management and operational manule-hydropower

8/11/2019 Management and Operational Manule-Hydropower

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Management and Operation Manual

for

Private Micro-Hydropower Plants

Prepared by

DCS Tecnology Development

P!O! "o# $ %& "utwal& 'epal

(nternational Centre for (ntegrated Mountain Development

)(C(MOD*

+atmandu& 'epal

,%


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Table of Contents

,! (ntroduction Page

.! Plant Management ,

.!, Operator/s Management 0

2.1.1 Selection and Terms of Employment 3

2.1.2 Training 4

2.1.3 Assignment and Supervision of Operators !or" 4

.!. (mproving Customer Services 1

2.2.1 #ublic $elations %

2.2.2 &ood Service %

2.2.3 'oad (anagement %

.!0 2inancial Management 3

2.3.1 )ncome and E*penditure Account +

2.3.2 ,udget for -e*t ear 1/

2.3.3 ,usiness E*pansion 11

2.3.4 E*tending Supply 12

.!4 Organi5ing Maintenance ,0

2.4.1 (aintenance Stoc" of Spares 13

2.4.2 (aintenance Tools 14

.!1 Organi5ing 6epairs ,1

2.%.1 #rocedures to 0eal it a ,rea"don and ault 0iagnosis 1%

2.%.2 0isassembling and Assembling te Euipment 15

2.%.3 Transporting Euipment for $epairs 15


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0! Operation ,%

0!, 7eneral Operation Procedure ,%

3.1.1 Te Startup #rocedure 1+

3.1.2 Continuous Cec"s 0uring $unning 16

3.1.3 Sutting 0on #rocedure 16

0!. Safety and 2irst 8id .9

3.2.1 !or"place Safety #recautions 2/

3.2.2 irst Aid for Electrical Soc" 21

3.2.3 Artificial $espiration Tecniues 21

0!0 :#tended Sut Down .0

0!4 6outine (nspection and Maintenance .0

3.4.1 0aily )nspection and (aintenance 24

3.4.2 !ee"ly )nspection and (aintenance 24

3.4.3 (ontly )nspection and (aintenance 24

3.4.4 Si* (ontly )nspection and (aintenance 24

3.4.% early )nspection and (aintenance 2%

3.4.5 Additional )nspection and (aintenance 2%

3.4.7 Some Additional Suggestions $egarding Operation and2%

(aintenance

0!1 ;og "oo< .3

4! Transmission = Distribution .

4!, House >iring 0,

4!. :arting 04


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4!0 7eneral 6ules for House >iring 04


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#$EACE

Te main ob7ective of preparing and distributing tis (anual on management and operation of

private or community oned8managed ((9# plants :especially te micro;range< is to provide

some assistance to te managers and operators o are oterise facing difficulties in tis

regard. Suc difficulties ave mainly emerged since te managers and operators of suc plants

are less educated= less e*posed to macinery and ave very fe opportunities to participate in

relevant and uality training programmes.

Te preparation of te (anual as visuali>ed= initiated and sponsored by )C)(O0 as a regular

component of -O$A0;sponsored pro7ect ?Capacity ,uilding for (ini; and (icro 9ydropoer

0evelopment in te Selected Countries of 9indu @us;9imalayan $egion= #ase ))?. )t is oneof five suc manuals aimed at te various groups of implementers= including site surveyors

and layout designers=;manufacturers of indigenous euipment= installers= managers and

operators ; and te repairers. Te first draft of tis (anual as prepared by 0CS;Tecnology

0evelopment ,utal= -epal and as e*tensively revised by me. Tus= tis is a first indigenous

and concerted effort to rite uality manuals aving a regional rater tan general perspective.0CS= in particular= deserves ac"noledgement and encouragement.

Te main focus of tis manual concerns te isolated= indigenous= local entrepreneur;oned

.plants in te micro;range. ,ut mostly= suc plants installed in -epal= #a"istan and )ndia ave

capacity less tanB 5/ "!. @eeping in mind tat te. managers and operators of suc plantsave very little education and even less tecnical "noledge= te manual as been "ept simple

and brief. or te same reason= te manual does not cover all different types of macines and

management systems. )n any case= it is almost impossible to cover all te managerial andoperational aspects in one manual of tis type. At te same time= one sould alays strive to

improve suc documents. Terefore= suggestions to improve it furter and ma"e it reasonably

useful are elcome= indeed earnestly solicited from e*perienced implementing agencies andoperators8managers o may be able to point out te additional aspects to be covered and temetodology.

Te above remar"s not itstanding= it is oped tat manual in te relevant languages in)ndia=-epal and #a"istan ould provide significant assistance and relief to te practicing managers

and operators. )t is also oped tat some training agencies ould find it to be a useful support

mater . al for teir training programmes.

Anar A. une7o

Coordinator= ((9# #ro7ect

)C)(O0


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8C6O'?MS$

#TC ;D #ositive Temperature. Coefficient

ECC ;D Electronic Current Cutout'#C ;D 'oad #riority Controller

-&O ;D -on &overnment Organisation

"! ;D @iloatt,#T ;D ,rea" #ressure Tan"

E'C ;D Electronic 'oad controller

(C, ;D (iniature Circuit ,rea"er A0,8- ;D Agriculture 0evelopment ,an"8-eal

)T0& ;D )ntermediate Tecnology 0evelopment &roup

)$ ;D ulcani>ed )ndian $ubber :)nsulationed= installed and isely operated and managed :includingproper repair and maintenance< to give long;term benefits. )f properly installed= a ((9#

plant may provide energy for ligting= grain grinding= oilseed e*pelling and oter milling

facilities= as ell as for possible use of communication by pone= radio and television and

industries suc as samills= papermills= !or"sops= etc. )t may even encourage facilitiessuc as ropeays= to reduce te burden of pysical pottering.

Tis manual as been prepared to assist in management of ((9# plants so as to givema*imum returns and benefits from te investment. )t assumes tat te survey= design=

installation and and;over or" as been completed amicably. Te roles of operator and

manager no become as important to te investors in te pro7ect as te role of a bus driver isto te safe operation of a bus. Carelessness on bealf;of eiter may result in an accident.

Te manual is intended for te use of managers and operators of micro;ydropoer :(9#e te operator it te macines and simpleoperational procedures. Fsually tis training may not be adeuate. Terefore= additional

e*tensive training sould also be provided. Tere are organi>ations ic provide suc

training trougout te year. Often te training is given free of cost. Te oner8community

sould ma"e temselves aare of suc opportunities available in teir country.

.!,!0 8ssignment and Supervision of OperatorAs >or


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'istening for any malfunction or similar problems.

Sutting don te plant if necessary.

Carrying out some minor repairs.

Te 7ob of te manager is to clearly e*plain tese assignments to te operators= to assist and

lead tem= and to supervise teir or"= especially during te initial stages of teir allotment.Te manager sould also assess te uac"s of te o aerators to learn and perform teir duties

amicably. 9e must also uestion tem or reprimand tem if necessary about any la*ness in

performing teir duties.

.!. (mproving Customer Services

.!.!, Public 6elations

Te manager and operator sould be gentle in speec to te customers ic is good for

siness. Any minor problems; it te customers sould be sorted out immediately. or

comple* problems= a general meeting sould be called= inviting all related personnel. Te

prevailing problems sould be discussed and a solution or"ed out 7ointly= especially in case ofelectrification scemes. Sometimes te operator 8 manager imself may ave to visit te local

or"sop or organi>ation remote from te plant. 0uring tis period= anoter capable personsould be instructed to loo" after te operation and management of te plant. Te public

sould be informed in advance of te appro*imate period and reasons for any sut dons of te

plant so tat tey can ma"e alternative arrangements.

Te operator8manager of an electrification plant sould visit te consumers and discuss it

tem problems or complaints tey may ave regarding te supply and discuss oter issues suc

as use of electricity= non payment of bill= lo voltage= etc. Every effort sould made to oldsuc discussions in a cordial manner..

.!.!. 7ood Service

Te operator8manager must provide good service to te customers on a first;come firstserved

basis it fe e*ceptions. or e*ample= people coming from distant places need to go ome

early= so tey may be given priority after reacing an understanding it oter customers.

!ile planning te supply of electricity= all ouses reuesting a fi*ed attage supply= sould be

connected first. Only after all suc ouses ave been provided for= additional available poer

sould be distributed as per te reuirements.

Fnsceduled and unannounced sut don of te plants ould lead to loss of revenue= business

and reputation. Terefore= every effort must be made to avoid te brea"dons and sutdons=troug regular maintenance and ta"ing care of small faults and problems ic may;

eventually lead to serious brea" dons.

.!.!0 ;oad Management

#oer demand ill e*ceed te installed capacity sooner or later in many plants because=

unfortunately= some consumers may ta"e more poer ten te amount tey ave subscribed for.

Tere is a need for some sort of monitoring device to ma"e certain tat te generating plant is


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not over;loaded and te investor is not suffering losses. )t is not practical to install a meter in

every ouse;old in a (9# sceme. Tis ill only introduce more costs and complications

especially since most consumers ill be subscribing in te range of %/;2// atts only.

A flat rate system is generally used= and in tis te consumers pay a fi*ed rate for attage

e8se subscribes to. #ositive Termal Coefficient :#TC< controllers are use for 2% to %/ attrange= electronic current cut;outs :ECC< are available for %/;2// arrange= and miniature

circuit ,rea"ers :(C,< are suitable for consumers subscribe for more tan 2// atts.

9oever= some problems ave been e*perienced en ECC ere used in -epal. Te oterto options may= terefore= be used.

'oad factors of (9# plants are generally poor= especially te electrification scemes Te main

use of electricity is for domestic ligting. Tus te poer demand is of certain ours in teevenings and sometimes in te mornings for about si* ours a day !ile= te available poer

from te plant remains unutili>ed for te remaining period resulting in less income. Te

oner8manager must= terefore= alays tin" of ays increase utilisation and8or sale of

electricity particularly to industrial or commercial units.

0uring te daytime and at nigt= en ligting is not necessary= oter end uses could beinstalled suc as= small industries= sops it B refrigerators= ba"eries= samills= and so on. Te

oner of te (9# plant may invest in suc applications imself or e ma encourage or see"

oters to install suc units and buy electricity from im. )f industrial uses can be enanced=poer distribution must be carefully managed to be acceptable to suc customers.

Sometimes due to ig costs= tere is a lac" of interest in industrial development. Te manager

sould motivate people to install industries= and carges sould be reduced if te investorsagree to operate during off pea" ours. )ndustries sould= erever possible= not be run during

pea" ours oterise tere ill be voltage fluctuation. $ates for suc industries sould be

decided before te industry is installed.

.!0 2inancial Management

)n order to "eep trac" of income and e*penditure= proper records and accounts of te income=

e*penditure and savings sould be maintained. B $epayments of te loan sould be planned=

based on te income and te savings and adeuate amount must set aside eac mont for tis

purpose. An account boo" maintained for tis purpose= must cover te folloing.

0aily records. of income and e*penditure including te outstanding amounts.

$ecords of Assets :property and stoc" oned= liabilities8bills or money still to be paid=on montly basis.

Amounts spent on ma7or repairs= ne euipment or business e*penses; sould also be recordeddaily and separately on montly basis.

All te income= e*penditure= outstanding income and liabilities must be reproduced in a

final table eac year to determine net profit or loss. Tese calculations ould be useful

for planning te business for te ne*t year.


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Fsually= one Account ,oo" ould be sufficient for a (9# plant= but it sould ave

many tables.

Tere are to main systems for. "eeping te accounts of a pro7ect i.e. single entry boo";

"eeping= ere te transactions are recorded once= and double entry boo""eeping= ere all te

business transactions are recorded tice. or e*ample= en a (9# pro7ect purcases spareparts= te spareBs account ill be increased and te ban" account or cas account ill be

reduced. Tis double entry boo";"eeping system is prefered because it is a more systematic

and professional metod of maintaining accounts= and can elp identify mista"es very easily.9oever= for smaller (9# scemes say belo %/ "!= te double entry system may be

unnecessarily cumbersome and single entries bot for income and e*penditure may be good

enoug.

An e*ample of boo";"eeping for a 3/ "!= (9# sceme is illustrated in te folloing tables.

Table .!, Details of Total ProBect Cost

S!'o! Description 8mount )6s!*

1 'and purcased %/=///

2 Civil construction :Canal= poerouse= desilting basin= forebay< 3//=///

3 (ecanical euipment :turbine= penstoc"= driving systems< 33%=///

4 Electrical :&enerators= E'C= components= etc.< 1=///=///

% Transportation cost 1//=///

5 )nstallation cost 2//=///

G Operator training 15,000

+ Total Cost 6s! .&999&999

Sources of funds1 'ocal contribution or self investment< 4//=///

2 grammar from -&O %//=///

3 'oan from ,an" 5//=///

4 Subsidy %//=///

Total 6s! .&999&999

Tis Table sould be provided on te irst #age of te Account ,oo".

Table .!. ;oan 6epayment Scedule for te MHP Plant

0escription Amount

Complete repayment in G yearly installments 5//=///)st yr. Ending une= 166G H repayment of capital +5=///

)nterest on 5//=// I 15J 65=///

)st installment of loan and interest to be paid by 1% uly= 166G 1+2=///

2ndyr. Ending 3/tune= 166+ H repayment of capital +5=///

)nterest on %14=/// I 15J +2=24/

2ndinstallment of loan and interest to be paid by 1% uly= 166+ 15+=24/

3rdyr ending 3/tune= 1666 H repayment of capital +5=///


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)nterest on 42+=/// I 15J 5+=///

)nterest on 42+=/// I 15J 5+=4+/

3rdinstallment of loan and interest to be paid by 1% uly= 1666 1%4=4+/

4tyr ending 3/tune= 2/// repayment of loan +5=///

)nterest on 3.42=/// I 15J %4=G2/

4t

installemtn of loan and interest to be paid by 1% uly= 2/// 14/=G2/%tyr ending 3/t une= 2//1 H repayment of loan +5=///

)nterest on 2=%5=/// I 15J 4/=65/

%tinstallment of loan and interest to be paid by 1% uly= 2//1 125=65/

5tyr ending 3/tune= 2//2 H repayment of loan +5=///

)nterest on 1G/=/// I 15J 2G=2//

5tinstallment of loan and interest to be paid by 1% uly= 2//1 113=2//

Gtyr. ending 3/tune= 2//3 Hrepayment of loan +4=///

)nterest on +4=/// I 15J 13=444

Gtinstallment of loan and interest 6G=444

Te total amount of loan $s. 5//=/// at an interest rate of 15J.

Tis Table sould be reproduced on page 2 of te Account ,oo" for easy reference.

.!0!, (ncome and :#penditure 8ccount

Te manager or oner of te pro7ect sould maintain records in te Account ,oo" :ledgeror


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To ensure tat sufficient ater is floing to te ballast eater tan"= te gate valve sould be

inspected daily. )f te ater flo reduces= te valve and union sould be removed= tested

and repaired if necessary.

3.% 9ouse !iring)t as generally been observed tat s"ills to underta"e iring itin te ouses and to provide

connections does not e*ist in te remote and under;developed mountain areas. Terefore=

managers or operators of suc areas are usually called upon to carry out iring at te premisesof te consumers. Te promoters of ((9# also recognise tis fact And training for ouse

iring is included in te training far suc persons. Terefore= some basic details of ouse

iring are also provided ere.

)nstallation of iring in a ouse involves installing te service 7unction bo* ma"ing te

connection it te incoming line poer outlets= and sitces mounted in te desired location

and ten ta"ing te ires to different desired locations along te beams= poles= etc= as

necessary. Table 4.1 sos some standard symbols for typical features of office ouse iring.

)t is recommended tat every ouse sould ave a main sitc and a fuse. ,lac" seatingdistribution cable sould be used as it protects against te sunBs ultraviolet radiation. )f te

connection to te consumer is not troug a attmeter and te tariff is based on ma*imum

alloable poer a #TC= (C, or ECC sould be installed= according to alloable attage:poer


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Conduit iring can be installed over te surface of alls and ceiling or may be concealed under

te plaster.

Cleat !iring

)n tis type of iring= cables are run over cleats. A special pattern of cleat may be used ere

ires pass round corners= so tat tere may be no ris" of ires toucing te all. !ere cleatiring is on a metal portion along its run= te space beteen suc metal and porcelain cleats

sould be filled or varnised.

Cleat iring sould not be employed on damp alls or ceilings.

!ood Casing !iring

Tis type of iring consists of running te cables inside a ood casing aving grooves. Tis is

ten covered it ooden capping. Te ire used sould be vulcani>ed rubber or #C

insulated cables.

Te casing and capping sould be of ell seasoned tea" ood or oter ard ood= free from

"nots or any oter defects.

$eady;made iring

Te main feature of ready;made iring is te 7unction bo* from ic radiate te reuirednumber of poer cords of predetermined lengts for different rooms8locations= terminating in a

ligt bulb or poer soc"et. Te ires are fastened to ooden columns= beams= etc= at

appropriate locations and te bulbs or sitces are left anging but properly secured.

4.1.1 (ost Common !iring #ractices

Fsually= te ouses in te mountain areas utili>ing (9# are one; or to;story structures. !alls

are usually made of mud and stone masonry and plastered it mud. Te upper floor=supporting columns and roof= are usually made of ood. ery fe #a""a ouses:bric"=

concrete< may also e*ist in te mountain areas aving more durable roof of corrugated

galvani>ed iron or even $.C.C.

Conventional batten iring is commonly used in #a""a omes it concrete or cement

plastered bric" alls ic loo"s simple and neat :ig. 4.1


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or ready;made iring= ligting fi*tures= sitces and poer outlets are permanently fi*ed into

alls= supporting posts or oter parts of te ouses. At te service entrance a ooden 7unction

bo* is installed= on ic are mounted te current limited= fuses and possibly some poeroutlets.

To ensure good connections and eliminate any problems arising from frayed ires= te tips ofte stranded conductor are solid red. Te igure 4.2 belo illustrates te ma7or components of

a typical ready;made iring= ile igure 4.3 sos a line diagram for te same system.

4.2 Earting

Earting is considered really necessary only for industrial loads and electric coo"ers. 9oever=

if te funding permits= appropriate earting sould also be provided in ouses. Acceptable

metods for providing an earting are as follos.

A 3m; 4 m long galvani>ed steel pipe= aving 2/ mm to 3/ mm. diameter is buried vertically

and connected to te eart line using brass or copper connections.

A copper or galvani>ed iron plate of total surface area not less tan 1 s. m= is buried at a dept

of at least 2 m. and connected to te eart line using brass or copper connections.

4.3 &eneral $ules or 9ouse !iring

1 Te current rating of te conductor sould be as per te reuirement of te load as

suggested in Table 4.2.

2. Every live :positive or pase< ire sould be. protected by a fuse of suitable rating.

3. All te metal covering used for protecting te ires must be earted= so tat tere is nodanger due to insulation lea"age.

4. Sitces sould also be provided on all live ires leading to a point in use.

%. Every circuit or apparatus sould be provided it a separate sitc.5. Te si>e of poer and ligt circuit must be calculated separately according to te load.

a< One sub;circuit of ligt sould be not more tan 1/ points or +// !atts.

b< One circuit of poer sould be 3///;4/// !atts= ma*imum.G. Sitc board= distribution board= sub distribution board and poer soc"ets sould be

installed about 1.3 meter above te floor level.

8. Tubeligt or bulb sould be installed about 2.% meter above floor level.

9. Celing fan sould be at least 2.% meter from te floor level

10. )n tree pase= four;ires system installation= load sould be eual on all te pases.

11. )n tree pase four ire system at te main board= te ire colours sould be $ed= ello

and ,lue. -eutral sould be indicated in green or blac"

Table 4!. Symbols @sed in Drawings of (nternal House >iring

S.-o. 0ESC$)#T)O- S(,O'

1. (ain fuse;board itout sitces= ligting

2. (ain fuse;board it sitces= ligting

3. 0istribution fuse board itout sitces= ligting

4. 0istribution fuse board it sitces= ligting


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%. 0ouble pole sitc

5. $e;ireable fuse

G. an

+. )ncandescent lamp or filament lamp :bulb

management and operational manule-hydropower

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