O&M Manual - Tudaya1 - Volume 1 of 5

OPERATION & MAINTENANCE MANUAL - TURBINE
Project: Tudaya1 2012
Type of machine: 1 Compact Pelton Turbine (CPT)

V5-G1-6/380/40-1/1160/340
Customer: Hedcor Sibulan Inc. (Hydropower Generation)

Sibulan, Sta. Cruz, Davao del Sur
Philippines
Sauter-
0 2013-03-01 2013-03-12 A. Brehm
Bocksch
Date Name Signature Date Name Signature
Revision
Created by Checked/Released by
Project number: M-1313467 Document number: 892008080
Originalsprache: Deutsch
Tudaya 1 2012
Overview Volumes
Volume 1
O&M Manual Turbine Chapter 1-10
Volume 2
O&M Manual Turbine Chapter 11-13
Volume 3
Hydraulic Governor with Oil Supply

Certificates, Device Lists, Drawings, Terminal Plan, Data Sheets
Volume 4
Generator
Volume 5
Generator
O&M Manual Overview Volumes i

Tudaya 1 2012
Table of contents
Abbreviations
1 Introduction
2 Safety
3 Technical Data
4 Description
5 Operation
6 Maintenance
7 Spare Parts
8 Decommissioning
9 Description of installed turbine equipment
10 Drawings
11 Shop assembly and site installation documentation of the turbine
12 Ball valve
13 Painting material
O&M Manual Table of contents ii

Abbreviations
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Abbreviations
Abbr. Description
ADR European Agreement concerning the International Carriage of Dangerous

Goods by Road (Accord europen relatif au transport international des
marchandises dangereuses par route)
CE Conformity with European directive (Conformit Europenne)
EMC Electromagnetic Compatibility
EN European Standard (Europa-Norm)
Fig. Figure
IEC International Electrotechnical Commission
PVC Polyvinyl Chloride
Tab. Table
VDE Association of German Electrical Engineers (Verband Deutscher
Elektrotechniker)
O&M Manual Table of contents iii

Abbreviations
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1 Introduction ........................................................................................ 1-2

1.1 About this manual .............................................................................................................. 1-2
1.2 Use of manual ..................................................................................................................... 1-3
1.3 Warranty and liability ......................................................................................................... 1-4
1.4 Name and address of the manufacturer.......................................................................... 1-4
1.4.1 Andritz Headquarters Address ......................................................................................... 1-4
1.4.2 Internal Supplier ............................................................................................................... 1-4
1.5 Copyright ............................................................................................................................ 1-5
1.6 Intended use ....................................................................................................................... 1-6
1.7 Notice of claims .................................................................................................................. 1-6
1.8 Transport ............................................................................................................................. 1-7
1.9 Storage ................................................................................................................................ 1-7
1.9.1 Incoming inspection.......................................................................................................... 1-7
1.9.2 Packing ............................................................................................................................. 1-8
1.9.3 Storage ............................................................................................................................. 1-9
O&M Manual Introduction 1-1

Tudaya 1 2012
1 Introduction
This manual is part of the project documentation for a machine/plant sup-
plied by ANDRITZ HYDRO. The manual is particularly adapted and refers
to the stipulated scope of supply solely.
The manual contains essential information about the correct, safe and pur-
poseful operation of the machine/plant. The adherence to these instruc-
tions helps to avoid so far well-known dangerous situations, to minimize
repair- and standstill costs and to optimise the availability and life cycle of
the plant.
But the manual can not cover all precautions, safety instructions and op-
erating instructions of hydro power plants. It contains only the most impor-
tant information (in compressed form), which have to be taken into account
and can not compensate technical competence and training of operating
personnel.
1.1 About this manual
Target group The manual is exclusively addressed to the operator and his personnel,
operating and maintaining the machine/plant (maintenance, inspection
and repair).
The personnel assigned to work on the machine/plant have to read the
manual before commencing work. During work, it is too late. This applies
particularly to people, who work only here and there, e.g. during mainte-
nance or repair of the machine/plant. In particular the following is to be
considered:
the entire chapter safety and
the safety instructions stated in the individual chapters.
Supplementing Existing national instructions regarding health & safety and environmental
instructions protection have to be added to this manual by the operator. Such instruc-
tions can regard e.g. handling with hazardous substances or availability /
wear of personal protective equipment, too.
Instructions, which consider the operational characteristics regarding la-
bour organisation, operational sequences and employed personnel have
to be added to this manual by the operator, too. This includes instructions
regarding obligatory supervision and notification requirements.
Storage The manual is to be kept always at place of installation within reach.

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1.2 Use of manual
Text formats The following text formats are applied in the present manual as follows:
Bold to highlight words/text passages or parameter

Italic to mark hyperlinks, terms in foreign languages or
placeholders
UPPER CASE to mark important terms, e.g. operating
conditions
List formats The following list formats are used in the present manual:
1. Step-by-step instructions with fixed order
2.
Listing without fixed order

Hyperlinks
Verweis: Paragraphs marked in this way contain links to project documentation.
Links within this manual are written in italics for highlighting.

E.g.: See section XXX of this manual.
Pictograms For all pictograms used in this manual see appropriate section 2.2 of this
manual.

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1.3 Warranty and liability
ANDRITZ HYDRO excludes warranty and liability claims of lacks or

damages, if these are particularly due to one or several of the below
mentioned causes:
Non-compliance with safety instructions, recommendations,
instructions and/or other details of the manual.
Non-compliance with maintenance instructions.
Misuse and wrong operation of machine/plant.
Unintended use of machine/plant.
Unauthorized, structural alterations on the machine/plant or modifica-
tion of user software. This applies also to the installation and adjust-
ment of safety devices and -valves as well as to the welding process
on supporting parts.
Use of not original spare parts.
Disassembly of transport devices, which is not authorised by the
manufacturer like e.g. lifting eyes, devices and similar things.
1.4 Name and address of the manufacturer
1.4.1 Andritz Headquarters Address
ANDRITZ HYDRO GmbH

Penzinger Strasse 76
A-1141 Vienna, Austria
ANDRITZ HYDRO can be contacted via the following email address:
contact@andritz-hydro.com.
Please address also information and suggestions (including possible rec-
ommendations regarding the layout of this manual) to the aforementioned
email address.
1.4.2 Internal Supplier
ANDRITZ HYDRO AG
Werkstrasse 4
CH-9243 Jonschwil
Phone: +41 71 929 3636
Telefax: +41 71 929 3630
Please contact the supplier in case of technical questions or details
regarding your installation.

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1.5 Copyright
This manual is the intellectual property of ANDRITZ HYDRO GmbH and

must neither be copied nor handed over to third parties without prior
express agreement of ANDRITZ HYDRO GmbH. Violation will cause
indemnities and can lead to prosecution. We reserve the right to make
changes of technical details in relation to the details stated in the manual.
2013 ANDRITZ HYDRO

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1.6 Intended use
The machine/power plant must be operated in accordance with the specifi-

cations acc. contract solely. Any operation exceeding the stipulated per-
formance limits or contrary to the intended company regulations, is consid-
ered as unintended and can lead to damages. ANDRITZ HYDRO does not
assume liability for these damages.
The intended use contains also the compliance with this manual as well as
the adherence to operating and maintenance conditions and the adher-
ence to cleaning and maintenance instructions.
The correct and safe operation of the machine/plant requires proper trans-
port and storage, installation and assembly as well as careful operation
and maintenance.
1.7 Notice of claims
Lacks and damages, detected by the customer or operating personnel,

serious accidents or other detected deviations from the normal operating
condition have to be announced immediately to ANDRTIZ HYDRO regard-
less of the occurrence during or after expiration of the warranty period.
This notification should contain in particular the following information:
Description of lack or damage (symptoms, detected by and when)
Identification of systems or components concerned (identification
number)
Already taken measures
Recordings of status-, error- and alarm messages
Entries in operating log
All recordings and prints of the electronic data logging
Maintenance data

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1.8 Transport
NOTICE
The goods must be transported to the place of destination by experienced
forwarding agents only. The forwarding agent is responsible for the trans-
port solely. ANDRITZ HYDRO has only an advisory or monitoring function.
As internationally usual, special symbols are imprinted on the packing.
Take these symbols into account when loading or unloading.
Attach and lift the crates and open parts only at the marked positions. See
also section Lifting and transport of components in chapter Safety.
1.9 Storage
1.9.1 Incoming inspection
NOTICE
Crates must be opened only after approval given by ANDRITZ HYDRO.
Damage Check the crates immediately upon arrival at the place of destination for
visible damages, preferably in presence of the forwarding agent.
Information
During the inspection take into account that special packings and/or
protective coatings are not damaged and thus are rendered unusable.
In case of obvious transport damages (dented crates, etc.) proceed as

follows:
1. Make photos of the transport damages.
2. Open the damaged crate so far that damages on components can
be verified and documented.
3. Inform responsible department about damages.
4. Then re-pack the damaged components carefully and store them in
a dry place.
Completeness Check the consignment for completeness using the packing list. Inform the
responsible department about missing parts/components.

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1.9.2 Packing
Depending on the packed components, the packing is used as protection

or only for covering the machine parts.
Sealed packings
Information
Sealed packings must not be opened on the way or during handling. The
customs and forwarding agents must be informed in time about the forth-
coming arrival of such consignments. Agree with the customs official that
the goods are locally inspected.
Sealed packings are used for very sensitive components, which are stored
in the recipient country for long time.
Contrary to normal packing machine parts are completely sealed into a
polyethylene foil with welded seams in order to close the parts airtight.
Sharp corners and edges are padded in order to avoid tearing of the
packing.
Unpacking Unpacking must take place only after approval given by ANDRITZ
HYDRO.
When unpacking consider the markings like e.g. Top, or This side up
and the warning and safety instructions on crates or packings.
In order to avoid damages open the crates and packings always carefully.
1. Remove all nails and bolted connections from the cover and remove
the cover itself.
2. Remove all supports and bracings, inner frames and safety devices
to enable unpacking of the parts without damages and risk.
3. Do not remove protecting covers during unpacking; but before the
assembly.
Information
Consider the corresponding disposal instructions for an environmentally
friendly disposal of the packings.
Remove polyethylene foils carefully, since these foils can be re-used for
covering the parts.

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1.9.3 Storage
NOTICE
Wrongly stored parts can suffer damage after a short period of time due to
climatic influences, which lead to re-treatment or re-machining.
Consider the manufacturer's data regarding storage of individual parts at
any time.
Each packing unit is assigned to a storage class in accordance with the

packing list. Store all delivered packing units in accordance with their
storage classes at the place of destination after their acceptance.
The storage class depends basically on the planned storage time (up to
3 months short-time storage or exceeding 3 months long-time storage)
and the component (material, size, weight, etc).
The conditions and minimum requirements of the 6 storage classes are
described in the following:
Storage Place of Storage conditions Minimum requirements

class storage
1 No Open-air storage area Stabilised, dewatered gravel
symbol (outdoors) floor
Open-air
2 storage Covered open-air storage area
or trajectory roof
3 Covered rooms Stabilised, dewatered gravel
floor
Tar or concrete floor if forklifts
4 Heated rooms > 8C
or mobile cranes are used
Covered Electrical light
5 storage Air-conditioned rooms 0 40C Protect shelves and depo-
Relative humidity 10 75% sitions against vermin and
6 Storage of dangerous goods rodents
*) Choice and execution of danger symbols in accordance with ADR,

Dangerous Materials Ordinance, etc.

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NOTICE
In order to avoid rust film on parts made of stainless steel, store them
always separately from parts made of C-steel.
As far as possible leave the parts in their original packing.
Consider always the allowed maximum floor loading during storage.
Special caution is required when piling wooden crates.
Inspections during Regular inspection of packing as well as corrosion protection of stored

storage period parts and if necessary, complete, repair or replace it.
Unless otherwise stipulated, check parts in open-air storage area monthly
and parts in covered storage areas every 3 months.
Take recordings of the inspections; if damages are detected, initiate
suitable measures in agreement with ANDRITZ HYDRO.
1.9.3.1 Storage of machine parts
Consider the following when storing machine parts:
In open-air Support the parts approx. 15 20 cm from the floor safely on wooden
storage areas beams, which are covered with plastic.
(outdoor storage) Store the parts in a way that rain water can run-off (preferably in
inclined position).
If covers are used, provide sufficient ventilation.
Remove wooden covers from flanges or similar things (prevention of
corrosion).
Enable access to the stored parts from all sides.
If necessary protect the parts against external mechanical influences.
In covered Support the parts approx. 15 20 cm from the floor safely on wooden
storage areas beams, which are covered with plastic.
Store small and particularly not packed parts in storage racks.
Take fire-protection regulations into account.
Provide sufficient ventilation and lighting.
Ensure that packings are not destroyed by vermin and rodents.

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1.9.3.2 Storage and preservation of technical rubber parts
The life cycle of rubber parts can be substantially impaired by several

influences and depends therefore to a great extent on a correct storage.
Properly treated rubber parts will not change their properties over several
years.
The following notices apply to the storage of technical rubber parts and
have to be kept strictly.
NOTICE
Rubber parts, which are stored outdoors, suffer damage after a short
period of time due to ozone, UV-radiation and different temperatures.
Thus a later use is not possible.
Rubber parts must not be extended, folded, broken or suspended on

hooks or something similar. The parts must be stored horizontally.
Pressing together must be avoided.
Thick-walled profiles are stored in elongated and flat position in order
to prevent a permanent deformation. Therefore packing of the profiles
in well closed pipes, made of aluminium or hard plastic, is recom-
mended.
Dark rooms are suitable as storage location.
Contact with solvents, fuels, oils, grease, chemicals and acids must be
avoided.
Consider the delivery sequence when using rubber parts. Thus a regu-
lar stock rotation is ensured.
Rubber parts must not exceed a storage period of 5 years after manu-
facturing.
Inspection of rubber parts for cracks by slight extension prior to the
installation. Defective rubber parts must be separated.

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2 Safety .................................................................................................. 2-2

2.1 Safety instructions ............................................................................................................. 2-3
2.2 Pictograms .......................................................................................................................... 2-4
2.3 Safety devices .................................................................................................................... 2-5
2.4 Basic safety instructions .................................................................................................. 2-6
2.4.1 Duties of operator ............................................................................................................. 2-6
2.4.2 General duties of personnel ............................................................................................. 2-8
2.4.3 Work on/in electrical systems........................................................................................... 2-9
2.4.4 Hydraulic, pneumatic ...................................................................................................... 2-10
2.4.5 Lifting and transport of components............................................................................... 2-10
2.4.6 Mobile usable machines and components .................................................................... 2-11
2.4.7 Gas, dust, steam, smoke ............................................................................................... 2-12
2.4.8 Noise............................................................................................................................... 2-12
2.4.9 Operating supplies ......................................................................................................... 2-12
2.4.10 Radio equipment ............................................................................................................ 2-12
2.4.11 Gas extinguishing system .............................................................................................. 2-13
2.5 Safety instructions trade .............................................................................................. 2-14
O&M Manual Safety 2-1

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2 Safety
The chapter Safety contains general safety instructions, which have to be
considered when working on the machine/plant.
Supplementary additional safety instructions to the individual activities are
provided in the chapters of the manual. These are set apart from the text
by special warning notices.
Safety instructions for components, which were not made by ANDRITZ
HYDRO, are included in the descriptions of the component suppliers and
have to be considered, too.
Non-adherence to the safety instructions can lead to personal injuries,
environmental damages and/or material damages.
ANDRITZ HYDRO assumes that the operator guarantees the following:
The operator prepared a comprehensive general safety program.
Each person, working on or in the surrounding of the machine/plant
was sufficiently trained (regarding operation of machine/plant and its
running procedures).

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2.1 Safety instructions
All data mentioned in the chapter 2 Safety are important safety-

relevant. Therefore the information in this chapter is not marked with
special danger symbols.
The warning notices, stated in the individual chapters, are marked with a
pictogram, signal word and signal colour as follows:
DANGER
This marking advises against direct danger for personal life
and health.
Non-adherence can lead to death or serious injuries and to extensive
material damages.
WARNING
This marking advises against an imminent danger for personal life
and health.
Non-adherence can lead to death or serious injuries and to extensive
material damages.
CAUTION
This marking advices against an imminent danger for personal
health.
Non-adherence can lead to medium or slight injuries and to environmental
and material damages.
NOTICE
This marking advises against a dangerous situation.
Non-adherence can lead to material damages.
Information
This marking contains useful information.
Considering this information facilitates or supports a correct performance
of the activity described.

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2.2 Pictograms
All prohibition-, warning- and action signs, which can be mounted on the
machine/plant and/or are used in this manual, are stated in the following:
Prohibition signs
No unauthorized entry No fire, no smoking No trespassing
No persons with Prohibition to extinguish Do not touch

pacemakers with water
Do not touch
danger of electric shock
Warning signs
Generic warning Warning of hot surfaces Dangerous voltage
Risk of falling Risk of crushing Warning for

magnetic field
Risk of slipping Floating loads Risk of tripping
Remotely started Environmental pollution Dangerous gases

equipment

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Mandatory signs
Use hearing protection Use protective eyewear Use protective footwear
Use gloves Wear protective helmet Use dust

protection mask
General protective Use and take along personal protective equipment in accordance with
equipment local instructions or instructions of plant operator.
The wear of protective footwear in all the factory premises is mandatory.
2.3 Safety devices
The access to all safety devices must be ensured at any time.

The machine/plant can be put from operation to a safe operating
condition at any time by pressing the EMERGENCY STOP BUTTON
(possible designs see illustrations below).
The operating and maintaining personnel of the operator must be informed

about the location and function of the EMERGENCY STOP BUTTONS.
The location and number of EMERGENCY STOP BUTTONS is shown on
the wiring diagrams.
Voltages and hydraulic pressures can still be present after pressing
the EMERGENCY STOP BUTTON.

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2.4 Basic safety instructions
2.4.1 Duties of operator
Intended use The operator of the machine/plant is responsible for the intended use of
the machine/plant. See section 1.6 Intended use.
Work instructions In addition to the manual observe and use the relevant national legislation
and other regulations regarding health & safety and environmental
protection.
Qualification of Operation, set-up and maintenance of machine/plant by qualified,

assigned reliable and authorized personnel only.
personnel Qualified personnel are persons, who were authorised by the responsi-
ble safety person due to their education, experience as well as knowl-
edge of relevant standards and regulations, rules for the prevention of
accidents and operating conditions to perform the necessary works
and to recognise and avoid possible dangers.
Ensure that only authorised personnel works on the machine.
Personnel in education may only work on the machine/plant after theo-
retical training and only under supervision of a qualified person.
Take the legal age into account.
Only an electricity specialist or person instructed by him is entitled to
work on electrical systems of the machine/plant under his direction or
supervision.
Only competent personnel are entitled to work on gas equipment (gas
consumption equipment).
Only personnel with special knowledge and experience are entitled to
work on hydraulic equipment.
Instruction The operating and maintaining personnel of the operator must be intro-
duced by qualified persons after completing the installation work.
The operator is obliged to introduce new operating and maintaining
personnel in the same extent and with the same care under considera-
tion of all safety instructions.
Persons, who are involved with the transport, assembly, commission-
ing, operation and maintenance of the machine/plant must have read
and understood this manual as well as the descriptions of the compo-
nent suppliers before commencing work.
Safety instructions for components, which were not made by ANDRITZ
HYDRO, are included in the descriptions of the component suppliers
and have to be considered, too.

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Definition of areas The operator is responsible for:

of responsibility the definition of the machine operator responsibility and the directive
authority,
the definition of the content (record of the function and malfunction of
monitoring equipment) and the responsibility for maintaining the shift
handover log,
the duties of the operating and maintaining personnel.
Inspections & tests The operator is obliged to:

check regularly whether the safety instructions are kept in accordance
with the manual when working on the machine,
train the operating and maintaining personnel regularly and to confirm
their knowledge.
Attachment of The operator ensures that all safety-relevant instructions are kept and all
safety devices necessary symbols and notices are attached in the production area in
accordance with the local instructions.
Beyond that ANDRITZ HYDRO recommends attaching of the following
devices, symbols and notices as far as these are not already contained in
the local instructions:
Emergency lighting
Information sign fire prevention equipment
Information sign emergency call
Direction sign exits
Direction sign escape routes
Information sign first aid
Observe the national fire protection regulations.
All safety- and warning notices on the machine/plant shall be complete and
readable.
Fire extinguisher The operating and maintaining personnel must be informed about the
location and handling of fire extinguishers.

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2.4.2 General duties of personnel
In order to avoid personnel injuries and material damages the following

safety instructions apply to all persons, working on the machine/plant:
Observe the safety instructions mentioned in the manual and attached
on the machine.
In case of safety-relevant malfunctions stop or secure the concerned
part of the machine immediately. Announce and repair the malfunc-
tions immediately.
Any safety-precarious mode of operation is not allowed.
Use only the provided entries, routes and aisles.
Keep the machine/plant and work place clean and tidy. Do not put
down tools and other items on the machine.
Do not wear cloths or pieces of jewelleries, which enable getting
caught by mobile machine parts. Ties, neckerchiefs, rings and chains
belong thereto.
Do not wear long hair loose.
Inform the personnel about the function and malfunction of monitoring
instruments before commencing work.
If necessary, place temporary barriers and limit the entrance when
working on the machine/plant.
Entering of danger zones is only allowed after the power supply is
safely disconnected and the mechanical safety devices are mounted.
Protective equipment must not be blocked or bridged.
Avoid contact with switched-on circuits or rotating parts.
Use or take along the personal protective equipment in accordance
with the national instructions or instructions of the operator when
working on the machine.
The wear of protective footwear in all the factory premises is
mandatory.
Re-establish the original condition after maintaining.

If the operating person can not survey the entire zone of danger,
nevertheless make precautions to ensure that no persons are in the
zone of danger when issuing control commands.
Set the operating mode to AUTO before leaving the power house in
order to ensure that the machine/plant can be stopped in case of
danger.

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2.4.3 Work on/in electrical systems
High voltage can lead to heavy or fatal injuries. Therefore it is essential to

observe the following:
Work on/in electrical systems must not be carried out unless a permit
has been issued by the senior authorised person.
Operation and maintenance of the machine/plant only by qualified
personnel.
A second person must be present when working on live parts. In
case of emergency this person can press the EMERGENCY STOP
BUTTON or the main switch with shunt trip. Demarcate the working
area with a red-white safety chain and a warning sign.
Use proper insulated tools, protection devices and personal protective
equipment and check them before each use.
It is recommended to make oneself familiar with the safety standards,
guidelines and electrical regulations as well as the usual national and
proven operating modes for plants (e.g. EN 50110, VDE0104 or IEC-
standards). The following steps have to be met as minimum require-
ment before commencing work on electrical machines/plants:
o Disconnect completely
o Secure against re-connecting
o Verify that the installation is dead (de-energised).
o Carry out earthing and short-circuiting
o Provide protection against adjacent live parts
After finishing the work, carry out the above 5 steps in reverse order.
Regular inspection of electrical equipment of machine/plant. Lacks
such as loose connections or scorched cables have to be repaired
immediately.
Use only original locking devices with stipulated amperage.
In addition to the general safety instructions observe and comply with
the local safety instructions and specifications.
Remove covers and safety devices only after the appropriate ranges
are de-energised and secured. Before energising mount the covers
and safety devices again.

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2.4.4 Hydraulic, pneumatic
Only personnel with special knowledge and experience are entitled to

work on hydraulic equipment.
Regular inspection of pipes, hoses and bolted connections for leakage
and externally visible damages (leaking-out oil can lead to injuries and
fire). Damages have to be repaired immediately.
System sections and pressure pipes (hydraulic, compressed air) have
to be depressurised before commencing repair work in accordance
with the module descriptions.
Hydraulic and compressed-air pipes have to be laid professionally
(connections must not be mistaken).
Armatures, length and quality of hose lines must correspond to the
requirements.
The operating space of the actuators must not be blocked and the ac-
cess to this space must be properly secured. This applies in particular
to closing weights, servo motors and the guide apparatus.
2.4.5 Lifting and transport of components
The notices, stated in the following, have to be kept when lifting and trans-
porting components in order to avoid injuries and material damages.
Do not stay or work below floating loads. Further it is not allowed to
ride on floating loads.
Adhere to the general and also local safety instructions as well as
specifications or manuals of the lifting tool or load lifting attachment
manufacturer.
The used lifting tool or transport vehicle must be suitable for the loads
to be transported. If a mobile crane is used, take additionally into ac-
count that this crane is mounted in accordance with the manufacturers
instructions.
Usage permission for the crane must be available. Operation of remote
controlled cranes only by personnel with proper written driving licence.
The results of the regular lifting tool inspection (inspection log book)
must be available.
All used slinging means (ropes, chains, shackles, eyebolts, lifting eye
nuts, S-hooks) must be used only in accordance with the manufac-
turer's data.

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Secure the loading properly before lifting and transport operations.

Determine the required space in the power plant or on other provided
(temporary) storage areas before commencing with lifting and transport
operations. Further make sure that the floor loading is adequate by
granting access to the as-built drawings.
During lifting observe the signs and other written instructions attached
on the packings or components; special customer requirements are to
be considered, too.
A "test brake" of the lifting unit is necessary when lifting heavy loads.
Lift the load approx. 10 cm and lower it in small steps. After each
switch-off, the brakes have to stop the lowering process.
Use 3D-lifting rings or eyebolts, if provided.
Direction of crane operation by show of hands or wireless only by
responsible specialist.
2.4.6 Mobile usable machines and components
Secure the machines/components with appropriate fixings against un-

intended positional changes before or immediately after finishing the
loading process.
Attach appropriate warning signs.
Disconnect the machines/components from any external power supply;
also in case of slight relocations.
Remove transport and slinging means duly before re-commissioning.
Mount and fasten the parts, which were removed for transportation
purposes, again before re-commissioning.
Connect the machines/components again with the system before re-
commissioning.
Re-commissioning only in accordance with the manual.

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2.4.7 Gas, dust, steam, smoke
Welding, burning and grinding operations on the machine/plant are

only allowed if expressly approved.
Remove dust and inflammable materials from the machine/plant and its
surrounding before welding, burning and grinding operations. Further
proper ventilation is to be ensured (danger of explosion)!
If necessary take available national instructions for work in close rooms
into account
2.4.8 Noise
Noise protection devices of the machine/plant must be in safe position

during operation.
When required, use hearing protection.
2.4.9 Operating supplies
Before operating supplies can be used, read the safety data sheets of the
machine and the instructions of the manufacturer. Based on these data
sheets prepare a proper protection concept and observe it.
Apart from that take the following measures in order to avoid damages and
injuries of the personnel:
Wear protective goggles
Avoid excessive skin contact with the product
Proper ventilation of surrounding
Use protective equipment
Do not work near naked flame
Ignoring of these precautionary measures can lead to injuries by inhalation
of poisonous steams or lead to suffocation.
Be careful when dealing with hot operating supplies. Danger of burns and
scalds!
Swarf of coatings, arising during repair work, must be disposed as
hazardous waste.
2.4.10 Radio equipment
Only EMC-conform radio equipment must be used within the plant.

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2.4.11 Gas extinguishing system
The entire operating and maintenance personnel of the operator must be

familiar with the operating mode of the gas extinguishing system, when
using such a system. Further it must also be familiar with the resulting
special safety precautions in case of emergency.
Ignoring of these safety precautions can lead to injuries or death of
persons by inhalation or quenching gas.
If the gas extinguishing system is part of the scope of supply of ANDRITZ
HYDRO, the description of the operating mode and special safety precau-
tions is contained in the project documentation of ANDRITZ HYDRO.

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2.5 Safety instructions trade
General safety instructions trade

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3 Technical Data ................................................................................... 3-2

3.1 Turbine ................................................................................................................................ 3-2
3.1.1 Design data turbine .......................................................................................................... 3-2
3.1.2 Runner dimension ............................................................................................................ 3-3
3.2 Generator, Indar LSA-1120-X/14 ....................................................................................... 3-4
3.2.1 Design data generator ...................................................................................................... 3-4
O&M Manual Technical Data 3-1

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3 Technical Data
3.1 Turbine
3.1.1 Design data turbine
Pelton Turbine Tudaya 1
Turbine-No.: M-1313467
Turbine type V5-G1-6/380/40-1/1160/340
Number of jets 6 pcs.
Rated speed n = 514,3 rpm
Rated net head = 227,69 m
Nominal flow = 3400 l/s
Nominal power output = 6852 kW
NOTICE
It is not allowed to operate the turbine with a flow less than 10% of
the nominal flow.
Any undercut of the minimal flow can cause any damages on the runner
and the nozzles!
NOTICE
It is not allowed to operate the turbine below the minimal head.
Any undercut of the minimal head can cause any damages on the runner!

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3.1.2 Runner dimension
Runner diameter D1 = 1160 mm
Bucket B2 = 340 mm
Runner weight approx. = 1353 kg
Outer runner diameter Da = 1480,8 mm

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3.2 Generator, Indar LSA-1120-X/14
Generator supplied by consortial partner Indar.

For details, see O+M-manual generator.
3.2.1 Design data generator
The synchronous generator is designed for following operation:
Rated output = 8317 kVA
Nominal active power P = 6653,6 kW
Tension = 6300 Volt
Frequency = 60 Hz
Rated speed = 514,3 rpm
Runaway speed 954 rpm <2min
Machine protection IP 23
Mounting form IM4011
Insulation class F
Temperature rise B
Power factor (Cos ) 0,8

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4 Specification ....................................................................................... 4-2

4.1 General layout drawing / General arrangement drawing .............................................. 4-2
4.2 Turbine ................................................................................................................................ 4-2
4.2.1 Turbine housing ................................................................................................................ 4-2
4.2.2 Runner assembly ............................................................................................................. 4-3
4.2.3 Nozzle assembly (Inlet) .................................................................................................... 4-3
4.2.4 Jet deflector with drive...................................................................................................... 4-3
4.2.5 Manifold ............................................................................................................................ 4-3
4.2.6 Instrumentation ................................................................................................................. 4-4
4.2.7 Inlet pipe ........................................................................................................................... 4-4
4.2.8 Intermediate pipe .............................................................................................................. 4-4
4.2.9 Dismantling pipe ............................................................................................................... 4-5
4.3 Generator (supplied by member of a consortium Indar)............................................... 4-5
4.4 Shut-off device ................................................................................................................... 4-6
4.4.1 Bypass over the shut-off device ....................................................................................... 4-6
4.5 Hydraulic Power Unit ......................................................................................................... 4-6
4.6 Lubricating Unit .................................................................................................................. 4-6
4.7 Cooling Water System ....................................................................................................... 4-6
4.8 Penstock drain pipe ........................................................................................................... 4-7
4.9 ANDRITZ Hydro control unit ............................................................................................. 4-7
4.9.1 Single Line Diagram ......................................................................................................... 4-7
O&M Manual Specification 4-1

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4 Specification
4.1 General layout drawing / General arrangement drawing
The general layout drawing / general arrangement drawing can be taken

from the "Drawing" register.
4.2 Turbine
The vertical Pelton turbine is designed for the direct drive of a generator.
The runner is arranged on the extended generator shaft directly. The
machine group is designed as a two bearing assembly. The two bearings
as well as the lock washer for speed measurement are included in the
generator scope of supplies. The turbine scope of supplies comprises the
following:
Turbine housing
Runner assembly
Nozzle assembly (Inlet)
Deflector
Closed circular pipeline
Instrumentation
Intake pipe
Removable pipe piece
4.2.1 Turbine housing
The turbine housing is a single-piece structure of welded steel and has

mounted-on flanges for the nozzle set and the deflector drive. The housing
is fitted with legs for installation on the concrete foundation.
The housing inside accommodates metal sheet fixtures for optimum water
discharge.

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4.2.2 Runner assembly
The runner assembly comprises the main components described below:
Pelton runner
Runner - generator shaft connection (clamping element)
Shaft seal
4.2.3 Nozzle assembly (Inlet)
The nozzle assembly with inside servomotor comprises the main

components as described below:
Welded intermediate piece
Cast intake pipe
Nozzle head with inserted nozzle and bearing eyes for deflector
Needle tip
Needle pin
Bearing sleeve with rod seal and dirt wiper
Hydraulic servomotor
4.2.3.1 Oil hydraulic servomotor
The cylinder is charged with oil on both sides and fitted with a front flange
for clamp-attachment into the nozzle torpedo. For the purpose of recording
the nozzle position, a position encoder system is installed. The rated
cylinder pressure is 160 bar. The piston rod is hard chrome-plated; the
sealing system is a low-friction type.
4.2.4 Jet deflector with drive
The jet deflector is supported on the nozzle head and driven by a spring-
type servomotor. Bearing is provided for by maintenance-free slide
bushes. Both deflectors are coupled by a stainless steel rod system in the
housing.
4.2.5 Manifold
The manifold consists of branch pipes and a pipe bend. The branches are
of cast material. The pipe pieces were fitted between the branches during
workshop assembly.

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The first pipe is provided with the instrumentation connections and the
bypass over the shut-off device.
For emptying the manifold, the first branch is provided with a drain with ball
valve. The piping for drainage is directly routed to below the turbine
housing.
WARNING
The manifold drainage is not designed for draining the penstock.
Opening the ball valve of the manifold drainage may result in the
destruction of the drain pipe and in a flooding of the plant.
The ball valve of the manifold drain may only be opened when the
manifold is depressurized and the shut-off device is closed and locked
(including the bypass over of the shut-off device).
It is recommended to secure the ball valve by means of a lock.
4.2.6 Instrumentation
The set of instruments comprises the following instruments:
A manometer upstream of the shut-off device

A manometer downstream of the shut-off device
A pressure switch downstream of the shut-off device
A pressure transducer upstream of the shut-off device
4.2.7 Inlet pipe
The intake pipe as the connecting pipe between the penstock and the
shut-off device comprises a taper and outlets for
A bypass upstream of the shut-off device

A manometer
A pressure transducer
4.2.8 Intermediate pipe
The intermediate pipe between the penstock and the shut-off device
comprises outlets for
A bypass downstream of the shut-off device

A manometer
A pressure transducer.

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4.2.9 Dismantling pipe
The dismantling pipe between the shut-off device and the first branch pipe
is required for dismantling the shut-off device. It is designed as a force-fit
type and consists of the following main components:
Pipe with flange
Sliding flange
Bolted connections
4.3 Generator (supplied by member of a consortium Indar)
The generator consists of a rotating-field main machine with salient pole or

non-salient pole rotor, an exciter to transmit the excitation power, and the
exciter equipment. For converting the three-phase current from the exciter
armature a rotating rectifier assembly mounted on the shaft is used.
This synchronous generator is designed for use in a hydropower plant in
which the Pelton runner is directly mounted on the shaft end.
The synchronous generator is suitable for parallel mains operation as well
as for operation in an isolated network.
The generator scope of supplies primarily comprises the following
components:
Rotor with extended generator shaft end for direct coupling of the
runner
Stator with terminal boxes
Exciter
Ball bearings
PT-100 for monitoring the winding temperatures
PT-100 for monitoring the bearing temperatures
speed sensors
vibration sensors
Brushless exciter
Voltage and Cos controller
Neutral point protection current transformer
For a more detailed description of the generator, please refer to Section

"Generator Documents".

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4.4 Shut-off device
The shut-off device consists of a ball valve with hydraulic drive, to open the
shut-off device, as well as of a counterweight to close the shut-off device.
The shut-off device may be closed securely under full flow condition.
The shut-off device is fitted with limit switches for the opened and/or
closed position.
For a more detailed description of the shut-off device, please refer to
Section "Shut-off Device Documents".
4.4.1 Bypass over the shut-off device
The bypass is designed for balancing the pressure between the shut-off
device and the turbine and comprises the following components:
Ball valve with electrical drive

Ball valve with hand lever
Pipework
For a more detailed description of the valve, please refer to Section

"Turbine Mounted-in Equipment ".
4.5 Hydraulic Power Unit
The hydraulic power unit generates the oil pressure to operate the turbine
nozzles, deflector and the ball valve.
For a more detailed description of the valve, please refer to Section
"Section Hydraulic Power Unit ".
4.6 Lubricating Unit
Not applicable.
Self-lubricated bearings installed on DE and NDE- side of the generator.

See generator O+M- manual
4.7 Cooling Water System
Not ANDRITZ Hydro scope of supply.

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4.8 Penstock drain pipe
The penstock drain pipe is used for fully emptying the penstock.
The emptying procedure is described in Section "Operation".
The penstock drain pipe consists of the following components:
Shut-off device
Pipe work
4.9 ANDRITZ Hydro control unit
The control unit is designed for automatic operation of the plant.

For a more detailed description of the control unit, please refer to the file
"Turbine Control".
4.9.1 Single Line Diagram
The single line diagram is included in the file "Electrical diagrams" as well
as other electrical related documents

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5 General Operation ............................................................................. 5-2

5.1 Safety instructions ............................................................................................................. 5-2
5.2 Process and control circuits ............................................................................................ 5-3
5.3 Starting conditions ............................................................................................................ 5-4
5.4 ANDRITZ Operation Manual.............................................................................................. 5-5
O&M Manual Operation 5-1

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5 General Operation
WARNING
In operation, the falling weight of the shut-off device is lifted and
lowered automatically.
It is prohibited to access the area of the closing weight of the shut-off
device.
The closing weight must not be blocked during operation.
ATTENTION
In Operation, temperatures of over 60C may occur at the following
plant components:
Bearing housing of generator and oil return lines
Drive units
Solenoid coils
Surface temperatures are to be checked prior to touching these
components.
ATTENTION
In case of leakages of any kind (e.g. cooling agents, oils, gases),the
system is to be deactivated and kept shut down until identification
and remedy of the leakage location.
Escaped medium residues must be collected and disposed of so that they
will not imply and danger for individuals or the environment. Statutory
provisions must be complied with.
Information
Prior to performing any work on the plant and starting the plant, the
general safety instructions included in Section 2 are to be read and
observed.
The plant is to be secured against an unintended start / use by means of

appropriate technical and organizational safety measures.

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5.2 Process and control circuits
nozzle
impulse open / close nozzle drive position
level encoder
water 4...2o mA
intake 4...20 mA
comand
and control deflector
deflector
I/O position
pressure drive
4...2o mA parameters: switch
penstock - reference level water
intake position: retracted / extended
- minimal generator output
- minimal penstock pressure
shut-off
shut-off
power device
4...2o mA I/O device
generator position
drive
switch
position: open / closed
Fig. 1.: Process and control circuits of turbine
The plant is designed for parallel mains operation with level control.
Due to the water level in the water catchment, the nozzle is opened and/or
closed by pulses in parallel mains operation. The position return of the
nozzles is effected by means of an electrical position encoder with
analogous output (420mA).
When commanded by the control, the deflector is retracted or extracted.
When the deflector is removed from the water jet, the spring in the
deflector cylinder is tensed. The position return of the deflector is effected
by means of two limit switches in the deflector drive (RETRACTED
position or EXTRACTED position).
When commanded by the control, the shut-off device is opened and
closed, respectively. The position return of the shut-off device is effected
by means of two limit switches (shut-off device OPEN or shut-off device
CLOSED).

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5.3 Starting conditions
Prior to starting the plant it must be ensured that the intake, the pressure
pipe and the tail water channel are cleared from obstacles so that water
may flow into and out of the plant without any trouble.
NOTE
Stones and objects in the intake and the pressure pipe may cause
damage to the shut-off device, the control valve, the nozzles and/or
the runner or even the destruction of these components.
Damages components shall be inspected immediately and replaced if
necessary.
After performing work on the water catchment, in the sand trap and on the
pressure pipe as well as after dismantling fittings, valves, etc. it must be
ensured by appropriate measures that no obstacles (stones, materials,
tools, etc.) have been left in the pressure pipe, the fittings/valves or the
pipework.
WARNING
If a fitting (e.g. pipe breakage cover) closes at the intake of the
pressure pipe or within the pressure pipe under insufficient
ventilation conditions, negative pressure may occur in the pressure
pipe and the turbine.
Negative pressure in pipes and fittings may result in damage to them or
their destruction.
It must be ensured that a pressure pipe vent (e.g. by means of a
ventilation valve, ventilation pipe, etc.) is provided downstream of each
fitting (e.g. pipe breakage cover).
In order that the turbine may be started, the following conditions must be
met:
The required level in the water catchment basin must be reached.
The pressure pipe must be filled and the minimum pressure must be
reached.
The grid must be available.
The relevant fittings in the water catchment and the pressure pipe (e.g.
pipe breakage covers, gate in catchment, etc.) must be opened.
All drainage connections in the control centre must be closed.

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All shut-off valves to sensors and manometers must be opened.
The generator speed must be below the minimum speed.
No alarm must be active.
5.4 ANDRITZ Operation Manual
The Operation Manual for the control unit is included in the project specific
operation manual in the chapter Control.

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6 Maintenance .......................................................................................... 2
6.1 Safety instructions .................................................................................................................2
6.2 General maintenance and inspection guidelines...............................................................3
6.2.1 Expert staff ...........................................................................................................................3
6.2.2 Recording .............................................................................................................................4
6.3 Factors influencing maintenance ........................................................................................4
6.4 Maintenance and inspection schedule ................................................................................4
6.5 Maintenance and inspection activities ................................................................................7
6.5.1 General plan inspection .......................................................................................................7
6.5.2 Turbine..................................................................................................................................9
6.5.3 Generator ...........................................................................................................................17
6.5.4 Shut-off device....................................................................................................................19
6.5.5 Hydraulic unit ......................................................................................................................20
6.5.6 Turbine bypass ...................................................................................................................26
6.5.7 Penstock drain pipe ............................................................................................................27
6.5.8 Control system....................................................................................................................28
6.6 Troubleshooting ...................................................................................................................29
6.6.1 Turbine failures ...................................................................................................................29
6.6.2 Generator operation failures ..............................................................................................30
6.6.3 Shut-off device operation failures ......................................................................................32
6.6.4 Hydraulic unit operation failures .........................................................................................33
6.6.5 Turbine bypass operation failures ......................................................................................34
6.6.6 Penstock drain pipe failure .................................................................................................35
O&M Manual Maintenance 6-1

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6 Maintenance
DANGER
Opening of pressurized valves and pipes imposes danger to life!
WARNING
When accessing the machine in the water-bearing area in the drained
condition of the machine (e.g. turbine chamber, etc.), the shut-off
devices (e.g. pipe breakage cover, shut-off device, bypass, etc.) must
be blocked; the stop logs must be installed and secured against
unintentional opening and/or removal.
The generator switch must be in the OFF position, disconnected and
secured against unintentional activation.
ATTENTION
Temperatures of over 60C may be reached on the plant components
listed below:
Bearing housing of generator and oil return lines
Stator and rotor of generator
Drive units
Solenoid coils
Surface temperatures are to be checked prior to touching these
components.
Information
Prior to performing any work on the plant, the general safety
instructions of Section 2 are to be read and observed.
Prior to performing any work on the valves, pipework and lines, the
following must be observed:
Make sure that valves, pipework and lines have been depressurized.
Make sure that any drive units, devices and electrical components have
been deactivated and that unintentional movement of drive units is
excluded. It must be considered that drive systems and cylinders may

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include strongly pre-tensioned springs (and hence serious injuries might

be caused).
When dismantling fitting and valves, media residues must be collected

and disposed of so that they will not imply any danger for individuals or
the environment. Statutory provisions must be complied with.
WARNING
Prior to restart it must be ensured that all openings (in pressure pipe,
pipework and turbine, etc.) are closed.
The system must not be filled without previous visual inspection and
recording the condition of all openings.
Non-compliance with this instruction may result in a flooding of the central
control station!
6.2 General maintenance and inspection guidelines
The thorough inspection and maintenance in accordance with the

instructions below is essential for the operational availability and reliability
of all plant components as well as for keeping them in a good condition.
Maintenance work must be performed appropriately in order to ensure the
normal service life of the equipment.
The purpose of inspections is to detect incipient defects or damage at an
early stage in order to avoid consequential damage and an extended
downtime of the equipment by immediate repair, parts replacement, etc.
Such inspections also include a regular check of the tight seat of all bolted
connections on the entire plant.
Maintenance work are performed to maintain all plant components in a
trouble-free functional condition for a maximum period of time.
It is recommended to contact ANDRITZ Hydro early if major repair work or
the replacement of components is required.
6.2.1 Expert staff
The plant expert staff must be qualified, trained and competent in the
handling of electrical and hydraulic equipment, in the maintenance
procedures and the tests.

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6.2.2 Recording
Records are to be prepared of all inspections. These records are to be

submitted to the Contractor upon request during the entire guarantee
period.
6.3 Factors influencing maintenance
Process water contamination may significantly affect maintenance and

inspection requirements. Inspection and maintenance intervals may have
to be adapted to particle contents and materials in the water.
The intervals given in the maintenance schedule are recommended
minimum requirements and do not apply for extended shutdown times.
They must also be adapted to the ambient operation conditions, and
compliance with them shall in no case be understood as a guarantee for
trouble-free operation.
6.4 Maintenance and inspection schedule
Interval
Maintenance and/or Reference /
Quarterly
No. Revision
Annually
annually
Monthly
Every 2
Weekly
Semi-
years
Daily
inspection activities Comments
1 General overview of condition Cf. Section 6.5.1
Power shut down with 25% output:

X
Record values
Inspection of safety devices X
2 Housing Cf. Section 6.5.2
Leakage check of housing bushing X
Corrosion protection check X
3 Runner Cf. Section 6.5.2
Dye penetrant test X
Visual check for abrasion, cavitation or

X
damage
4 Nozzle set Cf. Section 6.5.2
Cylinder leakage check X
Leakage check of needle tip and nozzle X
Lubrication of elec. drive lifting rod X

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Interval
Quarterly
No.
Revision
Annually
annually
Monthly
Every 2
Weekly
Semi-
years
Daily
Functional check of nozzle drive X
Lifting check X Cf. Start-up report
Regulating time check X Cf. Start-up report

X
other damage
5 Deflector Cf. Section 6.5.2
Cylinder leakage check X

X
other damage
Functional check of deflector drive X
Lifting check X Cf. deflector drawing
Regulating time check X Cf. Start-up report
Distance to jet centre X Cf. deflector drawing
6 Display and monitoring instruments Cf. Section 6.5.2
Check of plausibility of values X
Check of proper functioning X
7 Generator Cf. Section 6.5.3

Informative overview, for details refer to
manufacturers documentation
Leakage check X
Bearing temperature check X
Winding temperature check X
Manual vibration check X
Regrease bearings X
Insulation resistance measurement X
Polarity index determination X
Vibration measurement X
Drying and cleaning of winding X
8 Shut-off device Cf. Section 6.5.4


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Interval
Quarterly
No.
Revision
Annually
annually
Monthly
Every 2
Weekly
Semi-
years
Daily
Leakage check X
Check of regulating time for opening X Cf. Start-up report
Check of regulating time for closing X Cf. Start-up report
9 Hydraulic unit
Check of piping and hoses X Cf. Section 6.5.5
Oil level check in tank X
Check of oil filter for contamination X
Visual check of oil X
Pumping interval check X
Check of gas pressure and accumulator

X
attachment
Check of air filters X
Oil analysis X
Functional check of emergency closing

X
valves
Check of paint coating for damage X
Check of tight seat of bolts and

X
attachments
Cleaning of tank X At every oil change
Replacement of hoses X After 6 years at the latest
10 Turbine bypass Cf. Section 6.5.6
In operation: vibration check

Leakage check X
Activation of control valve X
Check of regulating time X Cf. Start-up report
Check of orifice diameter X
11 Pressure line drain pipe Cf. Section 0
In operation: vibration check

Leakage check X

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Interval
Quarterly
No.
Revision
Annually
annually
Monthly
Every 2
Weekly
Semi-
years
Daily
Purging of drain pipe X
Check of orifice diameter X
12 Control system
Check of displayed value plausibility X
Visual functional check of installed

X
equipment
Check of battery condition X
Power switch on/off check X
6.5 Maintenance and inspection activities
6.5.1 General plan inspection
6.5.1.1 Weekly inspections
The plant is to be inspected weekly. Particular attention must be paid to

irregular noise, smells and leakages.
If changes have occurred, the reasons as well as their cause must be
identified and remedied.
6.5.1.2 Corrosion protection
On principle, any damage to corrosion protection (inside and outside) shall

be remedied as quickly as possible. Runner inspections and other turbine
dismantling procedures are to be taken as occasions to remedy inside
corrosion protection damage, too. All uncoated surfaces (piston rod, etc.)
shall be wiped off with an oil-damp cloth every 2 weeks.
6.5.1.3 General overview of condition

Even minor damage to nozzle and nozzle needle may have an adverse
effect on the jet, which may result in damage to the runner and hence
losses in efficiency and power.
The following checks are intended to provide for an appropriate overview
of the situation every 3 months:
1. Control machine to 25% nozzle opening.

2. Monitor power and keep record.

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3. Monitor bearing vibration by manual measuring device and keep

record.
4. Trigger emergency shut-down as from 25% nozzle opening, monitor
pressure and speed increase and keep record.
The measured values should comply with the regularly recorded values
(minor inaccuracies attributable to reading and settings being acceptable)
In case of significant deviations, the reasons and cause must be searched
and remedied.
6.5.1.4 Check of safety devices

Safety devices are to be checked annually, such check must include the
test of the functions and a check of the regulating times listed below:
Emergency closing test with 25% of the nominal flow (record speed
and pressure increase)
Closing times of nozzles and deflector
Closing time of shut-off device
Test of electrical and mechanical trigger functions.

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6.5.2 Turbine
DANGER
Opening valves and fittings under pressure imposes danger to life!
WARNING
Changing opening and closing times may result in water hammers
and consequently to damage on and destruction of the turbine,
valves, pipework and pressure line.
The opening and closing times set upon start-up must not be changed.
6.5.2.1 Turbine housing
A leakage check of the housing bushings and all flanged connections shall
be performed every week. If leakage is detected, seals shall be replaced.
Corrosion protection shall be checked for damage annually. Damage
detected on corrosion protection shall be ground off, and new corrosion
protection is to be applied.
6.5.2.2 Runner
Upon the start-up tests, the runner is to be checked visually for abrasion,
cavitation and other damage. An initial crack test (hub and vanes) is to be
performed after approx. 2,000 3,000 operating hours. The
recommended test procedure to be applied is the dye penetrant
procedure.
Other visual and crack test shall be performed annually. Depending on
the contamination level of the water and the runner condition, visual and
crack tests shall be performed at shorter intervals!
Cracks detected shall be reported to the supplier immediately in writing
together with location sketches so that the damage may be evaluated and
repair work may be coordinated. Erosion damage might be remedied by
grinding.
Welding repair work is only permissible if electrodes of the same type are
used. Depending on the scope of repair work, the runner shall be stress-
relieved and re-balanced upon welding.
Weld procedure see Vol. 1 Chap .
Heat Treatment Protocol see Vol. 1 Chap..
Grinding Templates see Vol. 1 Chap.
All welding and grinding repair work may only be performed by qualified
expert staff.

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6.5.2.3 Installation and dismantling of runner (vertical, MAV 20kg)
WARNING
Never use lubrication agents based on molybdenum disulphide such
as Molykote, Never-Seeze or the like when applying clamping
elements.
HINWEIS
Prior to installation or dismantling of the runner, the clamping element
manufacturer's instructions in the "Turbine Mounted-in Components"
register are to be read and strictly observed.
The final condition of the runner installation is shown in drawing "Runner
on shaft end" in the "Drawings" register. The relevant data (in particular the
indicated tightening torques) must strictly be observed.
Fig. 1: Lifting device for clamping element
Runner installation
The clamping element is delivered ready to use. Should it be dismantled
for any reason whatsoever, the orientation of the sections and the position
of the thrust rings must be observed. These are only mounted correctly if
no holes are located below the threaded holes of the outer ring. The
computation of the transferable torque is based on a friction coefficient of

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=0.12 which is received by the rings, the bolts and the slightly lubricated
seats of the clamping element.
1. Make sure that the surfaces of the clamping bolts, the 3 rings of the
clamping element, the generator shaft and the runner hub are clean
and slightly greased and that the slots of the clamping element are
matched.
2. Release bolts by a minimum of 2 revolutions. Place mounting disc on
clamping element and turn in a minimum of two bolts into the draw-
off thread of the outside thrust ring (2) in order to separate the ring
from the outer ring.
Fig. 2: Clamping element ready for installation: 1) bolts, 2) outside thrust ring,
3) outer ring, 4) rear thrust ring
3. Separate the rear thrust ring from the outer ring using the threaded
alignment bars. Slightly compress the clamping element using the
clamping set so that the diameter becomes somewhat smaller than
the inside diameter of the runner hub. The clamping set is to be
mounted in a manner so that the clamping element may be pushed
into the runner hub as far as possible during installation. Make sure
that the outer ring surface is not damaged.
Fig. 3: Clamping element with mounting disc (with threaded alignment bars) and
clamping set.
4. Mount wheel intermediate flange and O-type sealing ring on runner.

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5. Connect three chain hoists on housing by means of eye bolts.

6. Carefully lift runner onto carriage up to the stop on the generator
shaft. Before the runner has arrived at the very top, clean clamping
element, generator shaft and runner again.
7. Turn in threaded bar into generator shaft. Lift clamping element with
mounting disc and fix it on threaded rod by use of nut and/or hand
wheel. The spacer sleeve must be mounted between the mounting
disc and the hand wheel. For safety purposes, additionally mount the
locknut with washer beneath the hand wheel. Now the clamping
element and the mounting disc may be turned upward and carefully
be inserted into the runner hub as far as possible.
WARNING
Overload on the hand wheel may result in a rupture of the thread in
the hand wheel.
In order to prevent the clamping element or the runner from dropping
down, the locknut must continuously be repositioned to the elevation of the
hand wheel.
8. After insertion of the clamping element into the runner hub, the
clamping set may be removed.
9. Make sure that the rear thrust ring is forced to the intermediate
wheel flange and the intermediate wheel flange is forced to the shaft
shoulder, respectively, by means of the threaded alignment bars.
Subsequently bring the bolts used for separating the rings back into
their original positions. All clamping bolts are to be tightened
manually crosswise first. Make sure that tightening is not
commenced on the bolts near the gap. Make sure that the outside
thrust ring is positioned in parallel to the shaft contact surface and
that the outer ring is pushed over the rear thrust ring before the end
ring is pushed into the outer ring.
10. Check that the runner is in the correct position. The runner edges
must be aligned on the elevation of the nozzle tip.
11. Tighten the bolts using a torque wrench. This wrench is to be set to
approx. 5% over the torque Ma indicated in the drawing. Tighten
bolts by revolutions crosswise, each.
12. When the bolts are tightened so that the runner keeps its position,
the runner carriage may be lowered.
13. Continue tightening the bolts using the wrench set to a torque of 5%
over the specified value by turning the bolts by revolutions
crosswise, each, until they are fixed tightly. Finish with some
additional pulls in order to compensate a potential lowering of the
rings or the bolts. Without the slight overload of 5%, numerous
additional pulls could be required in order to achieve the specified
tension.

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14. Set the torque wrench back to the specified torque (Ma, in
accordance with drawing "Runner on shaft end") and check the
correct seat of all bolts. None of them must be movable anymore,
otherwise repeat step 13 once or twice. It is not necessary to check
the tightening torque subsequently during operation.
15. Dismantle mounting disc, hand wheel and threaded bar.
16. Install wheel end disc with O-type sealing ring and tighten the
hexagonal bolts to the torque indicated in drawing "Runner on shaft
end" and secure them using LOCTITE 243. Clean wheel end bolt
and the tread (using acetone or thinner), slightly tighten the wheel
end bolt manually, secure it using LOCTITE 262 and seal it with the
silicon sealant LUCATO.
Runner dismantling
Basically, the runner is dismantled in the reversed order of the installation.
The following items, however, are to be observed:
Information
In order to avoid damage to the bolts, the draw-off threads and the
draw-off surfaces on the rings during dismantling, it must be ensured
that the bolt ends are ground even and provided with a 45 chamfer.
1. Make sure that movement of the clamping element rings as required

for dismantling is possible in the axial direction.
2. Lift carriage using chain hoist until it stops at the runner.
3. Remove special bolt and wheel end disc. Make sure that the draw-
off threads are in a good condition.
4. Mount threaded bar, mounting disc, spacer sleeve, hand wheel, and
locknut with washer. Attach mounting disc in a manner so that holes
are located beneath all bolt heads.
5. Remove all clamping bolts.
6. Reposition mounting disc so that holes are located beneath the
draw-off threads of the outside thrust ring. Secure mounting disc by
means of hand wheel and locknut.
7. Turn in the prepared jacking bolts in all draw-off threads of the end
ring and draw off the outside thrust ring: the jacking bolts must be
tightened gradually, clockwise or counter-clockwise, beginning at the
gap. Usually, the bolts are completely tightened after the first pull
already, without noticeable movements of the ring being observed.
Although it may seem that the bolts cannot be tightened further,
additional pulls will increase the force along with the partial release
of the outside thrust ring.

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Fig. 4: Drawing off outside thrust ring (2) from outer ring (3)
8. Remove mounting disc and outside thrust ring.
ATTENTION
Loose rings may drop accidentally
Make sure that the outer ring and the rear thrust ring are still fixed.
9. Mount mounting disc using threaded bar so that the holes of the
mounting disc are located beneath the draw-off threads (see figure
3) in the outer ring. Mount spacer sleeve, hand wheel, locknut and
washer.
10. Turn in the prepared jacking bolts in all draw-off threads of the outer
ring and draw off outer ring from the rear thrust ring. Procedure as
described under item 7.
Fig. 5: Drawing off outer ring (3) from rear thrust ring (4)
11. Lower outer ring, rear thrust ring and mounting disc by means of the
hand wheel and remove them.

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WARNING
Overload on the hand wheel may result in a rupture of the thread in
the hand wheel.
In order to prevent the clamping element rings from dropping down,
the locknut must continuously be repositioned to the elevation of the
hand wheel.
ATTENTION
Should the threaded bar be turned out during this procedure, the
mounting disc, the hand wheel and the clamping element rings might
drop accidentally.
Make sure that the threaded bar is not turned out from the generator shaft
during this procedure.
12. Turn out threaded bar from the generator shaft

13. Carefully lower runner onto carriage by means of chain hoists. It
must be ensured that the wheel intermediate flange does not touch
the generator shaft, and that neither the wheel intermediate flange
nor the generator shaft or the runner hub is damaged.
6.5.2.4 Nozzle set
ATTENTION
Prior to reaching into the nozzle (nozzle, needle tip, drive), it must be
ensured that the nozzle is depressurized and de-energized, and that
unintentional movements of the drive are excluded.
The needle tip and nozzle are checked for leakage every month.
Leakages indicate damaged needle tips and/or nozzles. The reasons as
well as causes for leakages must be identified and remedied.
NOTE
Damaged or worn-out nozzles and/or needles affect the water jet
quality. This may result in damage to the runner, the deflector and
the housing installations.
Damaged or worn-out nozzles and/or needles are to the repaired and/or
replaced.
The nozzle set is to be checked visually and/or a function test is to be

performed annually (or at shorter intervals, depending on the degree of
water contamination).

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The visual check is intended to identify leakages on the nozzle and at the
O-type sealing rings (waterside) as well as cracks and abrasion damage.
Especially the needles and nozzles are to be checked for damage and
abrasion. The nozzle set should always be in a proper condition since
comparatively minor damage may have an adverse effect on the jet
already.
The function of the nozzle drives (opened/closed) and closing/opening
times as well as the stroke have to be checked. Jerky movements are not
permissible. In case of deviations as against the values at start-up, the
reasons and causes have to be identified and remedied.
The bearing of the nozzle bar is maintenance-free.
6.5.2.5 Deflector
ATTENTION
Prior to reaching into the deflector adjustment device, make sure that
the deflector drive is depressurized and de-energized, and that
unintentional movements of the drive are excluded.
It must be considered that the deflector drive includes heavily pre-
tensioned springs.
The deflector is to be checked visually and/or a function test is to be

performed annually (or at shorter intervals, depending on the degree of
water contamination and duration of use in retracted condition).
The closing time and the stroke of the deflector are to be checked
annually. The deflector closing time may take a minimum of 2 seconds. At
the same time, the distance of the deflector to the jet centre is to be
measured. In case of deviations as against the values at start-up, the
6.5.2.6 Display and monitoring instruments
The display and monitoring instruments such as manometers, pressure

transducers, pressure switches, position encoders, etc. shall be checked
for their functional integrity weekly; the plausibility of values is to be
verified.

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6.5.3 Generator
NOTE
Key maintenance work for the generator is summarized below.
This summary shall not release the Client from observing the terms and
instructions of the generator supplier.
For further information on the generator maintenance, please refer to the
"Generator Documents" register.
6.5.3.1 Insulation resistance and polarity index description
Prior to start-up, during maintenance work or after extended shutdown

times, the winding insulation resistance must be measured. The purpose
of this test is to detect contamination and related problems on the
windings. The insulation resistance and the polarity index are tests which
are performed at the same time and with use of the same instrument.
The measuring voltage, the permissible insulation values and generator-
specific particularities are indicated in the documentation of the generator
supplier.
It is recommended to perform these tests at least once a year.
DANGER
The windings must be grounded after each test in order to prevent
electrical risks!
6.5.3.2 Vibration
It is advisable to measure vibration on the generator bearings at least

annually in operation under the same conditions in the x, y and z
direction. The machine may be classified according to its vibration
behaviour on basis of ISO 10816-3.
6.5.3.3 Antifriction bearings
The following checks shall be performed weekly:
Recording of bearing temperature

Manual vibration check
Sudden changes in temperature and vibration must be analysed.

The antifriction bearings must be lubricated at regular intervals as
specified by the manufacturer (e.g. on the nameplate). Only may greases
in accordance with the manufacturer specifications be used.

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6.5.3.4 Friction bearings
Greasing according to manufacturers speciation

Recording of bearing temperature
Manual vibration check
Leakage checks
Sudden changes in temperature or vibration must be analysed.
6.5.3.5 Winding
Recording of winding temperature
Sudden changes of the winding temperature must be analysed.
6.5.3.6 Water chiller
Not applicable

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6.5.4 Shut-off device
DANGER
WARNING
HINWEIS
Key maintenance work for the shut-off device is summarized below.
instructions of the shut-off device supplier.
For further information on the shut-off device maintenance, please refer to
the "Shut-off Device Documents" register.
The shut-off device shall be checked for leakages every month. Leakages
indicate a damaged seal, ball, valve or housing. The reasons and causes
for leakages must be identified and remedied.
The opening and closing times of the shut-off device shall be checked
annually. In case of deviations as against the values upon start-up, the
reasons and causes must be identified and remedied.
WARNING
Prior to re-starting the shut-off device, possible blockages (e.g. pins,
obstructions below the falling weight, etc.) are to be removed.

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6.5.5 Hydraulic unit
DANGER
WARNING
NOTE
Key maintenance work for the hydraulic unit is summarized below.
instructions of the hydraulic unit supplier.
For further information on the hydraulic unit maintenance, please refer to
the "Hydraulic Unit Documents" register.
6.5.5.1 Regular maintenance work
The following work shall be performed monthly:
Check pipework and hydraulic hoses for damage and traces of oil
leakage. In case of visible damage, the relevant components are to be
replaced.
Check oil level in oil tank. In case of low oil level, the cause is to be
identified and oil is to be refilled.
Check contamination degree of oil filter and replace filter as required.
Visual check of hydraulic oil: in case of colour changes, take and

analyse an oil sample. The oil must be filtered and/or changed
depending on the analysis result.
Check and record pumping interval. A shortened pumping interval

indicates that the gas pressure has been reduced. When the pumping
interval is halved, at the latest, the gas pressure in the bladder
accumulator has to be checked.
The following work must be performed quarterly:
Check gas pressure and accumulator attachments. In case of an

accumulator pressure of below 60 bar, the nitrogen in the bladder

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accumulator must be recharged. The procedure to check the gas

pressure is described in Section "Bladder accumulator: check and/or
recharge pressure".
Check all air filters. Contaminated ventilation valves are to be cleaned

or replaced as appropriate.
The following work shall be performed quarterly:
Analyse oil: cf. Section "Hydraulic oil"

The following work shall be performed after 8,000 operating hours and/or
annually at the latest:
Check emergency closing valves for emergency closing function
Check paint coating of surfaces with mere air contact for damage and
corrosion. Paint-coating shall be repaired as appropriate.
The firm attachment of bolts and other fixing elements on machinery

parts and pipes is to be checked.
6.5.5.2 Hydraulic oil
Hydraulic oil is to be checked visually after 500 operating hours and be

analysed by a laboratory as appropriate.
Hydraulic oil should be analysed and filtered and/or replaced every 3,000
4,000 operating hours. The minimum cleanliness degree is 18/15/12
pursuant to ISO 4406:1999.
Air filters and oil tanks have to be cleaned upon this occasion. For the
purpose of removing sludge and major accumulation of water, it is
recommended to remove and clean approx. 90% of the tank volume
through an external filter unit. The residual amount including contamination
and water deposits is to be disposed of.
On the occasion of the oil tank drainage, inside corrosion damage shall be
remedied, too.
As regards oil refills, care must be taken to use the same oil type from the
same manufacturer.
The hydraulic system requires approx. 200 l hydraulic oil of viscosity class
ISO VG 46 with a pureness of 10 m. The hydraulic unit is designed for
operation with mineral oil of category HLP (DIN 51524/2).
The first filling consisted of:
Was Hedcor supply.

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6.5.5.3 Bladder accumulator: Pressure check and/or accumulator

recharge
WARNING
The use of nitrogen in confined spaces may cause death by
suffocation.
When using nitrogen, rooms must always be ventilated. It must particularly
be observed that nitrogen is heavier than air and hence collects in hollows
and depressions.
Pressure checks in the bladder accumulator and recharging of the
accumulator may only be performed by qualified staff experienced and
trained in handling nitrogen and pressure fittings.
NOTE
Only use dry nitrogen from 200 bar pressure cylinders from a
renowned gas supplier.
Information
For recharging nitrogen, a standard charging fitting is required.
Hand wheel A for Lock nut B for installing Minimess connection

opening the the filling valve on the C for hose connection
cylinder valve on accumulator cylinder to nitrogen charging
the accumulator. valve. cylinder.
Fig. 5: Charging fitting with hand wheel A, lock nut and Minimess connection

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Hand wheel D for pressure release of hose and charging fitting.
Fig. 6: Charging fitting with hand wheel D and manometer
ATTENTION
When the cylinder valve is open, nitrogen may leak from the
accumulator
Prior to placing the charging fitting it must be ensured that the cylinder
valve is closed and hand wheel A is fully turned out.
The pressure in the accumulator may be checked as follows:
1. Stop machine.
2. Fully relieve oil pressure on accumulator relieve valve or on safety

block (drain control valve) (to 0 bar).
3. Remove cover lids on top of accumulator.
4. Fully turn out hand wheel A counter-clockwise on the charging fitting

and close hand wheel D of the relieve valve clockwise.
5. Screw charging fitting on the accumulator cylinder valve by means of

lock nut.
6. Turn hand wheel A clockwise to open the bladder accumulator valve.

The charging pressure of the bladder accumulator at the moment
must now be indicated on the manometer.

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For charging nitrogen into the accumulator, the steps below must now be
followed:
7. Connect hose to gas cylinder to minimess connection C.
8. If you open the gas cylinder valve now, nitrogen flows into the
bladder accumulator. At the same time, the manometer indicates the
gas cylinder pressure.
9. Intermediately close the gas cylinder valve time and again in order to
check the bladder accumulator pressure on the manometer. Only
charge the accumulator up to the pressure marked on the
accumulator head. In systems with a max. oil pressure of 110-
115 bar, the charging pressure of the bladder accumulator amounts
to exactly 67 bar with an oil pressure of 0 bar.
10. If you have achieved the accumulator charging pressure, close the
gas cylinder valve.
11. Now close the bladder accumulator valve using hand wheel A.
12. Subsequently relieve the nitrogen pressure from the charging hose
and fitting by opening hand wheel D.
13. Remove the charging hose from connection C.

14. Now you may remove the charging fitting by using lock nut B.
15. It is imperative that you check the bladder accumulator for leakage.
For this purpose, spittle is most suitable.
16. Subsequently mount both valve caps on the bladder accumulator.
6.5.5.4 Hoses
Hoses shall be checked for leakage and safe operating conditions by

expert staff and bolted connections re-tightened as appropriate monthly.
The lifecycle of hoses including storage time, if any, should not exceed six
years (extract from DIN 20066). According to experience, the lifecycle may
be extended or, in case of heavy duty conditions, reduced.
Hoses must be replaced if the following criteria are met during an
inspection:
Damage to outside layer down to liner (e.g. scrubbed locations, cuts or

ruptures).
Embrittlement or porosity of outside layer (formation of ruptures in the

hose material).
Deformation contrary to the natural shape of the hose, both in the

unpressurized and in the pressurized condition (cf. DIN 20066).

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Irregular changes in the diameter

Buckling under pressure
Leakages
Damage to or deformation of the hose fitting (sealing function affected);
minor surface damage do not justify replacement.
Hose migration off the fitting.

Corrosion of fitting with negative effect on function and strength.
Requirements of installation not complied with (cf. DIN 20066)
Storage time and lifecycle exceeded.
If in doubt with regard to the functional reliability of a hose, it shall be
subjected to a pressure test (test pressure as per hose manufacturer or
DIN).
Hoses may only be replaced by equivalent hoses!

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6.5.6 Turbine bypass
DANGER
NOTE
Key maintenance work for the turbine bypass is summarized below.
instructions of the part components suppliers.
For further information on the maintenance of the control valve, please
refer to the "Control Valve Documents" register.
The pipework of the turbine bypass is to be checked for vibration after

extended operation. Increased vibration indicates an increased flow
speed in the turbine bypass. Its cause may be either a worn pressure-
reducing valve or a worn orifice.
Work pressure-reducing valves and/or orifices must be replaced.
The control valve is to be checked for leakage monthly. Leakage indicates
worn-out control valves. The reasons and causes have to be identified and
remedied.
The control valve shall be opened and closed once in a quarter. During
this procedure, vibration is to be checked manually. Particular attention is
to be paid to changes in noise emissions.
The opening and closing times of the control valve are to be checked
annually. In case of deviations as against the values during start-up, the
During inspections, the diameter of the orifice downstream of the control
valve is to be measured. The orifice diameter is specified in the parts list in
the "Drawings" register.

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6.5.7 Penstock drain pipe
DANGER
NOTE
Key maintenance work for the penstock drain pipe is summarized below.
For further information on the maintenance of the shut-off device, please
refer to the "Shut-off System Documents" register.
The pipework of the penstock drain pipe is to be checked for vibration after
extended operation. Increased vibration indicates an increased flow
speed in the drain pipe. Its cause may be a worn-out pressure-reducing
orifice.
Worn-out pressure-reducing orifices must be replaced.
The shut-off device in the drain pipe is to be checked monthly. Leakages
indicate worn sealing elements. The reasons and causes have to be
identified and remedied.
In order to clean the drain pipe from deposited particles, the penstock
drain pipe is to be purged at least annually, depending on the particle
contents in the water. At the same time, vibration in the pipe, at the shut-off
device and at the orifice shall be checked.
Extended shutdown times may result in deposits in the drain pipe and
consequently to a reduced pipe cross-section!
The tightening of the bolts from the cover plate package downstream of
shut-off device should be controlled annually and additionally before and
after each use of the penstock drain pipe.
During inspections, the diameter of the orifice downstream of the control
valve is to be measured. The orifice diameter is specified in the parts list in
the "Drawings" register.

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6.5.8 Control system
NOTE
Key maintenance work for the control system is summarized below.
For further information on the maintenance of the shut-off device, please
refer to the "Control Cabinet Equipment Documents" register.
6.5.8.1 PLC
The PLC is to be visually checked for its functional reliability weekly

(LEDs, etc.), the displayed values shall be verified for plausibility.
In case of deviations as against the normal condition described in the
documentation, the reasons and causes have to be identified and
remedied.
6.5.8.2 Display and monitoring instruments
Display and monitoring instruments such as multimeter, synchronizer,

speed ramp; frequency, voltage and temperature monitors, etc. are to be
visually checked for their functional reliability (LEDs, etc.) weekly; the
displayed values shall be verified for plausibility.
In case of deviations as against the normal condition described in the
documentation, the reasons and causes have to be identified and
remedied.
6.5.8.3 Generator switch Not scope of ANDRITZ supply only

typical
The MASTERPACT NT power switch is to be activated and deactivated on

the panel and by remote control annually.
For further details, please refer to the MASTERPACT NT operation
manual in the "Control Cabinet Equipment Documents" register.
6.5.8.4 Check and/or replacement of batteries
The provided batteries are almost maintenance-free due to their sealed

design and the gas recombination within the cells. The lifecycle of the
batteries is up to five years (at 20 C).
It is recommended to check the battery annually using a battery load
tester. Batteries shall be replaced depending on the results of these tests.

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6.6 Troubleshooting
6.6.1 Turbine failures
6.6.1.1 Power decrease
Type of failure and possible Remedy

cause
Free flow impeded by foreign Cleaning

matter at intake rake
Foreign matter in shut-off device Attempt to wash out foreign matter

by opening and partly closing the
shut-off device. If this fails, the
penstock must be drained and the
foreign matter must be removed by
hand.
Foreign matter in nozzle Attempt to wash out foreign matter

by opening and closing the nozzles
several times. If this fails, the
machine must be emptied and the
hand.
Erosion or cavitation damage on Replacement of needle or nozzle.

nozzle set Please contact ANDRITZ Hydro.
Erosion or cavitation damage on Repair welding of runner.

runner Please contact ANDRITZ Hydro.
6.6.1.2 Extraordinary vibration

cause
Excessive bearing clearance of Please refer to Section 9,

generator bearings "Generator Documents"
Foreign matter in nozzle Attempt to wash out foreign matter

by opening and closing the nozzles
several times. If this fails, the
machine must be emptied and the
hand.
Erosion or cavitation damage on Repair welding of runner.

runner Please contact ANDRITZ Hydro.

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6.6.1.3 Water pressure too low

cause
Pressure line (partially) empty Machine may only be operated with

full pressure line.
Intake rake clogged Clean rake.
Intake shut-off device (e.g. pipe Open intake shut-off device.

breakage cover or gate) not
opened properly
Insufficient water flow Machine may only be operated

again when the intake at least
corresponds to the minimum
turbine flow rate.
6.6.2 Generator operation failures
NOTE
A summary of the most significant operation failures of the generator and
their remedy is given below.
This summary does not release the Client from observing the provisions
and instructions given by the generator supplier.
For further information on operation failures and their remedy, please refer
to the "Generator Documents" register.
6.6.2.1 High winding temperatures

cause
Generator operates outside its Check and correct conditions.

voltage, frequency or capacity
limits.
Malfunction of cooling cycle Check input and/or output

temperatures
Malfunction of measuring devices Check sensors and evaluators
Insufficient air flow Check filter and ventilation

components on contamination.
Check fan direction of rotation.
Ambient temperature above Increase room cooling

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specified values
Winding defect Check winding
6.6.2.2 High bearing temperature

cause
Insufficient bearing lubrication Check lubricant level (e.g. oil level)

and/or lubricant throughput
Wrong lubricant Replace lubricant by specified type
Excessive external forces Reduce forces, check loads, check

runner position
Excessive lubricant Reduce flow rate (oil) and/or grease

quantity
Malfunction of measuring devices Check sensors and/or evaluators
Foreign matter in bearing Clean bearing
Bearing damaged Replace bearing
6.6.2.3 Leakage on bearings

cause
Oil leakage Replace seals

Check installation and tighten bolts
Check oil level
6.6.2.4 No voltage supply or excessive excitation

cause
Controlling error Check control on basis of control

system manual
Excitation failure Check exciter winding
Rotor failure Check rotor winding
Malfunction of measuring devices Check sensors
Diode failure Replace diodes

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6.6.3 Shut-off device operation failures
NOTE
A summary of the most significant operation failures of the shut-off device
and their remedy is given below.
and instructions given by the shut-off device supplier.
to the "Shut-off Device Documents" register.
6.6.3.1 Leakage in shut-off device

cause
Foreign matter in shut-off device Attempt to wash out the foreign

matter by opening and partly
closing the shut-off device. If this
fails, the penstock must be emptied
and the foreign matter must be
removed by hand.
Main seal damaged Replace main seal
Leakage on shaft pin Tighten or replace shaft seal
6.6.3.2 Shut-off device does not close

cause
Foreign matter in shut-off device Attempt to wash out foreign matter

by opening the shut-off device. If
this fails, the penstock must be
emptied and the foreign matter
must be removed by hand.
Hydraulic orifice clogged Release hydraulic pressure and

clean orifice

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6.6.4 Hydraulic unit operation failures
NOTE
A summary of the most significant operation failures of the hydraulic unit
and instructions given by the hydraulic unit supplier.
to the "Hydraulic Unit Documents" register.
6.6.4.1 Failures detected during inspection

cause
Operation pressure lower than Check shut-off device on bladder

permissible accumulator as to whether it is set
to the operation position;
Check leakage of bladder
accumulator;
Check piping for leakage
Visual indication on filter Replace filter cartridge
Oil leakages Tighten bolted connections;

Replace seals;
Check oil tank for leakage
6.6.4.2 Oil level in tank too low

cause
Oil loss in piping, antifriction Search and repair leakages

bearing or lubricating oil unit
Insufficient oil quantity Refill oil

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6.6.4.3 Oil level in tank too high

cause
Excessive oil quantity Reduce oil quantity
6.6.4.4 Control oil pressure too high

cause
Pressure control valve set Check function of pressure control

incorrectly or defective valve
6.6.4.5 Control oil pressure too low

cause
Pressure oil pump defective Check pump
Pressure control valve set Check setting of pressure control

incorrectly valve
Bladder accumulator does not Check shut-off valve on bladder

equalize pressure accumulator as to whether it is set
to the operating position;
Check bladder accumulator for
leakage;
Check piping for leakage
6.6.5 Turbine bypass operation failures
NOTE
A summary of the most significant operation failures of the turbine bypass
and instructions given by the component suppliers.
to the "Turbine Bypass Documents" register.

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cause
Foreign matter in control valve Drain turbine bypass and remove

foreign matter by hand
Worn-out orifice Replace seat and cone
Worn-out orifice Replace orifice
Supports loose Tighten bolted connections
6.6.5.2 Control valve does not open or close

cause
Foreign matter in control valve Attempt to wash out foreign matter

by opening the control valve. If this
fails, the ball valve upstream of the
control valve must be closed and
the foreign matter must be removed
by hand.
Motor protection switch has Identify and remedy cause for

tripped overcurrent;
Reset motor protection switch
Drive system defective Check and/or replace drive system
Wiring defective Check wiring
6.6.6 Penstock drain pipe failure
NOTE
A summary of the most significant operation failures of the pressure line
drain pipe and their remedy is given below.
and instructions given by the component suppliers.
to the "Shut-off Device Documents" register.

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cause

matter by opening and partially
closing the shut-off device several
times. If this fails, the penstock
must be drained and the foreign
matter must be removed by hand.
Foreign matter in orifice Clean orifice
Worn-out orifice Replace orifice
6.6.6.2 Leakage in shut-off device

cause

matter by opening and partially
closing the shut-off device. If this
fails, the pressure line must be
drained and the foreign matter must
be removed by hand.
Main seal damaged Replace main seal
Leakage on shaft pin Tighten or replace shaft seal

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6.6.6.3 Shut-off device does not open or close

cause

matter by opening the shut-off
device. If this fails, the pressure line
must be drained and the foreign
matter must be removed by hand.
Motor protection switch has Identify and remedy cause for

tripped overcurrent;
Reset motor protection switch
Drive system defective Check and/or replace drive system
Wiring defective Check wiring

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7 Spare parts and assembly devices .................................................... 2

7.1 General ....................................................................................................................................2
7.2 Spare parts ..............................................................................................................................2
7.2.1 Turbine..................................................................................................................................2
7.2.2 Turbine runner assembly devices ........................................................................................3
7.2.3 Hydraulic power unit .............................................................................................................3
7.2.4 Ball valve ..............................................................................................................................3
7.3 Assembly devices ..................................................................................................................3
O&M Manual Spare Parts 7-1

Tudaya 1 2012
7 Spare parts and assembly devices

7.1 General
Due to the operating stress are some components of the turbine wear
exposed. Therefore have those components a terminable lifespan.
It is recommended to have enough spare pieces on stock.

Thereby it should be noted that:
The procurement lead time can take months depending on the

component.
Seals can even under optimal conditions be stocked maximal 5 years.
Sourcing on time of spare parts via ANDRITZ Hydro is an important

point for the constant operational readiness of the turbine.
7.2 Spare parts
7.2.1 Turbine
The following spare parts were parts of the scope of delivering:
6 mouth pieces
6 point of needles
6 sealing bushes
1 sealing kit
1 displacement transducer nozzle position
1 displacement transducer for deflector

ANDRITZ Hydro recommends to having following components on stock:
1 tensioning device
1 pressure transmitter
1 pressure switch
1 position switch (inductive sensor)

Tudaya 1 2012
Depending on the pollution degree oft he water and following oft he

abrasion oft he mechanical parts ANDRITZ Hydro recommends
additionally having following components on stock:
1 Pelton Runner
7.2.2 Turbine runner assembly devices
The following assembly devices were delivered:
Assembly frame (only for vertical turbine)
Assembly disc
7.2.3 Hydraulic power unit
Minimess set
1 pcs. proportional valve NG6
1 two-way pilot valve NG6
4 pcs. spare pressure oil filter
7.2.4 Ball valve
1 pcs. limit switch
1 pcs. ball sealing
1 pcs. shaft sealing
1 pcs. flange sealing
1 sealing set hydraulic actuator
7.3 Assembly devices
Assembly frame (only for vertical turbines)
Assembly yoke (only for horizontal turbines)
Assembly disc

Tudaya 1 2012
8 Decommissioning.............................................................................. 8-2
8.1 Information for disassembly ............................................................................................. 8-2
8.2 Disposal............................................................................................................................... 8-3
O&M Manual Decommissioning 8-1

Tudaya 1 2012
8 Decommissioning
If the machine/plant is no longer operational and shall be scrapped, it must
be put out of operation and disassembled.
8.1 Information for disassembly
Before dismantling evaluate the condition of the machine/plant through an

expert. Expert means a person who has gained experience in power
plants.
This evaluation shall contain the design conditions, static conditions, type
and condition of components as well as type and position of pipes and
other installations. On the basis of the determined findings an expert has
to provide a written disassembly plan. This plan shall include the following:
Extent, sequence and type of disassembly work.
Required tools and safety precautions.
Dangers to health by impact of possible hazardous ingredients.
Usually the disassembly takes place in reverse order than the assembly.
Therefore loosen or separate the connections of the individual parts
thermally.
Remove all liquids form the plant before dismantling or scrapping.
Fix the parts to be dismantled in such a way or with lifting tools on the
slinging means that they can not fall down or die after loosening or sepa-
rating the connections.
Work on plant parts that may fall down is only permitted if it is safe to stay
in the working area because of correctly installed safety devices.
Supporting and stiffening components must be removed only, if measures
for stability were met.
Take the danger of fire and release of hazardous vapours and combustion
products into account during thermal separation.

Tudaya 1 2012
8.2 Disposal
All national, regional and local legal requirements and regulations have to
be kept during the disposal or recycling of parts and components of the
machine/plant as well as for materials being necessary for the operation.
High-quality recyclable materials like steel or copper are integrated in the
machine, which can be recovered via a scrapping process with a high
recycling ratio.
CAUTION
Substance, being hazardous for water and soil, like parts contaminated
with oil, have to be stored in separated areas or collecting trays. If nec-
essary remove oil, grease and other contamination from the parts.
Separate the different materials (steel, copper, aluminium, casting, plastic

cables, etc.) as good as possible.
Remove electrical and electronic components from the machine and

collect them separately. A disposal via the normal domestic waste is
not allowed.

Tudaya 1 2012
9 Description of installed turbine equipment .................................... 9-2

9.1 Displacement transducer for nozzel 1-6, Make Balluff;
Type BTL7-E170-M0125-B-KA05 ...................................................................................... 9-2
9.2 Pressure transmitter / penstock, Make Envec;
Type P-30 with damping element ..................................................................................... 9-3
9.3 Pressure indicator, Make WIKA;
Type 213.53 ......................................................................................................................... 9-4
9.4 Displacement transducer for deflector, Make Balluff;
Type BTL7-E100-M0175-B-S32 ......................................................................................... 9-5
9.5 Nozzle servo motor, Make CYMAX;
Type diam. 80/28x115 ........................................................................................................ 9-6
9.6 Electric rotary actuator, Make Brkert ............................................................................ 9-7
9.7 Bourdon tube pressure gauge, Make WIKA ................................................................... 9-8
9.8 Clamping set for runner, Make MAV 4061;
Type D320/405x165 (Art. ID 24167) .................................................................................. 9-9
9.9 Deflector servo motor, Make CYMAX;
Type diam. ......................................................................................................................... 9-10
O&M Manual Description of installed turbine 9-1

equipment
Tudaya 1 2012
9 Description of installed turbine

equipment
9.1 Displacement transducer for nozzel 1-6,
Make Balluff; Type BTL7-E170-M0125-B-KA05
KKS-Number: MEA21 CG001

MEA22 CG001
MEA23 CG001
MEA24 CG001
MEA25 CG001
MEA26 CG001

equipment
Tudaya 1 2012
9.2 Pressure transmitter / penstock,

Make Envec; Type P-30 with damping element
KKS-Number: MEB60 CP001

MEB60 CP002

equipment
Tudaya 1 2012
9.3 Pressure indicator, Make WIKA; Type 213.53

MEB60 CP502

equipment
Tudaya 1 2012
9.4 Displacement transducer for deflector,

Make Balluff; Type BTL7-E100-M0175-B-S32
KKS-Number: MEA20 CG001

equipment
Tudaya 1 2012
9.5 Nozzle servo motor, Make CYMAX; Type diam. 80/28x115
KKS-Number: MEA21-26 BN010

equipment
Tudaya 1 2012
9.6 Electric rotary actuator, Make Brkert
KKS-Number: MEB61 AA101
MEB61 CG101
MEB61 CG102

equipment
Tudaya 1 2012
9.7 Bourdon tube pressure gauge, Make WIKA

MEB60 CP502

equipment
Tudaya 1 2012
9.8 Clamping set for runner,

Make MAV 4061; Type D320/405x165 (Art. ID 24167)
KKS-Number: .

equipment
Tudaya 1 2012
9.9 Deflector servo motor, Make CYMAX; Type diam.
KKS-Number: .

equipment
Tudaya 1 2012
10 Drawings........................................................................................... 10-2
10.1 Turbine drawings ............................................................................................................. 10-2
10.2 Diagrams ........................................................................................................................... 10-3
10.3 Lists ................................................................................................................................... 10-4
10.4 Control system diagrams ................................................................................................ 10-5
O&M Manual Drawings 10-1

Tudaya 1 2012
10 Drawings
10.1 Turbine drawings
Drawing No. Description
841 163 348 Foundation plan
841 163 575 Pelton turbine, Assembly
841 163 770 Disposition
841 163 600 Distributor pipe complete
841 163 834 Nozzle with servomotor complete
841 163 579 Deflector assembly complete
841 163 762 Dewatering of distributor
841 163 738 Foot plate of main inlet valve
841 163 285 Generator shaft end with forces
841 163 745 Oil hydraulic connection complete
841 163 888 Assembly device clamping set MAV
841 163 873 Runner on shaft end
841 163 748 Bypass ball valve

Tudaya 1 2012
10.2 Diagrams
M-131 3467-001-Hill Chart Expected prototype hill chart

Tudaya 1 2012
10.3 Lists
M-131 3467-158 Signal processing list

Tudaya 1 2012
10.4 Control system diagrams
M-131 3467-159 Hydraulic control diagram

O&M Manual - Tudaya1 - Volume 1 of 5

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OPERATION & MAINTENANCE MANUAL - TURBINE

Project: Tudaya1 2012

Type of machine: 1 Compact Pelton Turbine (CPT)

Customer: Hedcor Sibulan Inc. (Hydropower Generation)

Project number: M-1313467 Document number: 892008080

O&M Manual Turbine Chapter 1-10

O&M Manual Turbine Chapter 11-13

Hydraulic Governor with Oil Supply

O&M Manual Overview Volumes i

9 Description of installed turbine equipment

11 Shop assembly and site installation documentation of the turbine

O&M Manual Table of contents ii

ADR European Agreement concerning the International Carriage of Dangerous

O&M Manual Table of contents iii

1 Introduction ........................................................................................ 1-2

O&M Manual Introduction 1-1

1.1 About this manual

Storage The manual is to be kept always at place of installation within reach.

O&M Manual Introduction 1-2

1.2 Use of manual

Bold to highlight words/text passages or parameter

Verweis: Paragraphs marked in this way contain links to project documentation.

Links within this manual are written in italics for highlighting.

O&M Manual Introduction 1-3

1.3 Warranty and liability

ANDRITZ HYDRO excludes warranty and liability claims of lacks or

1.4 Name and address of the manufacturer

1.4.1 Andritz Headquarters Address

ANDRITZ HYDRO GmbH

1.4.2 Internal Supplier

O&M Manual Introduction 1-4

This manual is the intellectual property of ANDRITZ HYDRO GmbH and

O&M Manual Introduction 1-5

1.6 Intended use

The machine/power plant must be operated in accordance with the specifi-

1.7 Notice of claims

Lacks and damages, detected by the customer or operating personnel,

O&M Manual Introduction 1-6

1.9.1 Incoming inspection

In case of obvious transport damages (dented crates, etc.) proceed as

O&M Manual Introduction 1-7

Depending on the packed components, the packing is used as protection

O&M Manual Introduction 1-8

Each packing unit is assigned to a storage class in accordance with the

Storage Place of Storage conditions Minimum requirements

*) Choice and execution of danger symbols in accordance with ADR,

O&M Manual Introduction 1-9

Inspections during Regular inspection of packing as well as corrosion protection of stored

1.9.3.1 Storage of machine parts

Consider the following when storing machine parts:

O&M Manual Introduction 1-10

1.9.3.2 Storage and preservation of technical rubber parts

The life cycle of rubber parts can be substantially impaired by several

Rubber parts must not be extended, folded, broken or suspended on

O&M Manual Introduction 1-11

2 Safety .................................................................................................. 2-2

O&M Manual Safety 2-1

O&M Manual Safety 2-2

2.1 Safety instructions

All data mentioned in the chapter 2 Safety are important safety-

O&M Manual Safety 2-3

No unauthorized entry No fire, no smoking No trespassing

No persons with Prohibition to extinguish Do not touch