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Good practices in diagnosis of Hydro Mechanical Equipment
Agenda
I. Inspection methodology for Hydro Mechanical
Equipment (HME).
II. Criteria of Assesstment.
III. Investment considerations for Rehabilitation,
Modernization and/or Replacement.
2
Good practices in diagnosis of Hydro Mechanical Equipment
Hydro Mechanical Equipment
3
Gates
Gate Hoists
Intake Trashracks
Tank Trashracks
Trashracks CleanersPipelines
Penstocks
Valves
Tomado de
www.mecanhydro.com
All images in this document are part of
the author's experience and do not
represent the equipment of EPM; they are
presented as reference images for
academic purposes.
Good practices in diagnosis of Hydro Mechanical Equipment
I. Inspection Methodology
4
1. Context of service
2. Diagnosis
3. Assessment of
current condition
• Tech. Information.(D, C, E, O, M)
• Service History (O&M)
• Unavailability (Major Events)
• Structural Condition (View, NDT)
• Surface Protection (Ad., DFT)
• Aux. Systems (E, H, C, I, P)
• Defectology (Failure Modes)
• Functional Tests (Dry, Water)
• Expert Assessment
• Computat. Simulations (CFD, FSI)
• Global Assessment (Cualitative)
Fullfill minimal
requirements?
YES
NOT
• Improvement
(Rehabilitation vs Modernization)
• Replacement
• Maintenance
(Spares, Remaining Life)
Good practices in diagnosis of Hydro Mechanical Equipment
1. Context of service: Unavailability
5
Inadequate condition of trashrack
Lack/deficiency of trashrack cleaner
Inoperative/inefficient bottom outlet
Incipient discharge capacity
Inadequate handling of sediments/debris
Inadequate/changes design
(Hyd., CW, Mech.Eq.)
Low frecuency of drainage/dredging
Absence of early warnings
1. Context of service
2. Diagnosis
3. Assessment of
Current Condition
Fullfill
minimal
requirements
?
Good practices in diagnosis of Hydro Mechanical Equipment
1. Context of service: Unavailability
6
Deficiency/lack of maintenance
Excess of organic material
Clogged guides and seats
Low quality of materials
Deficiency/lack of maintenance
Wrong practices of repairing
Lack of inspection/diagnosis
Good practices in diagnosis of Hydro Mechanical Equipment
2. Diagnosis of HME: Defectology
7
1. Context of service
2. Diagnosis
3. Assessment of
Current Condition
Fullfill
minimal
requirements
?
Study case: Failure modes on high head radial gates
Probable Failure Modes (PFM)
Stem rupture
Trunnion or anchorages rupture
Arms collapse
Bottom seal failure
Seat failureSide seal failure
Skin plate rupture
Girders rupture
Assemble joints failure
Blindage failure
Upper seal failure
Good practices in diagnosis of Hydro Mechanical Equipment
2. Diagnosis of HME: Defectology
8
Bottom outlet radial gate
Good practices in diagnosis of Hydro Mechanical Equipment
2. Diagnosis of HME: Defectology
9
Bottom outlet radial gate
Good practices in diagnosis of Hydro Mechanical Equipment
3. Assessment of current condition
10
1. Context of service
2. Diagnosis
3. Assessment of
Current Condition
Fullfill
minimal
requirements
?
Value Description
1 The equipment presents an important condition of
detectable corrosion and/or cavitation under normal vision.
2 The equipment has notable deficiencies of surface
protection and lack of maintenance.
3 The equipment presents some areas that need to improve
their surface protection condition.
4 The equipment presents an acceptable condition, although
it requires to improve some specific zones or sections.
5 The equipment appears to have good maintenance and
condition for its operation.
Minimum acceptable
condition for any
component inspected will
be the equivalent of a
valuation of 3,5.
Assessment
2,6
C1 = 1,0
Surface Protection
20%
C2 = 3,0
Structural Condition
40%
C3 = 3,2
Aux. Systems
E+H+C+I+P
20%
C4 = 2,9
FunctionalCondition
20%
Good practices in diagnosis of Hydro Mechanical Equipment
II. Criteria of Assessment
11
C2: Structural Condition Criteria
C3: Auxiliar Systems Criteria (electric, hydraulic,
control, instrumentation, power)C4: Functional Condition Criteria
C1: Surface Protection Criteria
Good practices in diagnosis of Hydro Mechanical Equipment
III. Rehabilitation vs Modernization
12
Context of Service Diagnosis
DIAGNÓSTICO VÁLVULA
HOWELL BUNGER
ENSAYOS NO DESTRUCTIVOS
Metalografía
Ultrasonido
Tintas penetrantes
PRUEBAS FUNCIONALES
Vibraciones
Aireación
SIMULACIONES COMPUTACIONALES
CFD
FSI
FEM
FatigaAssessmentRehabilitation
Good practices in diagnosis of Hydro Mechanical Equipment
III. Rehabilitation vs Modernization
13
Howell Bunger
• Tech. Information: OK
• Service History: OK
• Unavailability: OK
• Structural Condition: DEF [ 7]
• Surface Protection: DEF [ 7]
• Aux. Sist. E+H+C+I+P: OK
• Defectology: DEF [ 7]
• Functional Tests: OK [ 7]
• Expert Assessment: OK [ 6]
• Comp. Simulations: OK [ 20]
• Global Assessment: OK [ 6]
• Improve: Rehabilit. [60, <15y]
• Moderniz. [90, <15y]
• Replace: New [300, >15y]
• Maintenan.: Spares: NOT DEF.
Rem.Life: NOT DEF.
1. Context of
service
2. Diagnosis
3. Assessment of
Current State
Fullfill minimal
requirements?
All values are in thousands of U.S. Dollar
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