Bulkhead Type B



Figure 16: Draft Tube Bulkhead



Figure 17: Wedges and Seals

Sealing is done using neoprene seals. Seals are located on the perimeter of the bulkhead: top, sides, and bottom as shown in Figure 17.


ORIGINAL O&M MANUAL

No original O&M manual is available

DRAWINGS

Drawings by IECO and Bodinson are fairly complete and have been used in the creation of this section.



CONDITION ASSESSMENT OF EXISTING BULKHEADS

There are photos from 2016 that show operation of the bulkhead crane, installation of the large (A type) bulkhead.

MAINTENANCE

Maintenance activity involves inspection to identify problems and remedial measures to address corrosion, sealing or structural degradation.


Draft tube bulkheads shall be inspected before each use, and at annual intervals.

Bulkheads should be inspected for damage. Damage may occur as a result of corrosion, external physical impact, UV degradation, rodent/animal damage, and weathering.

Contacting components are carbon steel and are susceptible to corrosion, which increases friction between moving parts. There is sliding contact on the back of the bulkhead near closure to improve the seal performance at low head. This is important because dewatering the draft tube is performed with pumps. Differential head, normally used to minimize leakage is not available at the beginning of the pumping cycle. The wedges should slide freely. If they are rusted, the bulkhead may not close and seal. Therefore, prior to use, inspect, clean, and lubricate wedges, guide shoes and guide rails.

This applies to the wedges on the backside and to the guide shoes on the ends of the bulkhead.

ANNUAL MAINTENANCE

1. Inspect the bulkhead. Repair and Repaint as required 2. Inspect Seals Restore Damaged Seals 3. Inspect Wedges and Guide Shoes Clean and Grease



8.5 TRASHRACK

8.5.1 INTRODUCTION

This users manual has been divided into sections and the descriptions have been simplified to ease understanding while at the same time providing the information necessary for safe operation and maintenance.

8.5.2 DESCRIPTION

LAYOUT

The trashrack is a segmental semicircle with a nominal 16-0 (4.88 meters) radius. It is supported on a surface sloped at 30 degrees from vertical. It covers the tunnel entrance and extends 25 feet (7.62 meters) above the opening to obtain a nominal thru flow of 1 m/sec. The trashrack is composed of five segments with field-welded joints (Figures 18, 19 and 20).

The top edge of the trashrack is exposed at minimum operating water surface, EL 1012.0

NORMAL OPERATION

The trashrack prevents debris from entering the tunnel and impacting the rotating turbine parts. It is not designed to be removed and does not have any operable components.

Figure 18: Power Intake Trashrack Layout shows the layout of the intake structure with the trashrack, ventilation shaft and intake gate guidance. In addition the upstream part of the tunnel is shown.

Figure 19: Trashrack Plan and Elevation and Figure 20: Trashrack Elevations and Details show the trashrack elevation and the trash rack design and geometry.

Inspection of the trashrack by remotely operated vehicle (ROV) by 77 Construction Company during installation of Turbine #2 project on September 19, 2016, shows no significant corrosion or debris accumulation (see Figures 21 and 22).



Figure 18: Power Intake Trashrack Layout



Figure 19: Trashrack Plan and Elevation



Figure 20: Trashrack Elevations and Details



Figure 21: Underwater Inspection of Trashrack (1)



Figure 22: Underwater Inspection of Trashrack (2)





Inspection and maintenance are performed to ensure the functional capacity of the system as the trashrack can be damaged by corrosion, impact from large floating objects, and plugging by debris. Debris on the face of the trashrack causes a head difference to develop across the trashrack, which in extreme cases will cause a structural overload, resulting in trashrack failure, which can damage the wicket gates, turbine runner, and could plug the tunnel.

There is no log boom (physical barrier to prevent large floating debris from contacting the trashrack) on the reservoir nor are there any instruments installed to measure differential pressure across the trashrack. Consequently, inspection and cleaning will be established based on a schedule and observation of floating debris following major flood events.

The trashrack should be cleaned on a regular basis. The cleaning should be performed as needed, preferably in the autumn or early winter when the reservoir level is at its minimum.

REGULAR MAINTENANCE

In the absence of water level measuring devices, underwater video inspection and cleaning should be scheduled every 10 years, or whenever large volumes of floating debris are observed or are known to have entered the reservoir following a major flood.

Removal of debris may be accomplished by a number of different methods. Employing underwater divers to physically clean and remove debris is most common.



8.6 INTAKE GATE

8.6.1 INTRODUCTION

Kajaki Hydroelectric Power Plant is located in Helmand Province and at the Helmand River on which there exist a major power dams in the Southern part of Afghanistan. The dam of Kajaki HEPP is located on Helmand River and 100 miles away from Kandahar Province of Afghanistan (161 km North-West of Kandahar) and operated by the Helmand and DABS Valley Authority. It has a dual function that produces electricity and used for irrigation of farmland. The installed capacity of Kajaki HEPP is 38 MW and it has 2 power turbines in operation that generates average electricity of 25 MWh per year. A third turbine was recently completed at this facility.

On September 19, 2016, 77CC performed the intake gate and hoist inspection. The following were inspected:

1. Motor, brake and drum 2. The cable 3. The 400/220 Volt AC power, control and instrumentation of the head works 4. The interlocks and interlocking between the hoist gate system and power plant system 5. The hoist gate wheels and guide ways 6. The hoist gate steel structure 7. The sealing material on the hoist gate

Refer to Appendix 8.6-A for full inspection report.

8.6.2 DESCRIPTION

Hoist and gate are used to close the tunnel on the Units 1, 2 and 3.

LAYOUT

The tunnel intake sill is at EL 994.0. The wire rope hoist is at El 1061.75. Figure 23 shows the general arrangement installed.

Figure 24 shows the general framing strategy for the intake gate. Three panels were welded together on site. There are nine wheels on each side with eccentric axles to allow alignment of the wheels. Final alignment position is welded in place.

Wheel bearings are spherical, with two rows of rollers to ensure the wheel and rail maintain line contact as shown in Figures 24 and 25. The lubrication line fill points for the wheel bearings and axles are shown Figure 25.



Figure 23: Intake Gate General Arrangement Drawing



Figure 24: Detailed Intake Gate Drawing



Figure 25: Intake Gate Wheel Lubrication Drawing



Figure 26: General Configuration of Intake Gate



NORMAL OPERATION

The normal position of the gate is immediately above the intake so that closure can be made relatively quickly. For inspection and maintenance, the gate is raised above high water, EL 1047.

INTAKE GATE OPENING PROCEDURE

1. Make sure the pressure inside the tunnel is the same as the pressure outside, before attempting to open the intake gate;

2. Make sure the intake gate and hoisting mechanism are fully operational; 3. Make sure the pressure inside the spiral case and the penstock are the same; 4. Close the Main Inlet Valves (MIV)inside the power house for each unit; and then 5. Open the intake gate.

There is a 12 inch pipe from Irrigation penstock to power penstock that is the primary means of filling the tunnel.

There is an air vent behind the gate to allow air to escape when filling the tunnel.

ALTERNATE TUNNEL REFILLING

To minimize the risk, crack the gate slightly, less than 30 cm until the tunnel fills and head is balanced.

INTAKE GATE CLOSING PROCEDURE:

1. Make sure the pressure inside the spiral case and the penstock are the same; 2. Close the Main Inlet Valves (MIV)inside the power house for each unit; and then 3. Make sure the intake gate and hoisting mechanism are fully operational; 4. Start lowering the gate to close the power tunnel.


DRAWINGS

Refer to Figures 23, 24, 25, and 26.


Table 8: Summary of Maintenance No Description Remarks

1 General Periodic Inspection To ensure long term functional viability of the gate including the wheels.

2 General maintenance To ensure long term functional viability of the gate including the wheels.

3 Periodic Lubrication To provide reliable, consistent operation, and that the gate seals are intact.

4 Periodic gate structure checks for structural damage due to corrosion or impacts or stress

5 Visually check and inspect the steel structure of hoisting mechanism

6 Anchor Girder: Visually check all the nuts, studs, bolts of anchor for their proper tightness

7 Visually check all welding connections.



8 Visually check whether drain holes in anchor girder are clean. The water should not have accumulated in the slots.

9 Visually check all the welding joints of horizontal girder assembly for proper soundness

10 Visually check whether the drain holes of horizontal girder are clear to prevent accumulation of water and rusting.

Take immediate action for repair if any deformity found

11 Visually check for any deformation of girders particularly at ends Take immediate action for repair if any deformity found

12 Visually check the Brake drum and the liner Brake drum and line should be free from grease oil.

13 Visually check the solenoid/magnetic coil for its proper functioning

14 Visually check worm reducer for smooth operation and oil level. Make sure the oil level are in sufficient quantity.

15 Visually check all electrical connections of hoist motors, brakes, and starters and limit switches for proper insulation and tightness.

This should be done be an electrician.

16 Visual check manual operation arrangements and adjust gears / chain etc. if required.

WHEELS, BEARINGS

Wheels and bearings should be checked for corrosion since these are not painted surfaces. At wheel rail contact, no paint could withstand the wear, so there is an obvious corrosion site.

The bearings are intended to be protected from corrosion by lubrication. Lubrication must be monitored and reapplied as needed. Frictional resistance of bearings will increase hoist load.

Wheel bearings should be greased annually.

Wheels should be rotated to verify function by lowering the gate till the wheels complete a full rotation and bringing it up to its initial position. If wheels cannot be rotated, the bearings should be examined for rust. They must be evaluated, and should be verified whether cleaning alone is possible or replacement is required.

SEALS

Possible causes of seal damage include erosion, impact, rodent attack, UV degradation. In addition there is a potential lintel seal failure due to excessive motion, if operated under differential pressure. This is possible, due to the configuration of the lintel seal (Section AA), that the seal may roll when the gate is lifted if there is significant differential head and the gate is raised above the limit.



Figure 27: Intake Gate Seals

Table 9: Preventative Maintenance Plan Component Maintenance Action Other inspect Remedies Frequency

Gate Frame Inspect Corrosion damage Penetrant dye on suspect areas Clean and paint Five year intervals

Gate seals Inspect Integrity of seal and Teflon Replace where damaged Annual

Wheel surface, rail Inspect Corrosion and pitting Check rail straightness Clean and grease Annual

Wheel bearing Manually rotate, use levers. Remove cover to clean bearings If pitted bearings, replace. Annual

Wheel bearing Fill with grease Verify grease to each wheel bearing Replace grease lines. Annual



8.7 LIST OF MANUFACTURERS

TURBINE (TURBINES 1 AND 3)

Allis-Chalmers Corp.

TURBINE (TURBINE 2)

Sichuan Dongfeng Electric Machinery Works Co., Ltd

Fujian Nanping Electric Machinery Works

Guangdong Shaoguan Zhongli Power Equipment Co., Ltd

Hangzhou Power Equipment Works

GENERATOR (TURBINES 1 AND 3)

Westinghouse Electric Corporation

GENERATOR (TURBINE 2)

Sichuan Dongfeng Electric Machinery Works Co., Ltd

Fujian Nanping Electric Machinery Works

Guangdong Shaoguan Zhongli Power Equipment Co., Ltd

Guangdong Xingning Electric Machinery Works Co., Ltd

GOVERNOR

Tianjin Design And Research Institute Of Electric Drive

INLET VALVE

Changsha Valve Works

Tie ling Valve Jrnp. & Exp. Co., Ltd

Ningbo Valve Works

PRESSURE REGULATOR VALVE

Jiajiang Hydraulic Machinery Works

Tianjin Design And Research Institute of Electric Drive

MAIN TRANSFORMER

Thea Hengyang Transformer Co. Ltd.

Baoding Railway Transformer Works Of Electrification Engineering Bureau Of Ministry Of Railway

Tianjin Transformer Co., Ltd, Etc.

EXCITATION SYSTEM

Tianjin Design and Research Institute of Electric Drive



GENERATOR NEUTRAL CUBICLE


Northeast Electric Transmission & Transformation Equipment Group

Huali Energy Equipment Manufacturing Co., Ltd

13.8KV SWITCHGEAR

ABB Inc.

400V AC, DC SWITCHBOARD

Tianjin Design And Research Institute Of Electric Drive

SCADA SYSTEM AND EQUIPMENT


PROTECTION SYSTEM & EQUIPMENT

Sun Nanjing Automation Equipment Co., Ltd

Xuchang Relay Co. Ltd

LIGHTNING ARRESTER

Fushun Porcelain Insulator Work

Shanshai Porcelain Insulator Work

13.8KV NON-SEGREGATED PHASE BUS

Zhengya Engineering Apparatus Cooperation Work

Shengda Apparatus Cooperation Work

Huadong Electricity Equipment Work

POWER AND CONTROL CABLES

Tainjin Cable General Work

Shanghai Cable Work

Tainjin Siemens Cable Co. Ltd

Mingxing Cable Work

INSTALLATION

Hubei Dayu Water Resource & Hydroelectric Corp. Ltd.

China 10th Engineering Bureau Of Water Conservancy & Hydropower

Engineering Bureau of Shanxi Hydropower Co. Ltd.



8.8 HIGH VOLTAGE POWER TRANSFORMERS

8.8.1 INTRODUCTION

Hydro generators in Kajaki HPP delivers produced electricity to grid through three single phase power transformers. These transformers transported to site demounted because of their sizes.

The descriptions have been made simple and easy to understand while at the same time providing the information necessary for safe operation and maintenance.

An obvious condition for the safe running of the transformers is that they are only operated by qualified personnel. The users manual is an important aid which operational personnel are obliged to make themselves familiar with. The users manual should therefore be kept easily accessible for the operators. It is the duty of the operator in charge to ensure that unqualified personnel do not gain access to the machinery.

CONTACT ADDRESS OF SUPPLIER

Requests for assistance should be directed to the suppliers listed in Table 10.

Table 10: Supplier Information Supplier Name Address Phone Email

China,

350012

Not Available

8.8.2 SCOPE OF SUPPLY AND TECHNICAL DESCRIPTION

SCOPE OF SUPPLY

Three oil-immersed power transformers were made and supplied by the Fuzhou Tianyu Electric Co., Ltd. For the project.

SUPPLIER INFORMATION

Commissioning testing of the transformers was performed in accordance with GB50150, Commissioning Test Standard for Electric Apparatus Assembly Projects.

MAIN DATA AND CHARACTERISTICS

Main Data

Main specifications, data and parameters for the high voltage transformers are provided in Appendix A and summarized in Table 11.

Table 11: Main Data for High Voltage Transformers Type DF9-25000/63.51

Product Code 1RB.700.5194.1

Low side voltage 13.8 kV

High side voltage 63.5 kV

Phases One

Rated Power 25000 kVA

Frequency 50 Hz



Service Condition Outdoor

Cooling Method ONAN/ONAF1/ONAF2

Total Weight 32420 kg

Declaration of Conformity

The high voltage transformers comply with IEC standard 60076.

DESCRIPTION OF COMPONENTS

General Information

The high voltage transformers are described in the operating instructions, included in Appendix A and shown in the drawings included in Appendix B.

INSTRUMENTS

The high voltage transformers are equipped with sensors to remotely read the winding temperature and oil temperature. Oil level gauges allow for reading the oil level in the transformers and bushings.

PARAMETERS AND DATA FOR SURVEILLENCE

The oil temperature, winding temperature, voltage, and current should be monitored while the transformers are in operation.

8.8.3 PREPARATIONS BEFORE START

Commissioning and startup instructions are provided in in Appendix 8.8-E.

8.8.4 OPERATION

ASSEMBLY AND START UP

Assembly and startup instructions for the high voltage transformers are provided in Appendix 8.8-E.

STORAGE

Special measures should be taken if the transformers are stored in a non-operating condition for more than three months, as described in Section 3 of the transformer operations manual, included in Appendix 8.8-A.

DANGERS AND PREVENTATIVE MEASURES

The high voltage transformer and power lines are dangerous when energized. Disconnect from all power sources and verify equipment is de-energized before inspecting or servicing.

Maintenance should only be performed by qualified personnel.

8.8.5 MAINTENANCE

MAINTENANCE PLAN

To ensure that the equipment functions satisfactorily over a longer period of time, check-ups and maintenance must be carried out at regular intervals. A list of the recommended inspection and maintenance activities for the transformers is shown in Table 12.



Table 12: Recommended Inspection and Maintenance Activities for Transformers Feature Activity

Hourly

Ambient temperature Measure air temperature near the transformers

Winding temperature Check that winding temperature is less than 60C

Oil temperature Check that oil temperature is less than 50C

Load Check that input load is less than 1812 A

Voltage Check that output voltage is 63.51 kV 4x2.5%

Noise and vibration Check for abnormal noises or vibration

Daily

Oil level Check oil level in transformers using oil level gauges Check oil level in bushings using bushing oil level gauges

Pipe work and accessories Check for oil leaks

Relief vent diaphragm Check for any visible cracks

Fans and oil pumps Check that fans and oil pumps are running

Weekly

Anti-condensation heaters Not applicable

Monthly

Dehydrating breather Check color of silica gel Check oil level in the oil cup Check oil from oil cup visually for contamination Check that air passageways are clear

Oil temperature indicator Record the maximum temperature during the month

Winding temperature indicator Record the maximum temperature during the month

Cooling fans Check operation of fans manually, when temperature is below the set point

Quarterly

Bushings Visually inspect bushings for cracks and dirt deposits

Cooling fans Check contacts and manual controls

External earth connections Check all external connections for discoloration or hot joints

Marshalling box/Control box Check that wiring and the terminal connection are tight

Oil in transformer Check dielectric strength and moisture content

Insulation resistance Measure insulation resistance value between windings and ground

Bi-Annual

Alarm, trip, and protection circuits

Check operation of alarm/trip contacts of each protection circuit

Oil in transformer and bushings Sample and test oil, including dissolved gas analysis

Oil in bushings Check moisture content of oil

Annual



Oil and winding temperature indicators

Calibrate and check difference between winding temperature indicator and oil temperature indicator Check that oil is in the heating pockets

Magnetic oil level gauge and prismatic level indicator

Check oil level in conservator by dip stick method and compare to oil gauge glass Clean oil gauge glass

Gas Relays (Buchhloz Relay) Inspect box for leaks or loose connections Check movement of floats Check tightness of merc

pdf.usaid.govpdf.usaid.gov/pdf_docs/pa00mvnp.pdf · kajaki hydroelectric power plant (hpp)...

Documents