GOOD PRACTICES IN DIAGNOSIS

OF HYDRO MECHANICAL

EQUIPMENT IN SMALL HYDRO

1

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

José David Vera Rodríguez

Profesional Gestión Proyectos e Ingeniería

Centros de Excelencia Técnica

Unidad Ingeniería de Proyectos 1

Tel: (574) 380 66 55

www.epm.com.co