Management and Operation Manual

for
Private Micro-Hydropower Plants
Prepared by
DCS Tecnology Development
P!O! "o# $ %& "utwal& 'epal
(nternational Centre for (ntegrated Mountain Development
)(C(MOD*
+atmandu& 'epal
,--%
Table of Contents
,! (ntroduction Page
.! Plant Management ,
.!, Operator/s Management 0
2.1.1 Selection and Terms of Employment 3
2.1.2 Training 4
2.1.3 Assignment and Supervision of Operators !or" 4
.!. (mproving Customer Services 1
2.2.1 #ublic $elations %
2.2.2 &ood Service %
2.2.3 'oad (anagement %
.!0 2inancial Management 3
2.3.1 )ncome and E*penditure Account +
2.3.2 ,udget for -e*t .ear 1/
2.3.3 ,usiness E*pansion 11
2.3.4 E*tending Supply 12
.!4 Organi5ing Maintenance ,0
2.4.1 (aintenance Stoc" of Spares 13
2.4.2 (aintenance Tools 14
.!1 Organi5ing 6epairs ,1
2.%.1 #rocedures to 0eal 1it2 a ,rea"do1n and 3ault 0iagnosis 1%
2.%.2 0isassembling and Assembling t2e E4uipment 15
2.%.3 Transporting E4uipment for $epairs 15
0! Operation ,%
0!, 7eneral Operation Procedure ,%
3.1.1 T2e Startup #rocedure 1+
3.1.2 Continuous C2ec"s 0uring $unning 16
3.1.3 S2utting 0o1n #rocedure 16
0!. Safety and 2irst 8id .9
3.2.1 !or"place Safety #recautions 2/
3.2.2 3irst Aid for Electrical S2oc" 21
3.2.3 Artificial $espiration Tec2ni4ues 21
0!0 :#tended Sut Down .0
0!4 6outine (nspection and Maintenance .0
3.4.1 0aily )nspection and (aintenance 24
3.4.2 !ee"ly )nspection and (aintenance 24
3.4.3 (ont2ly )nspection and (aintenance 24
3.4.4 Si* (ont2ly )nspection and (aintenance 24
3.4.% .early )nspection and (aintenance 2%
3.4.5 Additional )nspection and (aintenance 2%
3.4.7 Some Additional Suggestions $egarding Operation and
2%
(aintenance
0!1 ;og "oo< .3
4! Transmission = Distribution .-
4!, House >iring 0,
4!. :arting 04
4!0 7eneral 6ules for House >iring 04
#$E3ACE
T2e main ob7ective of preparing and distributing t2is (anual on management and operation of
private or community o1ned8managed ((9# plants :especially t2e micro;range< is to provide
some assistance to t2e managers and operators 12o are ot2er1ise facing difficulties in t2is
regard. Suc2 difficulties 2ave mainly emerged since t2e managers and operators of suc2 plants
are less educated= less e*posed to mac2inery and 2ave very fe1 opportunities to participate in
relevant and 4uality training programmes.
T2e preparation of t2e (anual 1as visuali>ed= initiated and sponsored by )C)(O0 as a regular
component of -O$A0;sponsored pro7ect ?Capacity ,uilding for (ini; and (icro 9ydropo1er
0evelopment in t2e Selected Countries of 9indu @us2;9imalayan $egion= #2ase ))?. )t is one
of five suc2 manuals aimed at t2e various groups of implementers= includingA site surveyors
and layout designers=;manufacturers of indigenous e4uipment= installers= managers and
operators ; and t2e repairers. T2e first draft of t2is (anual 1as prepared by 0CS;Tec2nology
0evelopment ,ut1al= -epal and 1as e*tensively revised by me. T2us= t2is is a first indigenous
and concerted effort to 1rite 4uality manuals 2aving a regional rat2er t2an general perspective.
0CS= in particular= deserves ac"no1ledgement and encouragement.
T2e main focus of t2is manual concerns t2e isolated= indigenous= local entrepreneur;o1ned
.plants in t2e micro;range. ,ut mostly= suc2 plants installed in -epal= #a"istan and )ndia 2ave
capacity less t2anB 5/ "!. @eeping in mind t2at t2e. managers and operators of suc2 plants
2ave very little education and even less tec2nical "no1ledge= t2e manual 2as been "ept simple
and brief. 3or t2e same reason= t2e manual does not cover all different types of mac2ines and
management systems. )n any case= it is almost impossible to cover all t2e managerial and
operational aspects in one manual of t2is type. At t2e same time= one s2ould al1ays strive to
improve suc2 documents. T2erefore= suggestions to improve it furt2er and ma"e it reasonably
useful are 1elcome= indeed earnestly solicited from e*perienced implementing agencies and
operators8managers 12o may be able to point out t2e additional aspects to be covered and t2e
met2odology.
T2e above remar"s not 1it2standing= it is 2oped t2at manual in t2e relevant languages in )ndia=
-epal and #a"istan 1ould provide significant assistance and relief to t2e practicing managers
and operators. )t is also 2oped t2at some training agencies 1ould find it to be a useful support
mater . al for t2eir training programmes.
An1ar A. Cune7o
Coordinator= ((9# #ro7ect
)C)(O0
8C6O'?MS$
#TC ;D #ositive Temperature. Coefficient
ECC ;D Electronic Current Cutout
'#C ;D 'oad #riority Controller
-&O ;D -on &overnment Organisation
"! ;D @ilo1att
,#T ;D ,rea" #ressure Tan"
E'C ;D Electronic 'oad controller
(C, ;D (iniature Circuit ,rea"er
A0,8- ;D Agriculture 0evelopment ,an"8-eal
)T0& ;D )ntermediate Tec2nology 0evelopment &roup
E)$ ;D Eulcani>ed )ndian $ubber :)nsulation<
#EC ;D #oly Einyl C2loride
T$S ;D Toug2 $ubber S2eat2ed :)nsulation<
SOE ;D Sund2ara Oil E*peller
0# ;D 0ouble #ole :S1itc2<
((9# ;D (ini; and (icro;9ydropo1er
(9# ;D (icro; 9ydropo1er
('T6OD@CT(O'
To develop any village= region= or even a countryB. proper resource mobili>ation= 12et2er
2uman or natural= plays a vital role. )n t2e 9indu @us2;9imalayan :);)@9< region t2ere are
fe1 natural mineral resources of 1ort2= e*cept abundant 1ater resources and a large pool of
2uman resources= alt2oug2 uns"illed. Fsing currently available tec2nology= 12ic2 is based on
practical= installation e*perience= micro; and mini;2ydropo1er :((9#< can be installed to
2arness t2is available 1ater resourceA and combined 1it2 t2e 2uman resource= t2roug2 training=
can play a significant role in en2ancement of living standards in t2e remote and under;
developed mountain areas.
As 1e;approac2 t2e 21? century= electricity is no longer considered to be a lu*ury= but a basic
need of people every12ere. )t is synonymous 1it2 a better standard of living and is vital for
better communications= 2ealt2 care and reduced p2ysical labour.
)nstallation of e4uipment is not t2e end of t2e 7ob many pro7ect. #roper o pertain and
management of t2e plant and organising repair and maintenance are also essential for
satisfactory performance 12ic2 can be ac2ieved t2roug2 training and bac";stopping. )ndeed=
proper management of t2ese stages is t2e main determinant in t2e success or failure of t2e
entire pro7ect.
)n 9@9 region= settlements and 2ouses are scattered and remote from road 2eads or national
grid. Transmission of electricity or transport of fuel to many of t2ese locations is
pro2ibitively e*pensive. T2erefore= old forest trees are being felled= 1it2 fe1 ne1 plantations
to replace t2em= to provide fire1ood for coo"ing= commercial use and even lig2ting. Suc2
deforestation also contributes to1ards flas2 floods and landslides. Some practical options to
mitigate t2ese problems are ne1 plantation programme and use of ((9# to meet t2e local
energy needs.
T2e capital re4uired for investing in ((9# is beyond t2e reac2 of t2e people of mountain
communities and loans must be ta"en. )f t2ese loans are not to be a burdenA t2e ((9#
sc2emes must be carefully scrutini>ed= installed and 1isely operated and managed :including
proper repair and maintenance< to give long;term benefits. )f properly installed= a ((9#
plant may provide energy for lig2ting= grain grinding= oilseed e*pelling and ot2er milling
facilities= as 1ell as for possible use of communication by p2one= radio and televisionA and
industries suc2 as sa1mills= papermills= !or"s2ops= etc. )t may even encourage facilities
suc2 as rope1ays= to reduce t2e burden of p2ysical pottering.
T2is manual 2as been prepared to assist in management of ((9# plants so as to give
ma*imum returns and benefits from t2e investment. )t assumes t2at t2e survey= design=
installation and 2and;over 1or" 2as been completed amicably. T2e roles of operator and
manager no1 become as important to t2e investors in t2e pro7ect as t2e role of a bus driver is
to t2e safe operation of a bus. Carelessness on be2alf;of eit2er may result in an accident.
T2e manual is intended for t2e use of managers and operators of micro;2ydropo1er :(9#<
plants of upto 1// "! capacity. 9o1ever= many c2apters may also be relevant for larger
((9# plants of= say= up to 2// "! capacity. 9o1ever= since t2e manual does not contain
c2apters on transformers or 2ig2;transmission transmission lines= suc2 information 1ould 2ave
to be ac4uired from ot2er sources.
)deally= t2e manual 1ould be more useful for t2ose managers and operators 12o 2ave also
attended a training programme based on t2is manual. 9o1ever= t2ose serving managers and
operators may also find it beneficial 12o "no1 t2e (9# plants and t2eir parts reasonably 1ell
and t2eir reading capabilities are ade4uate. ,asically= t2e manual 2as been 1ritten for
electrification sc2emes. 9o1ever= t2e (9# plants :prime movers< po1ering ot2er industrial
applications suc2 as agro;processing can e4ually benefit from t2e contents of t2is manual.
.! P;8'T M8'87:M:'T
)n small plants t2e operator and manager is usually t2e same personA or= t2e manager also
assists in operation and maintenance. 3or plants larger t2an %/ "!= t2ere s2ould be t1o
different positionsA bot2 for a manager and operatorA but t2is again depends on t2e level of
management s"ill of t2e operator and also t2e interest and commitment of t2e manager 12o
may also be t2e o1ner of t2e plant.
T2e operator is responsible for not 7ust running t2e plant but also for maintenance and
occasional repair. T2erefore= 2e must understand t2e location and functions of eac2 mac2ine
and components. 9e s2ould be continually listening= testing and c2ec"ing for malfunctions and
problems. 9e needs. to "eep uppermost in mind t2at prevention is al1ays better t2an cure ; ?a
stitc2 in time saves nine?. 9is responsibility 1ill normally be for all e4uipment and structures
from source to distribution including routine inspections= operation= loading of t2e system=
distribution and good condition of e4uipment.
T2e manager is responsible for overall management of t2e plant including organi>ation=
planning= management= budgeting= tariff setting= "eeping of boo"s= etc.
.!, OperatorsA Management
.!,!, Selection and Terms of :mployment
(anagement selects and appoints t2e operator 12o s2ould be suitable for t2e 7ob. T2e operator
s2ould be at least literate= preferably educated upto class + if possibleA 2e s2ould be
e*perienced= sincere= 2onest and 2aving t2e capacity to learn and build good relations2ip 1it2
ot2ers. 9e s2ould be able to do basic trouble;s2ooting. )f not= 2e s2ould be trained properly by
good trainers at a suitable 'ocationA including at a running (9# plant.
A suitable local person s2ould be selected as operator if possible= because 2e is less li"ely to
leave t2e 7ob. T2is may not al1ays be possible t2oug2A in 12ic2 case a more e*perienced
person s2ould be selected from outside and a 2ig2er salary offered. A more 4ualified person
1ill run t2e pro7ect more smoot2ly and 2is 2ig2er salary is more li"ely to "eep 2im t2ere.
An operator can 1or" + 2ours a day normallyA but if t2e plant runs for more t2an + 2ours per
day= an additional operator 1ill be needed to cover illness and emergencies also. )f t2e
o1ner8manager is capable of running t2e plant= 2e may ta"e t2e place of an emergency
operator. T1o operators s2ould be appointed if t2e plant 2as agroprocessing plus electrical
generator.
0etails of salary= leave= overtime and ot2er facilities s2ould be made clear at t2e time of
appointment and it is recommended t2at a contract be dra1n up covering all important
conditions so as to avoid disputes later. Terms of resignation and period of notice by bot2 sides
s2ould also be specified in t2e contract. T2e operator s2ould preferably be appointed during
t2e e4uipment installation stage of t2e pro7ect and be re4uired to 1or" along side t2e installers
so t2at 2e learns about t2e procedure of installation= assembly= etc. )f possible= installers s2ould
e*plain to t2e operator about 12at can go 1rong 1it2 eac2 component and 2o1 to run t2e
e4uipment= apply tension to belts= grease t2e lubrication points and 2o1 to deal 1it2
emergencies.
)f t2e plant is coupled to agro;processing e4uipment= t2e operator s2ould also be trained to
operate t2e agro;processing e4uipment and its accessoriesA i.e. s2aft pulley= belt= etc. T2e
operator s2ould "no1 2o1 to c2ange belts safely= 2o1 to fi* alignment and diagnose faults of
agro;processing mac2ines. )f t2e operator leaves t2e 7ob after only a s2ort time it 1ill not only
2inder t2e day to day 1or" but also cause economic loss to t2e o1ner. )t is= t2erefore=
important to select t2ose people 12o 2ave little c2ance of leaving t2e 7ob. Ade4uate incentives
including good salary may be 2elpful in retaining good operators= in addition to good be2aviour
and treatment.
.!,!. Training
)f t2e operator 8 manager is 2ired in t2e early p2ases of t2e pro7ect= t2e subse4uent training
needs may be less. )t is= 2o1ever= necessary to provide special training= if t2e employee is
2ired after t2e 2andover of t2e pro7ect. T2e o1ner8community s2ould be a1are of t2e ii;
importance of training= 1it2out 12ic2 a pro7ect 1ill not run smoot2ly. T2e installer provides
some basic training at t2e pro7ect site= to familiari>e t2e operator 1it2 t2e mac2ines and simple
operational procedures. Fsually t2is training may not be ade4uate. T2erefore= additional
e*tensive training s2ould also be provided. T2ere are organi>ations 12ic2 provide suc2
training t2roug2out t2e year. Often t2e training is given free of cost. T2e o1ner8community
s2ould ma"e t2emselves a1are of suc2 opportunities available in t2eir country.
.!,!0 8ssignment and Supervision of OperatorAs >or<
T2e number of po1er2ouse operators needed by a micro;2ydro pro7ect and t2eir 1or"
assignments are determined by t2e capacity of t2e pro7ect= t2e comple*ity of t2e transmission
lines= 2eadrace= penstoc"= etc. T2e usual 1or" load of t2e operators can be classified as
follo1s.
$egularly inspecting t2e civil 1or"s and penstoc" for damage and cleaning up.
3lus2ing 8 cleaning t2e inta"e= 2eadrace= desilting basins= forebay= etc.
$epairing damage to civil 1or"s.
Stabilising 8 cleaning surrounding areas to avoid landslide damage.
Cleaning and properly maintaining t2e po1er2ouse and t2e e4uipment t2ere.
#roperly operating t2e mac2ines 1it2in t2e po1er2ouse.
'istening for any malfunction or similar problems.
S2utting do1n t2e plant if necessary.
Carrying out some minor repairs.
T2e 7ob of t2e manager is to clearly e*plain t2ese assignments to t2e operators= to assist and
lead t2em= and to supervise t2eir 1or"= especially during t2e initial stages of t2eir allotment.
T2e manager s2ould also assess t2e 4uac"s of t2e o aerators to learn and perform t2eir duties
amicably. 9e must also 4uestion t2em or reprimand t2em if necessary about any la*ness in
performing t2eir duties.
.!. (mproving Customer Services
.!.!, Public 6elations
T2e manager and operator s2ould be gentle in speec2 to t2e customers 12ic2 is good for
siness. Any minor problems; 1it2 t2e customers s2ould be sorted out immediately. 3or
comple* problems= a general meeting s2ould be called= inviting all related personnel. T2e
prevailing problems s2ould be discussed and a solution 1or"ed out 7ointly= especially in case of
electrification sc2emes. Sometimes t2e operator 8 manager 2imself may 2ave to visit t2e local
1or"s2op or organi>ation remote from t2e plant. 0uring t2is period= anot2er capable person
s2ould be instructed to loo" after t2e operation and management of t2e plant. T2e public
s2ould be informed in advance of t2e appro*imate period and reasons for any s2ut do1ns of t2e
plant so t2at t2ey can ma"e alternative arrangements.
T2e operator8manager of an electrification plant s2ould visit t2e consumers and discuss 1it2
t2em problems or complaints t2ey may 2ave regarding t2e supplyA and discuss ot2er issues suc2
as use of electricity= non payment of bill= lo1 voltage= etc. Every effort s2ould made to 2old
suc2 discussions in a cordial manner..
.!.!. 7ood Service
T2e operator8manager must provide good service to t2e customers on a first;come firstserved
basis 1it2 fe1 e*ceptions. 3or e*ample= people coming from distant places need to go 2ome
early= so t2ey may be given priority after reac2ing an understanding 1it2 ot2er customers.
!2ile planning t2e supply of electricity= all 2ouses re4uesting a fi*ed 1attage supply= s2ould be
connected first. Only after all suc2 2ouses 2ave been provided for= additional available po1er
s2ould be distributed as per t2e re4uirements.
Fnsc2eduled and unannounced s2ut do1n of t2e plants 1ould lead to loss of revenue= business
and reputation. T2erefore= every effort must be made to avoid t2e brea"do1ns and s2utdo1ns=
t2roug2 regular maintenance and ta"ing care of small faults and problems 12ic2 may;
eventually lead to serious brea" do1ns.
.!.!0 ;oad Management
#o1er demand 1ill e*ceed t2e installed capacity sooner or later in many plants because=
unfortunately= some consumers may ta"e more po1er t2en t2e amount t2ey 2ave subscribed for.
T2ere is a need for some sort of monitoring device to ma"e certain t2at t2e generating plant is
not over;loaded and t2e investor is not suffering losses. )t is not practical to install a meter in
every 2ouse;2old in a (9# sc2eme. T2is 1ill only introduce more costs and complicationsA
especially since most consumers 1ill be subscribing in t2e range of %/;2// 1atts only.
A flat rate system is generally used= and in t2is t2e consumers pay a fi*ed rate for 1attage
2e8s2e subscribes to. #ositive T2ermal Coefficient :#TC< controllers are use for 2% to %/ 1att
range= electronic current cut;outs :ECC< are available for %/;2// 1 arrange= and miniature
circuit ,rea"ers :(C,< are suitable for consumers subscribe for more t2an 2// 1atts.
9o1ever= some problems 2ave been e*perienced 12en ECC 1ere used in -epal. T2e ot2er
t1o options may= t2erefore= be used.
'oad factors of (9# plants are generally poor= especially t2e electrification sc2emes T2e main
use of electricity is for domestic lig2ting. T2us t2e po1er demand is of certain 2ours in t2e
evenings and sometimes in t2e mornings for about si* 2ours a day !2ile= t2e available po1er
from t2e plant remains unutili>ed for t2e remaining period resulting in less income. T2e
o1ner8manager must= t2erefore= al1ays t2in" of 1ays increase utilisation and8or sale of
electricity particularly to industrial or commercial units.
0uring t2e daytime and at nig2t= 12en lig2ting is not necessary= ot2er end uses could be
installed suc2 as= small industries= s2ops 1it2 B refrigerators= ba"eries= sa1mills= and so on. T2e
o1ner of t2e (9# plant may invest in suc2 applications 2imselfA or 2e ma encourage or see"
ot2ers to install suc2 units and buy electricity from 2im. )f industrial uses can be en2anced=
po1er distribution must be carefully managed to be acceptable to suc2 customers.
Sometimes due to 2ig2 costs= t2ere is a lac" of interest in industrial development. T2e manager
s2ould motivate people to install industries= and c2arges s2ould be reduced if t2e investors
agree to operate during off pea" 2ours. )ndustries s2ould= 12erever possible= not be run during
pea" 2oursA ot2er1ise t2ere 1ill be voltage fluctuation. $ates for suc2 industries s2ould be
decided before t2e industry is installed.
.!0 2inancial Management
)n order to "eep trac" of income and e*penditure= proper records and accounts of t2e income=
e*penditure and savings s2ould be maintained. B $epayments of t2e loan s2ould be planned=
based on t2e income and t2e savings and ade4uate amount must set aside eac2 mont2 for t2is
purpose. An account boo" maintained for t2is purpose= must cover t2e follo1ing.
0aily records. of income and e*penditure including t2e outstanding amounts.
$ecords of Assets :property and stoc" o1ned= liabilities8bills or money still to be paid=
on mont2ly basis.
Amounts spent on ma7or repairs= ne1 e4uipment or business e*penses; s2ould also be recorded
daily and separately on mont2ly basis.
All t2e income= e*penditure= outstanding income and liabilities must be reproduced in a
final table eac2 year to determine net profit or loss. T2ese calculations 1ould be useful
for planning t2e business for t2e ne*t year.
Fsually= one Account ,oo" 1ould be sufficient for a (9# plant= but it s2ould 2ave
many tables.
T2ere are t1o main systems for. "eeping t2e accounts of a pro7ectA i.e. single entry boo";
"eeping= 12ere t2e transactions are recorded once= and double entry boo""eeping= 12ere all t2e
business transactions are recorded t1ice. 3or e*ample= 12en a (9# pro7ect purc2ases spare
parts= t2e spareBs account 1ill be increased and t2e ban" account or cas2 account 1ill be
reduced. T2is double entry boo";"eeping system is prefered because it is a more systematic
and professional met2od of maintaining accounts= and can 2elp identify mista"es very easily.
9o1ever= for smaller (9# sc2emesA say belo1 %/ "!= t2e double entry system may be
unnecessarily cumbersome and single entries bot2 for income and e*penditure may be good
enoug2.
An e*ample of boo";"eeping for a 3/ "!= (9# sc2eme is illustrated in t2e follo1ing tables.
Table .!, Details of Total ProBect Cost
S!'o! Description 8mount )6s!*
1 'and purc2ased %/=///
2 Civil construction :Canal= po1er2ouse= desilting basin= forebay< 3//=///
3 (ec2anical e4uipment :turbine= penstoc"= driving systems< 33%=///
4 Electrical :&enerators= E'C= components= etc.< 1=///=///
% Transportation cost 1//=///
5 )nstallation cost 2//=///
G Operator training 15,000
+ Total Cost 6s! .&999&999
Sources of funds
1 'ocal contribution or self investment< 4//=///
2 grammar from -&O %//=///
3 'oan from ,an" 5//=///
4 Subsidy %//=///
Total 6s! .&999&999
T2is Table s2ould be provided on t2e 3irst #age of t2e Account ,oo".
Table .!. ;oan 6epayment Scedule for te MHP Plant
0escription Amount
Complete repayment in G yearly installments 5//=///
)st yr. Ending Cune= 166G H repayment of capital +5=///
)nterest on 5//=// I 15J 65=///
)st installment of loan and interest to be paid by 1% Culy= 166G 1+2=///
2
nd
yr. Ending 3/
t2
Cune= 166+ H repayment of capital +5=///
)nterest on %14=/// I 15J +2=24/
2
nd
installment of loan and interest to be paid by 1% Culy= 166+ 15+=24/
3
rd
yr ending 3/
t2
Cune= 1666 H repayment of capital +5=///
)nterest on 42+=/// I 15J 5+=///
)nterest on 42+=/// I 15J 5+=4+/
3
rd
installment of loan and interest to be paid by 1% Culy= 1666 1%4=4+/
4
t2
yr ending 3/
t2
Cune= 2/// repayment of loan +5=///
)nterest on 3.42=/// I 15J %4=G2/
4
t2
installemtn of loan and interest to be paid by 1% Culy= 2/// 14/=G2/
%
t2
yr ending 3/t2 Cune= 2//1 H repayment of loan +5=///
)nterest on 2=%5=/// I 15J 4/=65/
%
t2
installment of loan and interest to be paid by 1% Culy= 2//1 125=65/
5
t2
yr ending 3/
t2
Cune= 2//2 H repayment of loan +5=///
)nterest on 1G/=/// I 15J 2G=2//
5
t2
installment of loan and interest to be paid by 1% Culy= 2//1 113=2//
G
t2
yr. ending 3/
t2
Cune= 2//3 Hrepayment of loan +4=///
)nterest on +4=/// I 15J 13=444
G
t2
installment of loan and interest 6G=444
T2e total amount of loan $s. 5//=/// at an interest rate of 15J.
T2is Table s2ould be reproduced on page 2 of t2e Account ,oo" for easy reference.
.!0!, (ncome and :#penditure 8ccount
T2e manager or o1ner of t2e pro7ect s2ould maintain records in t2e Account ,oo" :ledger<
similar to t2e e*ample given belo1 in Table 2.3. All income s2ould be dated= and sources of
income and e*penditure clearly detailed. T2ere 1ill be different e*penditures suc2 as salaries=
travel= ot2er e*penditures and loan installment. T2e Account ,oo" s2ould be updated daily and
all transactions recorded in c2ronological order. #ending incomes to be received and necessary
e*penditure may be noted do1n separately but not accounted until t2ey are actually received or
underta"en. T2e final figures of income and e*penditure s2ould also be 1or"ed out for eac2
mont2 and year.
Table .!0 8 Sample of Daily :ntries in an 8ccount "oo< for Mont of Canuary&,--%
Date Description Credit Debit
"alance
)(ncome* ):#penditure*)'et
(ncome*
)
st
Can= B6+ (oney in 2and :opening 1/=///
balance<
)
st
Can= B6+ income from electricity sale 1/=///
from Area 1= 1// customers I
$s. 1 // eac2
)
st
Can= B6+ Salary for t1o staff a 1%// ; 3=///
eac2 for 0ecember 6G
)
st
Can= B6+ Travel e*penses paid ; 2%/
)
st
Can= B6+ $epair K maintenance e*penses ; %//
for canal
)
st
Can= B6+ Stationery :#ostage K ; 1/
Telep2one paid<
)
st
Can= B6+ Ot2er e*penses ; 5
2
nd
Can= B6+ #lant closed due to festival ;
3
rd
Can= B6+ Sale of electricity from area G=%//
-o. 2=
G% customers I $s. 1// eac2
4
t2
= Can= B6+ Sale of electricity from area 3=///
-o.3
3/ customers a $s. 1// eac2
%
t2
Can= B6+ Sale of electricity from area 2=///
-o.4
2/ customers I $s. 1// eac2
Total for Canuary ,--%
At t2e end of eac2 year it 1ould be useful if incomes and e*penditures of all ma7or 2eadings
are recorded on a single page for suc2 t2ings as loan repayment= repairs= income from
electricity= agro;processing= etcA as s2o1n in t2e e*ample in Table 2.4. )n t2is table t2e
remaining net balance can be used for t2e personal or family e*penditure of t2e o1ner8investor.
3or electricity sales= it= is unli"ely t2at cas2 payments 1ill be made in t2e beginning of every
mont2. Sometimes= money is not received until t2e follo1ing mont2. )n suc2 cases record of
pending payments due at t2e bottom of t2e first page of t2e mont2 s2ould be maintained 12ic2
s2ould be struc" off and entered as a regular entry in t2e Account ,oo" 12en received.
Table .!4 (ncomes and :#penditures under various eads for ,--%
Description Credit Debit "alance
)(ncome* ):#penditure*)'et (ncome*
,alance from 166G 21=///
)ncome from electricity 2G/=///
)ncome from Agro;processing 1+/=///
)ncome from sale of Agro; 21%=///
processing commodities
)ncome from sale of Agro;residues 13=///=
Salary of Staff 35=///
(aintenance 1+=///
$epair of generator 4/=///
#urc2ase of spares 14=///
Stationary= telep2one 5//
'oan )nstallment :Capital L )nterest< 1%4=4+/
Travel K transport 16=///
Total 3--&999 .%.&9%3 4,3&-,4
-et yearly income for 166+ $s. 415=614
-et average mont2ly income $s 34=G43
.!0!. "udget for 'e#t ?ear
@eeping in mind t2e income= e*penditure and net profit of previous 2;3 years= it is advisable to
prepare budget for t2e ne*t year= say year 1666. T2e o1ner8manager s2ould prepare anot2er
table :Table 2.%< on t2e ne*t page of t2e Account ,oo" Bafter Table 2.4 s2o1ing anticipated
incomes and e*penditures for t2e ne*t year and planning for some additional e*penditure= sayA
ma7or repairs= e*pansion of forebay= cleaning and repairs of penstoc"= etc. T2e e*penditure
must also include personal needs of o1ner and s2o1 t2e net savings 12ic2 can be spent for
repairs or for buying some ne1 e4uipment. T2e final figures in t2e Table s2o1 t2at t2e o1ner
2as to arrange additional $s. 2G=/// from 2is o1n resources if 2e decides to go a2ead ;1it2 2is
plans. 9e must also reali>e t2at t2e actual e*penditure may be significantly different from t2e
anticipated figures recorded in t2e budget.
Table .!1 Proposed "udget for te ?ear ,---
Description Credit Debit "alance
)(ncome* ):#penditure*)'et (ncome*
,alance8saving from 166+ %/=///
8nticipated
(ncomeD:#penditure
)ncome from Electricity 2+/=///
)ncome from Agro;processing 150,000
income from sale of commodities 21/=///
)ncome from ot2er sources 2/=///
Salary of staff 3+=///
(aintenance 2/=///
#urc2ase of Spares 1/=///
Travel= training= etc. 1/=///
'oan installment 15+=24/
Ot2er e*penditure 11=G5/
E*penditure on self 24/=///
Total E,9&999 4-E&999 .,0&999
Proposed additional e#penditure
#urc2ase of C2iura :beaten rice< 1%/=///
mac2ine
)nstallation of ne1 e4uipment 3/=///=
E4uipment repair including 5/=///
penstoc"
Total .49&999 - .E&999
.!0!0 "usiness :#pansion
)nstallation of additional end use e4uipment and8or supplying electricity to additional
customers especially during t2e off pea" 2ours s2ould be one of t2e main considerations of t2e
o1ner8manager of an (9# plant= after 2e 2as ac2ieved success in operating and managing t2e
current end uses optimally. One suc2 e*ample is s2o1n belo1 12ere t2e o1ner8manager of an
e*isting electrification sc2eme decided to add some agroprocessing e4uipment to 2is plant to
utilise additional po1er and t2us earn more income. T2e cost of t2e ne1 e4uipment and
e*pected yearly returns are given in Table 2.5= 12ic2 suggests t2at t2e simple paybac" period is
about 4 years. T2is means also t2at t2e simple rate of return is about 2%JA a 2ealt2y profit.
One could suggest more complicated met2ods of financial analysis. 9o1ever= since t2e overall
investment is small= t2ese simple figures may be ade4uate for t2e initial feasibility.
Table .!3 :stimated (ncome and :#penditure for te 'ew 8gro-processing
:Fuipment
Description Credit Debit "alance
)(ncome* ):#penditure*)'et (ncome*
Capital Costs
Cost of grinder= 2uller and oil e*peller 1//=///
Ot2er mec2anical e4uipment 50,000
:s2afts= belts= pulleys= etc<
Transportation cost 2%=///
Civil 1or"s :materials= Tabour= etc< 3/=///
)nstallation costs :materials= labour= 15,000
testing= etc<
Total Capital Costs 22/=///
Estimated average yearly income 65=///
:from 3 units<
Salaries= etc 24=///
(aintenance +=///
Average repair costs per year :M 4J of 6=///
total investment<
Total )per year* -3&999 4,&999 11&999
Assuming t2at t2e yearly income does not fluctuate severelyA t2e o1ner 1ould recover 2is
investment in about 4 years.
.!0!4 :#tending Supply
Anot2er met2od of earning additional income is to e*tend electricity to some nearby areas if an
additional capacity is available 1it2in t2e plant. T2is s2ould 2opefully also mean ade4uate
additional income as compared to t2e investment involved. Calculations similar to t2ose made
in t2e above e*ample may be repeated to estimate t2e costs and incomes. 9o1ever= t2e factors
involved 2ere are a bit more comple* and need to be assessed and estimated more carefully=
mainly because t2e consumers are not 1it2in t2e premises of t2e plant :as is t2e case B!it2
agro;processing units< and many t2ings can go 1rong. 3or e*ample= t2e prospective customers
may refuse to get connections once t2e transmission lines 2ave been e*tended into t2eir areaA or
t2ey may not pay bills regularly. T2erefore= a more t2oroug2 survey needs to be carried out
12ic2 s2ould not only involve t2e counting of t2e 2ouse2olds and t2eir po1er re4uirementsA
but t2e assessment. of t2eir ent2usiasm for getting electricity and 1illingness to pay t2e
connection fee as 1ell as t2e bills. T2e o1ner;manager may also try to get some advance from
residents of suc2 areas before 2e starts installing t2e transmission lines.
T2e capital cost estimates may t2en be prepared along 1it2 estimates of income and recurrent
e*penditure. Fsually= t2e net incomes from t2e electrification sc2emes are 4uite small and t2e
net yearly incomes of about 1% per cent of t2e original investment may be considered ade4uate.
)f= 2o1ever= it becomes necessary to obtain a loan on normal interest from a financial
institution= t2en t2e pro7ect may not be viable and ;possibilities of getting a subsidy or grant
from a donor agency may be e*plored.
T2e capital cost estimates may t2en be prepared along 1it2 estimates of income and recurrent
e*penditure. Fsually= t2e net incomes from t2e electrification sc2emes are 4uite small and t2e
net yearly incomes of about 1% per cent of t2e original investment may be considered ade4uate.
)f= 2o1ever= it becomes necessary to obtain a loan on normal interest from a financial
institution= t2en t2e pro7ect may not be viable and ;possibilities of getting a subsidy or grant
from a donor agency may be e*plored.
.!4 Organi5ing Maintenance
To maintain t2e (9# plant in t2e best possible condition= it is essential t2at routine
maintenance be carried out in accordance 1it2 a predetermined sc2edule. (anufacturerBs
maintenance sc2edules for items li"e bearings and generators s2ould be follo1ed carefully.
$outine preventative maintenance 1ill result in e*tended plant life and reliable operationA and
reduce t2e long;term operating costs. !aiting for t2e plant to brea" do1n= t2en trying to fi* it
1ill result in increased long;term operating costs= reduced plant life and user dissatisfaction.
T2e manager s2ould clearly instruct t2e operator to c2ec" items outside and inside t2e
po1er2ouse on a regular basis to ensure reliable operation. 9e s2ould also randomly supervise
2is 1or". #roblems if any= s2ould be rectified as soon as possible to prevent t2em getting
1orse.
.!4!, Maintaining Stoc< of Spares
A micro;2ydro sc2eme needs repair and maintenance 4uite often and t2e manager is
responsible to organise it. Some spare parts s2ould al1ays be "ept in stoc"= suc2 as bearings=
tools= grease= oil= belts= etcA to avoid delays in procuring t2em 12en t2ey are needed. ,earings=
s2ould be stored in t2e original pac"ingA if t2is 1as not possible= t2en t2ey s2ould be coated
1it2 grease. Eee or flat belts need to be 2ung on a 1all and not left coiled on t2e floor.
Electrical parts s2ould be pac"ed= labeled and stored a1ay from moisture. T2e storage area
s2ould be clean and secure.
)t is recommended t2at one set of follo1ing spare parts s2ould be "ept in stoc" for an (9#
#lant.
Turbine bearings 1 set :usually t1o<
E;,elts 1 set
3lat belts Ade4uate lengt2 enoug2 to cover
t2e longest belt lengt2 used in
t2e plant.
&rease 1 "g.
&enerator bearings 1 set
&as"ets 1 set :for all locations<
#enstoc" nuts= bolts %J of total installed
E*pansion 7oint gas"et 1/J of total installed
3uses All installed si>es
)n addition= if t2e funding permits= one turbine runner and an AE$ s2ould also be "ept i stoc"
as spares.
.!4!. Maintenance Tools
To enable t2e (9# plant to be "ept 1ell maintained= good 4uality tools are essential. manager
s2ould be responsible for "eeping t2e tools properly and s2ould instruct guide t2e operators to
use t2em properly. T2e follo1ing suggestions 1ill 2elp "eep tools in a good useable condition.
Clean tools after use and return t2em to storage area.
'ubricate t2em to prevent corrosion 12erever necessary.
@eep a record of tools.
0o not t2ro1 tools= 2andle 1it2 care.
Fse tools as t2ey are meant to be used.
C2ec" condition of tools and donBt use damaged tools.
#urc2ase ne1 tools or repair t2em if t2ey become unusable.
Store 2and tools on a board or in a cupboard.
Store measuring instruments :multi;meter= vernier= etc.< in a cupboard or a dra1
to protect t2em from dust and impact.
T2e spares and tools s2ould preferably be "ept in a separate room under loc" and "ey and
record of t2eir issuance and re;storing must be "ept in t2e log boo" or a separate register. 3ig.
2.1 gives some idea about proper storage of t2e tools.
Desirable Tools
T2e follo1ing is a list of tools 12ic2 1ill be useful in t2e maintenance of a (9# sc2eme.
:lectrical
Combination pliers
-ose pliers
Soldering iron and solder
9ac"sa1
'ine tester and multi;meter
Torc2 or portable lamp
)n addition= if funding is availableA one 1irepuller and safety belt s2ould also be "ept in t2e
stoc".
Mecanical
9ammer
3ile set :flat= ;round= etc<
Open and ring spanners= one set eac2
Slide 1renc2 :2// mm. or 3// mm.<
Scre1 drivers :large= small<
#2illips 2ead scre1 driver :medium= small
&rease gun
(etric Allen "ey set
,enc2 vice and vice grip
#ortable 2and drill
T1ist drill set
(easuring tape
#aint brus2
Oil can
9ac" sa1
!ire brus2
Emery paper :various si>es<
Civil
#ic"
Spade
S2ovel
Cro1 bar :lever<
.!1 Organi5ing 6epairs
.!1!, Procedures to Deal >it a "rea<down and 2ault Diagnosis
!2en a brea"do1n occurs= necessary steps need to be ta"en to prevent furt2er damage to t2e
plant and possible in7ury to staff. T2is usually re4uires s2utting do1n of t2e plant until t2e
fault is diagnosed and t2e problem is rectified. $efer to t2e B(anual for (aintenance and
$epairs of (9# #lantsB for problem diagnosis and corrective action.
.!1!. Disassembling and 8ssembling te :Fuipment
,efore commencing disassembly 1or"= al1ays study carefully t2e layout of t2e unit to be
dismantled. 0ecide 12ic2 components need to be removed and 12ic2 do not. T2e manager
s2ould decide 12et2er a faulty part or mac2ine can be repaired locally or it s2ould be
transported to t2e manufacturer. )f it is not locally repairable and t2e operator is not
e*perienced= t2en components 12ic2 do not need to be removed s2ould not be removed. !it2
any disassembly and re;assembly t2ere is al1ays a c2ance of e4uipment damage and 1aste of
time. 9o1ever= in some situations 12ere t2e transportation 2as to be manualA some 2eavier
parts may be removed and not transported. 3or e*ample== if t2e turbine runner or s2aft is=
damaged= t2en it may be cumbersome and unnecessary to carry t2e 12ole turbine to t2e
repairers. On t2e ot2er 2and= if t2e s2aft needs to be repaired t2en it may not fit or align
properly in t2e casing and8or bearing 2ousing after it 2as Bbeen repaired. T2ese are t2e types of
decisions t2at need to be ta"en by t2e managers 12en t2e repairs need to be organised.
Obviously= t2e 1rong decisions 1ould result in delays= e*tra e*penditure and sometimes more
damage to t2e e4uipment.
T2e manager s2ould only allo1 t2e operator to do local repairs if 2e is 1ell e*perienced. T2e
manager or operator s2ould 2ave a basic "no1ledgeB of electricity. (inor carelessness can also
cause serious e4uipment damage= personal in7ury or deat2 12en dealing 1it2 electricity
especially if electrical e4uipment is incorrectly assembled or 1ired= or not properly eart2ed.
.!1!0 Transporting :Fuipment for 6epairs
(ore complicated repairs to items suc2 as generators= runners and electronic e4uipment may
need to be carried out by t2e manufacturer or ot2er competent repairer at 2is premises.
Transport of t2ese items from site may be difficult due to poor access. )t is= t2erefore=
important t2at before transportation=. care is ta"en toN
pac" e4uipment 1ell using timber or t2ic" cardboardA
protect e4uipment from 1ater damage by 1rapping it in plasticA
print t2e Brig2t 1ay upB and B2andle 1it2 careB signsA
inform persons responsible for transport about t2e need for care in 2andling= especially
12en loading and unloading from ve2icles.
3igure 2.2 also illustrates a fe1 Brig2ts and 1rongsB 1it2 regard to transportation of t2e
e4uipment.
0! OP:68T(O'
Correct operation and maintenance of a (9# plant is beneficial in many (anagers and
operators must be fully familiar 1it2 t2e e4uipment= its functions a operational procedures.
Tec2nical specifications must also be "no1n and pr: recorded in t2e Operations K (aintenance
(anual provided by t2e installer. and a t2e 'og ,oo". An e*ample of specifications is given in
Table 3.1 :p. 25;2G<.
0!, 7eneral Operation Procedure
T2e follo1ing c2ec"s s2ould be made during starting= stopping and running of plate any stage a
problem is noticedA say= unusual sound= t2e plant s2ould be stop problem rectified before
starting or running t2e plant.
0!,!, Te start up procedure
2or >ater and Turbine
3ollo1 t2e specified procedure for cleaning up t2e civil 1or"s as applicable
Eisually inspect all e4uipment :e.g. turbine= generator= control panel= is s1itc2= etc.<.
C2ec" oil levels in any e4uipment using oil reservoirs.
Ensure t2at penstoc" and turbine valves are closed.
Turn on 1ater at inta"e.
2or :lectricity
C2ec" t2at all s1itc2es on t2e load side are in t2e ?O33? position :if an E installed<= orA
C2ec" t2at all s1itc2es on t2e load side are in t2e ?O-? position :if t2ere E'C<.
)nform users t2at plant 1ill be starting :some system needs to be developed
operationlised= since it is difficult to inform all t2e consumers<. )f belts are removed=
put t2em on t2e pulleys= c2ec" belt tension also. &radually open t2e penstoc" valve :if
fitted< to fully open position. &radually let 1ater into t2e turbine by opening t2e turbine
valve= 12ile c2e" t2e pressure gauge to maintain smoot2 rise in pressure.
)f t2ere are any pus2 button s1itc2es for e*citing t2e generator= press t2e voltage rises
up to 2// E.
)ncrease 1ater flo1 by opening turbine valves furt2er until t2e speed= and po1er comes
up to desirable8rated level.
3or plants 2aving E'C= gradually divert po1er to t2e. load by s1itc2ing t2e load
s1itc2es.
)f t2ere is no load controller increase t2e 1ater flo1 until t2e voltage rises 22/ E 12ile
t2e load is connected.
T2e allo1able voltage fluctuation= for plants belo1 2% "! is L 1/J a 14JA for larger
plants it s2ould be 1it2in O 1/J.
2or agro-processing
C2ec" all nuts= bolts= etc. of agro;processing mac2ineryA move everyt2ing a1ay from
t2e drive system.
Engage t2e belt from t2e turbine to t2e line s2aft and t2en to t2e mac2ine.
)f t2ere is no line s2aft= place t2e belt directly from t2e turbine to t2e mac2ineA for
e*ample= rice 2uller.
Admit grains to t2e 2uller= oil seed to t2e e*peller= etc.
'et 1ater into t2e turbine= gradually opening t2e turbine valve until t2e re4uired speed
is reac2ed.
C2ec" t2e pressure gauge to ensure t2at pressure is not fluctuating rapidly.
'isten for any abnormal noise or vibration 12en t2e unit is running. Stop t2e turbine if
t2is 2appens and loo" for t2e fault.
C2ec" drive systems :belt= coupling= etc.<
Connect only t2ose units simultaneously for 12ic2 po1er is sufficient.
)f t2e turbine is po1ering a generator and agro;processing e4uipment simultaneouslyA
priority goes to electricity and connect t2e agro;processing unit only if sufficient
additional po1er :i.e flo1< is available.
0!,!. Continuous Cec<s during 6unning
T2e follo1ing c2ec"s are to be made during t2e running of t2e plant. )f at any stage an
abnormal condition arises= t2e plant s2ould be s2ut do1n and t2e problem diagnosed and
rectified.
Every 2our c2ec" voltage= fre4uency and po1er output and record in t2e log boo" once
a day. Abnormal readings must be recorded 12enever noticed along 1it2 t2e corrective
action ta"en.
)f voltage or fre4uency decreases due to over;load= remove some loads.
C2ec" for abnormal noises and 1ater lea"s.
C2ec" bearing and generator temperatures by touc2ing t2e 2ousings.
#eriodically c2ec" penstoc" pressure.
Compute consumed po1er from panel meter :current and voltage< if 1att;meter is not
installed.
)f t2e po1er consumption is more t2an design capacity= disconnect some load from t2e
distribution bo*.
)f over;load occurs= it could be t2at some consumer is using a 2ig2er load :i.e. 2eater=
etc.< t2an permitted so c2ec"s s2ould regularly be made at t2e premises of suc2 type of
users=
0!,!0 Sutting down procedure
3ollo1ing procedure s2ould be follo1ed prior to and during s2utting do1n of. t2e (9# plant.
)nform users t2at t2e plant 1ill be s2ut do1n= if time permits :unless t2ey already "no1=
in t2e case of regular s2ut do1ns<.
S1itc2 BO33B all connected load.
Close turbine control valve gradually to prevent rapid penstoc" pressure rise.
Close penstoc" valve.
Stop 1ater from forebay tan" and inta"e if necessary.
Ensure t2at po1er2ouse and e4uipment are clean and tidy.
)f t2e s2ut do1n is due to an emergency= t2e actions s2ould be 4uic" and emergency devices
suc2 a 7et deflectors :for #elton turbines< s2ould be actuated.
0!. Safety and 2irst 8id
!2ile 1or"ing 1it2 electricity= if 1e do not ta"e ade4uate care= it can be very dangerous even
t2oug2 it 2as some benefits. )t is t2us important to be a1are of and remember safety
precautions= and even more essentialA to "no1 2o1 to perform first aid and primary treatment
12en an accident 2appens.
0!.!, >or<place Safety Precautions
3ollo1ing precautions may ta"en 12ile operating an (9# sc2eme or even 1or"ing in a
po1er2ouse 12ile it is in operation.
1. )f possible= s2oes s2ould be rubber soledA t2ey must not be damp or 1et.
2. !2ile 1or"ing= 2ands s2ould not be 1et.
3. ,efore starting 1or"= t2e electrical supply to t2e 1or" area= s2ould be turned off if
possible.
4. T2e location of t2e s1itc2 to turn off t2e 12ole electrical supply s2ould al1ays be
"no1n before2and to 1or"ers.
%. !2ile 1or"ing on an electrical circuit= only essential fuses s2ould be left in
placeA ot2ers s2ould be removed.
5. (a"e sure t2at metal covered items suc2 as t2e main s1itc2 and panel bo* are properly
eart2ed.
G. )f fire or an electrical accident occurs= t2e electrical po1er s2ould inunediately be
turned off.
+. Tools and materials= 12en not in use= s2ould be put in t2eir proper place and only
proper tools and materials s2ould be used for particular 1or".
6. After finis2ing 1or"= everyt2ing s2ould be cleaned and returned to its proper. place= and
t2is practice s2ould become a 2abit.
1/. !or" in a systematic 1ay. )f any 1or" is unfamiliar= an e*perienced person s2ould be
as"ed to assist or adviseA especially in case of electrical mac2ines.
11. Oil s2ould not be put in a mac2ine t2at is running. !2ile 1or"ing in front of a mac2ine
:i.e. grinding= drilling= 1elding= etc.< glasses and gloves s2ould be used.
12. !2ile lifting any mac2ine or material you s2ould 2ave a straig2t bac" and bend your
"nees.
13 -ecessary primary treatment :first aid< s2ould be immediately given to t2e in7ured
person if an accident occurs.
14. $epaired 1or" s2ould only be operated after it 2as been carefully tested.
15. T2e 1or" table s2ould be 1ell insulated :s2ould be a 1ooden table<.
0!.!. 2irst 8id for :lectrical Soc<
)f any person suffers an in7ury from a.1 electricity related accidentA 2e s2ould be ta"en to a
doctor as 4uic"ly as possible. )f t2is is difficult or not possible :e.g t2e road may be bloc"ed=
transport facilities may be limited or t2e distance may be long< t2e sic" person may 2ave to
remain in place for some time. )n t2at situation= t2e in7ured person s2ould be "ept calm and
first aid s2ould be provided. )t 1ould be muc2 beneficial= if some personnel 1ere properly
;trained at suitable places :civil defense centres= 2ospitals= etc< to administer first aid. )n any
case= follo1ing procedure may be adopted for providing first aid to an in7ured person.
1. T2e electrical line s2ould immediately be disconnected= t2e main s1itc2 turned BO33B=
and t2e s2oc"ed person separated from t2e source of t2e s2oc". 0onBt forget clot2ing 12ic2
may also be in contact 1it2 electric supply.
2. )f t2e s1itc2 can not be reac2ed 4uic"ly= t2e live 1ire s2ould be removed from t2e
person 1it2 t2e 2elp of a non;conductor suc2 as 1ood= plastic= rubber= etc.
3. )f t2e person is unconscious and not breat2ing= artificial respiration= as described belo1=
s2ould be administered or else t2e person may die.
4. After giving artificial respiration= t2e area affected by t2e s2oc" s2ould be massagedA
because an electric s2oc" causes blood circulation to stop. T115 arms= feet= etc.= s2ould be
rotated at t2e 7oints.
%. 3eed t2e s2oc"ed person some 1arm mil" or tea.
5. T2e s2oc"ed person s2ould be encouraged to tal" and move if possibleA to give 2im
confidence and to 2elp 2im remain conscious. 0onBt let 2im lose consciousness.
G. Every effort s2ould be made to ma"e t2e s2oc"ed person as comfortable as possible.
+. )f t2e condition of t2e in7ured is still serious :say= t2e breat2ing is irregular or 2e is
s1eeting<= 2e s2ould be ta"en to a 2ospital or to a good doctor. A c2ec" up and treatment by a
4ualified doctor is even ot2er1ise necessary as soon as it becomes available.
0!.!0 8rtificial 6espiration TecniFues
Anyone 12o receives a 2ig2 voltage electrical s2oc" may become unconscious= or even stop
breat2ing. )f so= t2e in7ured person must immediately be given artificial respiration= until 2e
begins to breat2e by 2imself. T2e follo1ing t1o tec2ni4ues are usually used to revive
breat2ing artificially.
2ace down metod
T2is met2od is simple and easy to learn and is t2us more commonly used. )n t2is met2od t2e
person giving first aid "neels in front of t2e sic" person and lays t2e sic" person face do1n on
t2e floor bet1een 2is "nees. T2e t1o 2ands of t2e in7ured person are folded in front of 2is 2ead
and t2e fore2ead rested on t2em= as illustrated in 3ig 3. 1. )n t2is 1ay= t2e nose air passage
remains open. T2en t2e person giving first aid places 2is t1o 2ands 1it2 t2e fingers spread on
t2e bac" of t2e sic" person belo1 t2e s2oulders= and placing 2is t1o t2umbs e4ually on t2e ribs
of t2e sic" person= slo1ly presses do1n1ard 1it2 2is 2ands= 1atc2ing car;;fully to see 2o1 i;
muc2 pressure is needed. T2e pressing s2ould be suc2 t2at air emerges from t2e lungs and t2ey
are emptied. T2e 2ands s2ould t2en slo1ly be released. T2e sic" person is t2en grasped by t2e
upper arms 7ust above t2e elbo1s 1it2 bot2 2ands= and t2e arms are pulled up1ards to1ards t2e
person giving first aid. )n t2is 1ay= t2e c2est e*pands and air enters t2e lungs. T2e person
giving treatment s2ould repeat t2is cycle at a rate of about 12 times per minute until suc2 time
t2at t2e sic" person begins to breat2e naturally by 2imself.
Mout to Mout 6espiration
T2e sic" person s2ould be made to lie flat on 2is bac". 3irst c2ec" t2at t2e 7a1s of t2e in7ured
person can be easily openedA if not= open t2em by 2and. #lace t2e left 2and under t2e bac" of
t2e sic" personBs nec" to raise it a little and using t2e rig2t 2and= bloc" 2is nose. T2e person
giving treatment t2en s2ould place 2is mout2 over t2e sic" personBs. mout2. 9olding t2e nose
closed so t2at air cannot emerge= t2e person giving treatment s2ould blo1 into t2e sic" personBs
mout2 to fill 2is lungs 1it2 air. After t2at= release open .t2e nose so t2at t2e air in t2e lungs
comes out. T2e rig2t 2and t2en again bloc"s t2e nose and t2e cycle is repeated at a rate of 1/;
1% times a minute until t2e person giving first aid notices t2at t2e pressure 12ile blo1ing in is
reducing. T2is met2od is grap2ically illustrated in 3ig. 3.2.
0!0 :#tended Sut Down
)f t2ere is a ma7or repair to be done in a (9# plant= t2e po1er2ouse 1ould 2ave to be s2ut
do1n for a long ;period to organise and complete t2e repairs at t2e plant or else12ere. )f an
e*tended s2ut do1n becomes necessary= t2e operator8manager s2ould notify t2e villagers about
t2e situation and about t2e tentative duration of t2e s2ut do1n. T2e e4uipment remaining
1it2in t2e po1er2ouse must be protected from corrosion= rain= landslides= pilferage and ot2er
suc2 eventualities. Some items located outside t2e po1er2ouse :e.g. tras2rac"= canal gate< may
also be dismantled and stored 1it2in t2e po1er2ouse or some ot2er safe place.
0!4 6outine (nspection and Maintenance
T2e operator s2ould c2ec" t2e follo1ing items outside and inside t2e po1er2ouse on a regular
basis to ensure reliable operation. A suggested fre4uency of c2ec"ing is s2o1n belo1. Any
damage noticed during t2ese c2ec"s s2ould be rectified as soon as possible to relevent t2e
problem getting 1orse.
0!4!, Daily (nspection and Maintenance
Every day t2e follo1ing items s2ould be inspected and corrective action ta"en if necessary.
See also section 3.1.2
"efore Start @p
Clean t2e tras2 rac"s at t2e inta"e= desilting. basin and forebay.
C2ec" 12et2erB sufficient 1ater is flo1ing ;t2roug2 t2e 2eadrace.
)f notA t2e plant load s2ould be reduced accordingly or it s2ould not be started at all.
3lus2 t2e forebay and disilting basin during t2e monsoons :every ot2er day if t2e debris
amounts are less<.
During Operation
C2ec" t2e temperatures and vibration level of 2ousings8casings of bearings of turbine and
generator.
C2ec" t2e lea"age from valves= turbine 2ousing= or base frame.
)f t2e lea"age is e*cessive from any location= repairs s2ould be organised straig2t a1ay or
in due course as t2e situation demands.
0!4!. >ee<ly (nspection and Maintenance
!al" to t2e inta"e via t2e 2eadrace8pipeline and c2ec" for damage suc2 as 1ater lea"age=
crac"ed pipe= 1ater emerging from t2e ground above t2e pipeline= etc. 3lus2 forebay and
desilting basins.
(a"e detailed inspection of civil structures or surrounding areas for brea"age= sliding= roc"
falling= etc.
C2ec" t2e penstoc" for 1ater lea"age or damage= say from stones.
0!4!0 Montly (nspection and Maintenance
!al" from t2e po1er2ouse along t2e penstoc" to t2e forebay and c2ec" all e*pansion
7oints= flanges and 1elds for lea"age.
Close all t2e turbine valves= open up bearings and put t1o fingers full of grease in eac2. 0o
t2e same for t2e generator bearings using a grease gun.
)nspect t2e generator= (C, s1itc2= and E'C bo* and feel t2e cables to c2ec" if t2ey are
very 2ot. Also c2ec" to see if t2e colour of t2e cables 2as c2anged.
C2ec" fencing around 2ig2 voltage transformer if installed.
)nspect all t2e civil structures= including penstoc" and surrounding areas for landslides and
damage and impending signs of land slides.
0!4!4 Si# Montly (nspection and Maintenance
)nspect condition of poles and repair t2e damaged ones.
C2ec" transmission line clearance from t2e ground and tree branc2es. C2ec" line
connections of lig2tning arrestors and 7umpers.
C2ec" stay 1ire tension.
C2ec" connections of distribution 1ires.
)nspect distribution s1itc2es= fuses= etc.
One of t2e si*;mont2ly inspections s2ould be underta"en immediately after t2e monsoons.
Cold Season >or<
)nspect all places 12ere 1ater may 2ave lea"ed from tan"s= or 2eadrace8pipeline and ta"e
corrective action.
3.4.5 ?early (nspection and Maintenance
Open side plate of t2e generator and clean any collected dust on t2e 1indings.
Clean any collected dust= cob1ebs= etc. on t2e inside and outside of t2e E'C bo* and t2e
main s1itc2. Also clean t2e deposited sediment from t2e ballast tan". ;
Test t2e eart2ing 1ire connection inside t2e po1er2ouse. Test t2e 24/ volt insulators of
transmission line and distribution line approac2ed eit2er side of t2e lines.
)nspect t2e po1er control devices and service 1ires at consumerBs 2omes.
Cut do1n tree branc2es near t2e transmission lines.
)nspect all tras2 rac"s and repair or replace t2em if necessary.
3.4.5 Additional )nspection and (aintenance
Every t1o years inspect t2e turbine runner= penstoc"= generator= load controller and all civil
1or"s. )f possible= t2is inspection s2ould be done by a competent consultant.
Every t1o years= dig up all eart2ing $elates and inspect t2em for e*cessive corrosion. )f
necessary= t2e plate s2ould be replaced= 1it2 several layers of salt and c2arcoal or coal dust
placed in t2e 2ole= one after t2e ot2er= above t2e plate. )f t2e eart2 plate connection is loose=
it s2ould be tig2tened or redone.
Every four years paint t2e penstoc" completely
3.4.G Some Additional Suggestions $egarding Operation and (aintenance
E*cept for t2e cold mont2s of 0ecember and Canuary= t2e penstoc" s2ould not be left empty
on and sunny day :because t2e steel= pipe can 2eat up and t2e e*pansion may damage t2e
penstoc"< 12en t2e plant is not running.
Overflo1 from t2e forebay s2ould be as little as possibleA to ac2ieve t2at= allo1 a small
amount of e*cess 1ater to come from t2e desilting basin gate.
)f t2e po1er2ouse is to be closed for longer t2an one 2our= t2e flus2 gate from t2e desilting
basin s2ould also be left open.
)f t2e po1er2ouse is to be closed for a full day or longer t2e 1ater flo1 from t2e source
s2ould also be minimised or stopped if possible.
0uring operation= ade4uate ventilation s2ould be provided in t2e po1er2ouse so t2at t2e
generator receives t2e needed cooling air.
To ensure t2at sufficient 1ater is flo1ing to t2e ballast 2eater tan"= t2e gate valve s2ould be
inspected daily. )f t2e 1ater flo1 reduces= t2e valve and union s2ould be removed= tested
and repaired if necessary.
3.% 9ouse !iring
)t 2as generally been observed t2at s"ills to underta"e 1iring 1it2in t2e 2ouses and to provide
connections does not e*ist in t2e remote and under;developed mountain areas. T2erefore=
managers or operators of suc2 areas are usually called upon to carry out 1iring at t2e premises
of t2e consumers. T2e promoters of ((9# also recognise t2is fact And training for 2ouse
1iring is included in t2e training far suc2 persons. T2erefore= some basic details of 2ouse
1iring are also provided 2ere.
)nstallation of 1iring in a 2ouse involves installing t2e service 7unction bo*A ma"ing t2e
connection 1it2 t2e incoming lineA po1er outlets= and s1itc2es mounted in t2e desired locationA
and t2en ta"ing t2e 1ires to different desired locations along t2e beams= poles= etc= as
necessary. Table 4.1 s2o1s some standard symbols for typical features of office 2ouse 1iring.
)t is recommended t2at every 2ouse s2ould 2ave a main s1itc2 and a fuse. ,lac" s2eat2ing
distribution cable s2ould be used as it protects against t2e sunBs ultraviolet radiation. )f t2e
connection to t2e consumer is not t2roug2 a 1attmeter and t2e tariff is based on ma*imum
allo1able po1erA a #TC= (C, or ECC s2ould be installed= according to allo1able 1attage
:po1er<= to prevent t2e consumers from over;using t2e po1er.
9ousing 1iring s2ould be carried out in accordance 1it2 a recognised standardA suc2 as
Electrical &uidelines publis2ed by )T0& and A0,8-= -epal. Suc2 guidelines are usually
available in every country.
T2e follo1ing are different types of internal 1iring applicable to rural areas.
,atten !iring
T2is is t2e most common and c2eap type of 1iring system 12ere 1ires are run on 1ooden
battens fi*ed to t2e 1alls or ceiling. )t is classified into t1o parts.
T$S or #EC !iringN )n t2is system= T$S or #EC 1ires are fi*ed to 1ell seasoned straig2t soft
timber battens. ,atten 1iring= particularly 1it2 #EC cable= is 1idelyB used for indoor
installations.
(etal s2eat2ed 1iringN )n metal s2eat2ed 1iring t2e cables used are T$S or #EC insulated
1ires 1it2 metal outer covering.
)t is suitable for places e*posed to sun= provided no 7oint of any "ind is e*posed. T2is system
may be installed in damp places.
Conduit !iring
T2is system consists of eit2er E)$ or #EC 1ires passed t2roug2 rigid steep conduit pipes.
Conduit 1iring can be installed over t2e surface of 1alls and ceiling or may be concealed under
t2e plaster.
Cleat !iring
)n t2is type of 1iring= cables are run over cleats. A special pattern of cleat may be used 12ere
1ires pass round corners= so t2at t2ere may be no ris" of 1ires touc2ing t2e 1all. !2ere cleat
1iring is on a metal portion along its run= t2e space bet1een suc2 metal and porcelain cleats
s2ould be filled or varnis2ed.
Cleat 1iring s2ould not be employed on damp 1alls or ceilings.
!ood Casing !iring
T2is type of 1iring consists of running t2e cables inside a 1ood casing 2aving grooves. T2is is
t2en covered 1it2 1ooden capping. T2e 1ire used s2ould be vulcani>ed rubber or #EC
insulated cables.
T2e casing and capping s2ould be of 1ell seasoned tea" 1ood or ot2er 2ard 1ood= free from
"nots or any ot2er defects.
$eady;made 1iring
T2e main feature of ready;made 1iring is t2e 7unction bo* from 12ic2 radiate t2e re4uired
number of po1er cords of predetermined lengt2s for different rooms8locations= terminating in a
lig2t bulb or po1er soc"et. T2e 1ires are fastened to 1ooden columns= beams= etc= at
appropriate locations and t2e bulbs or s1itc2es are left 2anging but properly secured.
4.1.1 (ost Common !iring #ractices
Fsually= t2e 2ouses in t2e mountain areas utili>ing (9# are one; or t1o;story structures. !alls
are usually made of mud and stone masonry and plastered 1it2 mud. T2e upper floor=
supporting columns and roof= are usually made of 1ood. Eery fe1 #a""a 2ouses:bric"=
concrete< may also e*ist in t2e mountain areas 2aving more durable roof of corrugated
galvani>ed iron or even $.C.C.
Conventional batten 1iring is commonly used in #a""a 2omes 1it2 concrete or cement
plastered bric" 1alls 12ic2 loo"s simple and neat :3ig. 4.1<. 9o1ever= it is more difficult to
install in village 2omes 2aving mud and stone masonry 1alls because of t2e unevenness of t2e
1alls and t2e difficulty of fi*ing t2e batten to t2e 1alls. 3urt2ermore= availability of t2e
re4uired s"ills for 2ouse 1iring in rural areas is limited= and t2e cost of labour for conventional
1iring can t2erefore be significant.
3or t2ese reasons= ready;made 1iring 2as been developed in -epal and is becoming 4uite
popular. $eady;made 1iring includes. a current limited and fuse mounted on a 1ooden
7unction bo*= from 12ic2 radiate a number of good 4uality= double insulated po1er cordsA eac2
terminating in a lig2t bulb or po1er outlet.= T2e lengt2s of 1ires are predetermined. A section
of ready made 1iring system is s2o1n in 3ig. 4.2.
3or ready;made 1iring= lig2ting fi*tures= s1itc2es and po1er outlets are permanently fi*ed into
1alls= supporting posts or ot2er parts of t2e 2ouses. At t2e service entrance a 1ooden 7unction
bo* is installed= on 12ic2 are mounted t2e current limited= fuses and possibly some po1er
outlets.
To ensure good connections and eliminate any problems arising from frayed 1ires= t2e tips of
t2e stranded conductor are solid red. T2e 3igure 4.2 belo1 illustrates t2e ma7or components of
a typical ready;made 1iring= 12ile 3igure 4.3 s2o1s a line diagram for t2e same system.
4.2 Eart2ing
Eart2ing is considered really necessary only for industrial loads and electric coo"ers. 9o1ever=
if t2e funding permits= appropriate eart2ing s2ould also be provided in 2ouses. Acceptable
met2ods for providing an eart2ing are as follo1s.
A 3m; 4 m long galvani>ed steel pipe= 2aving 2/ mm to 3/ mm. diameter is buried vertically
and connected to t2e eart2 line using brass or copper connections.
A copper or galvani>ed iron plate of total surface area not less t2an 1 s4. m= is buried at a dept2
of at least 2 m. and connected to t2e eart2 line using brass or copper connections.
4.3 &eneral $ules 3or 9ouse !iring
1 T2e current rating of t2e conductor s2ould be as per t2e re4uirement of t2e load as
suggested in Table 4.2.
2. Every live :positive or p2ase< 1ire s2ould be. protected by a fuse of suitable rating.
3. All t2e metal covering used for protecting t2e 1ires must be eart2ed= so t2at t2ere is no
danger due to insulation lea"age.
4. S1itc2es s2ould also be provided on all live 1ires leading to a point in use.
%. Every circuit or apparatus s2ould be provided 1it2 a separate s1itc2.
5. T2e si>e of po1er and lig2t circuit must be calculated separately according to t2e load.
a< One sub;circuit of lig2t s2ould be not more t2an 1/ points or +// !atts.
b< One circuit of po1er s2ould be 3///;4/// !atts= ma*imum.
G. S1itc2 board= distribution board= sub distribution board and po1er soc"ets s2ould be
installed about 1.3 meter above t2e floor level.
8. Tubelig2t or bulb s2ould be installed about 2.% meter above floor level.
9. Celing fan s2ould be at least 2.% meter from t2e floor level
10. )n t2ree p2ase= four;1ires system installation= load s2ould be e4ual on all t2e p2ases.
11. )n t2ree p2ase four 1ire system at t2e main board= t2e 1ire colours s2ould be $ed= .ello1
and ,lue. -eutral s2ould be indicated in green or blac"
Table 4!. Symbols @sed in Drawings of (nternal House >iring
S.-o. 0ESC$)#T)O- S.(,O'
1. (ain fuse;board 1it2out s1itc2es= lig2ting
2. (ain fuse;board 1it2 s1itc2es= lig2ting
3. 0istribution fuse board 1it2out s1itc2es= lig2ting
4. 0istribution fuse board 1it2 s1itc2es= lig2ting
%. 0ouble pole s1itc2
5. $e;1ireable fuse
G. 3an
+. )ncandescent lamp or filament lamp :bulb<
6. 3lorescent lamp :Tube lig2t<
1/. T1o pin soc"et
11. T2ree pin soc"et
12. One 1ay s1itc2
13. T1o 1ay s1itc2
14. Eart2ing :Eart2 point<
)n t2e follo1ing diagrams :3igure 4.4 to 4.14< some typical circuits for 2ouse 1iring are s2o1n.
3ig. 4.4 0iagrams of one;lamp or t1o lamp circuits.
3ig. 4.% T1o lamp circuit controlled by t1o single s1itc2es 1it2 fuse.
3ig. 4.5 E*ample of t1o;lamp and po1er soc"et circuits.
3ig. 4.G T2ree lamp circuit controlled by t2ree single 1ay s1itc2es and on double pole
s1itc2 and fuse. T2e 0.#. s1itc2 is useful if a sub;circuit needs to be
disconnected from a different location.
3ig. 4.+ T2ree lamp K t1o pin soc"et circuit controlled by 4 single s1itc2es= 0.#. s1itc2
and fuse.
3ig. 4.6 Staircase lamp 1iring 2aving t1o= t1o;1ay s1itc2es
3ig. 4.1/ Staircase 1iring 1it2 2 lamps and t1o t1o;1ay s1itc2es
3ig. 4.11 !iring diagram for a florescent lamp 0.#. s1itc2 is optional
3ig. 4.12 3lorescent tube circuit 1it2 &lo1 starter and c2o"e
Symbols
& P &lo1 type starter
T P 3lorescent tube
' P C2o"e
Cl P Small condenser= across t2e t1o bimetallic strips to suppress t2e radio
interference generated by t2e c2o"e
C P Condenser across t2e supply mains is used for improving t2e po1er factor
3ig. 4.13 ,loc" circuit diagram for 2ouse 1iring
Symbols
A P (ain fuse board 1it2 0ouble pole s1itc2
, P 0istribution fuse board 1it2out s1itc2es
C P &angbo* 1it2 4 s1itc2es one 1ay type K one t1o pin soc"et
0 P 'oad
3ig. 4.14 T1o lamp circuit and t1o pin soc"et controlled by T2ree one 1ay s1itc2es= 0.#.
S1itc2 and 3use
Symbols
( P (ain board :(ain distribution board< )ncluding 0.#. s1itc2 "it;"at.
S P (ain supply :22/ E<
& P &ang ,o* :4 1ayA 3 one s1itc2= T1o pin soc"et<
C P Cunction bo*
) P )ncandescent lamp 1it2 2older
6eference
9arvey= A. 9.A ,ro1n= A.A 9ettiarac2i= #.A and )nversin= A.$.N 1663. Q(icro;9ydro 0esign
(anual= -ational $ural Electric Supply Cooperative Association :)T0&<= F.@.
)nversion= A.$.A 1664. R-e1 0esigns for $ural Electrification. R#rivate;Sector E*periences in
-epal= -ational $ural Electric Supply Cooperative Association :-$ESCA<= F.S.A.
(urcia= E.A 16+%. R$ecord @eeping for Small $ural ,usiness= )ntermediate Tec2nology
#ublis2ers= F.@.
A &eneva &roupA 166/. R9o1 to $un a Small 0evelopment #ro7ect Centre for )ntergrated
Education= F.S.A.