presentation by - wrd.maharashtra.gov.in webinar 17052020_g… · presentation by er. h. v. gunale...
TRANSCRIPT
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Presentation by Er. H. V. Gunale
(Mobile No. 9922004034)Superintending Engineer
Sangli Irrigation Circle, Sangli
Execution and Maintenance of LISWebinar On
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Name of Scheme / Project
No Of Stages No Of Pumps
Rising Main no / length
Km.
Power Requirement
( HP )
I.P.( H.a)
UtilisationTMC
Takari Scheme 4 39 8/15.23 54184 34397 9.34
Mhaisal Scheme 7+5 LIS 121 25/44.73 113681 82922 17.44
Tembhu Lift Irrigation Project
5+6 LIS 123 29/90.44 200771 111856 22
283 62/150.4 Km. 368636 229175 48.78 TMC
3
Lift Irrigation Schemes Under S.I.C Sangli
Mhaisal Scheme 3 Lift Irrigation Schemes ( 6A, 6B, Agalgaon- Jakhapur), Tembhu Lilft Irrigation
project 2 Stages ( Stage IV, Stage V, 5 LIS & Visapur-2 Punadi-3) have been executed in last 5 years.
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Proposal sent to CDO by field office incorporating fortnight crop water Requirement as per
modified Penman method, proposed layout of scheme.
On basis of field data received, pumping machinery note inclusive of rising main, pump
parameters and general layout prepared by CDO sent to subcommittee members.
Sub committee meeting
Chairman SE PH (CDO), SE (Civil), SE (Electrical),SE (Mechanical) meeting held and various
controlling levels ( MDDL,POL,FSL,DC(FSL),Pump floor level, Sump Bottom level, Delivery pipe
level etc.) Rising main details ( thickness, length ), Pumps ( types, HP, alignment), & electrical
voltage are finalised.
Standing committee
Standing committee meeting under respective corporation is held and parameters are finalised.5
Finalisation of LIS Parameter, Layout & Detailed Design
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After sanctioning of parameters general layout is prepared at field level and is submitted to
CDO Nasik for sanction. After GL finalisation and approval, design of rising main, approach
channel, inlet arrangement , pump house, delivery chamber is done and sanctioned at field
level.
Mechanical wing finalises the valves in pump house and at start where as other valves on rising
main are finalised by CDO. For surge analysis and antisurge arrangements Mechanical wing will
process guidance of CDO.
Surge analysis done by authorised technical institute ( CWPRS Pune, IISC Bangalore, IIT
Mumbai, VJIT as other competent institute) depending on data provided and in consultation
with Mechanical wing, Civil wing. Work to be started after finalising the arrangement with CE
(Civil ).
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1) Intake Structure.
2) Approach Channel
2) Pump House.
3) Rising main with Manifold
4) Valves
5) Anti Surge System
6) Delivery Chamber
7
COMPONENTS OF LIS TO BE EXECUTED BY CIVIL WING
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Intake structure & Forebay of Aagalgaon Jakhapur
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9
Tembhu Pump House Stage- IV & Stage - V
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Sand Blasting
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Gunitting & Internal Epoxy painting
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Manifold & Rising main
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Air valve & Delivery chamber
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Antisurge arrangement –Bladder vessel
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• Bell mouth
• Bowl assembly
• Column pipe and intermediate shaft- ( Delivery pipe )
• Shaft, Bearing housing- thrust bearing.
• Motor and pump coupling
• Motor
• Control Panel
• Incomer
• Motor feeder.
• Bus coupler.
• KAV, cooling valves, NRV, BF valves15
Component of LIS to be executed by Mechanical wing
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Vertical Turbine Pump & Submersible Pump
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E. O. T. Crane
Actuator
Butterfly valve
N.R.V..
Valves
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1. Outgoing Bay MSEDCL / Transmission line.
2. Point of supply- tapping point ( HT connection point )
3. Switch yard
a) Plot development, foundation, Cable, Trenches, Control room erection (by civil wing )
b) Power transformer
c) Circuit Breaker
d) Current Transformer ( CT )
e) Potential Transformer ( PT )
f) Isolator
g) Lightening Arrestor
4. Transmission line ( in case of connection to other LIS point )
5. Control panel
6. Transmission line tower type / RSJ pole.
7. Power supply cable / bus duct. 18
Component of LIS to be executed by Electrical Wing
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Switch yard & Control panel
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Transmission line & Transformer
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Estimate, Tendering Sequence and Coordination
Estimation and Tendering of Civil Components.
Actual start of Execution of Civil Components i.e approach channel, Forebay , Pump house.
At the same time when Civil works are started, the estimates of Mechanical and Electrical Components
shall be ready.
Tendering of mechanical and electrical components .
After 50 % completion of Civil Components, procurement of mechanical components shall be started.
Electrical HT line & works of switch yard shall be started.
Finalization of Surge Analysis.
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Surge Analysis study
After finalisation of tenders of pump, all data pertaining to surge analysis submitted to
C.W.P.R.S Pune / I.I.Sc Bangalore/ I.I.T Mumbai/ V.J.T.I Mumbai or any reputed technical
Institute. Provision of Training to two Engineers each from C.D.O Nashik (P.H) and
Mechanical Organisation.
Surge Analysis report studied by C.D.O and Mechanical Organisation and submitted to
C.E Civil Wing.
On approval of Field Civil C.E, Estimates Tendering and actual works taken in Hand.
Anti-Surge arrangements constructed till rising main work is completed.
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Co-ordination within Civil, Mechanical and Electrical Wing
Civil wing with Electrical wing.
I. Layout of switch yard for cable trench, Earth matting and Equipment fixing.
II. Foundation loads for foundation design and construction for transformer.
III. Size of control panel.
IV. Regular Monitoring of Number of poles erected.
V. Load sanction process monitoring.
Civil wing with Mechanical wing.
I. Construction up to Gantry level for pump Assembly.
II. Valve position/ Saddle support position, Opening sizes.
III. Embedment's and Anchorages.
IV. Monitoring of pump procurement and allied equipments.
Electrical wing with Mechanical wing.
I. Motor H.P, Voltage level to be given by Mechanical wing for transformer and switchyard equipment design.
II. Errection of Incomer panel by Mechanical wing for cable/ Bus duct connection
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Execution Methodology
1. Intake Structure, Forebay, Sump
Approach road to site of pump houses is necessary to carry heavy equipment.
Construction of Intake Structure, forebay, sump to be carried in non-monsoon / non-rotation period of
canal preferably.
In case where source is from canal, care to be taken to line the canal in vicinity to avoid flooding
of sump and hampering activities of pump erection. (Agalgaon Jakhapur case)
Backfilling of forebay walls done only after full period of curing.
Construction joints to be filled properly.
Weep holes to be constructed as per drawing.
Batter and side slopes are to be maintained meticulously for floor and side walls.
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2) Pump House
• Excavation of pump house, forebay.
• Earthmat- embedments.
• R.C.C works of sump well. service bay including embedments for support to delivery pipes of pump.
• Pump foundations.
• Work upto gantry beam and erection of E.O.T. crane.
• Installation & erection of pumps, manifold valves e.g. reflux valve, B.F valve, Kinetic Air valve. etc.
• forebay concreting.
• Forebay concreting.
• Head regulator work e.g Service gates, Trash Rack etc .
• Manifold- Fabrication, concreting.
• Antisurge works.
• Superstructure of pump house building.26
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3) Rising main
• Procurement of M.S pipes.
• Excavation for pipe trench/ and sand bedding.
• Wrapper coating or External Gunitting- fixing of wire. mesh, sand blasting, gunitting & curing.
• Internal Epoxy .
• Laying pipes & bends in position & welding.
• Ultrasonic testing for joints.
• Concreting works for anchor blocks, thrust blocks.
• Antisurge arrangements.
• Hydraulic testing of pipe line.
• Backfilling trenches.
4) Mechanical Works
• Earth mat for pumping machinery.
• Erection of Gantry crane.
• Erection of pumps.
• Erection of reflux valve, BF valve, KA. valve & manifold.
• Erection of control panels, feeders panel, installation of cables from feeder panel to pumps\ motors etc.
• Trial of pumps. 27
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5) Electrical Works
• Layout of switch yard, control room.
• Embedment in foundation of various equipments in switchyard.
• Civil works like concreting, construction of building for panels, batteries.
• Erection of components like transformers, L.A. foundation etc.
• H.T. line, erection.
• Testing of all equipments, H.T. line and obtaining license from Electrical Inspector.
• Supply to feeder panel and testing of pumps.
6) Commissioning
• After testing of all equipments commissioning of scheme is done.
• Electricity supply is taken to switch yard.
• Transformer is charged
• Electricity supply from switch yard to HT panel .
• Dry test run of pumps.
• Load test of pump.
• During commission of all equipments, valves ,Rising main, antisurge system, gets tested . Finally scheme is commissioned.
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Operation and Maintenance of LIS
Operation and Maintenance of civil components
Operation and Maintenance of Mechanical components
Operation and Maintenance of Electrical components
Role of civil wing : co-ordination of all above activities
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Preparation of operation and Maintenance Plan
Activities of Maintenance
Civil - Intake structure, Pump House, Manifold, Anti-surge, Rising
Main & Delivery Chamber
Mechanical - Pump, Motor, Valves, Control Panel, Surge System, Allied
Components
Electrical - Transmission Line, Power Transformer, Circuit Breaker,
Current & Potential Transformer, Isolator, Lightning Arrester,
Control Panel
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Procedure for Operation and Maintenance
Identification of Operation activities, Maintenance activities & Estimation
Preparation of Procurement schedule
Funds Availability –
Irrigation
Non Irrigation
Recovery from beneficiaries against electricity bills (19%)
Government share (81%)
Tendering process
Execution of work
Maintenance of required stock of inventory
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Sr. No.
Staff Required for Regular O.M.R. of Pump
house and switchyard
(Excluding for Idle period)
Staff required for single shift
Number of Pumps Up to 8 9 to 16 17 to 24 25 & above
1 Pump Operators 1 2 2 3
2Electrician (Electrical Systems Operator) +
Electrician for switch yard1+1 1+1 1+1 2+1
3 Wireman for switch yard/ transmission line 1 1 1 1
4 Fitter (For Repairing etc.) + for switch yard 1+1 1+1 2+1 2+1
5 Helper/Technical helper for switch yard 1+1 2+1 2+1 2+2
6 Sweeper (only for general shift) 1 1 2 2
Total 9 11 13 16
Activities of Operation
I. Operation
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II. Security1) Single point entry for pump house premises under Vigilance of C.C. cameras displayed
at security cabin.
2) Well armed security guard deployed at pump house premises for three shifts.
III. Check List
1) Water level & Discharge at pump house
2) Prestart checkup of electrical equipments
3) Supply from MSEDCL at Switchyard and switchyard to control room
4) Checkup of control panel & Protection relay
5) Prestart checks of motor, pumps & control valves
6) Checking of manifold / anti surge device/ Rising main /Kinetic air valve etc. up to
delivery chamber
Before Starting Pumps
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1) Daily observation of water level & discharge
2) Running of no. of pumps as per water required from civil wing
3) Cooling water system for pumps / motor assembly
4) Monitoring of voltage, current, power factor, bearing temperature of motor
& pumps
5) Daily Discharge monitoring with mechanical wing
During Rotation
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Intake Structure
Periodical Repairs
• Cleaning
•Desiliting
•Painting
Special Repairs
• Structural Repair work
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Pump House Building
Periodical Repairs
Cleaning
Internal & External colouring & painting
Repair works to water Supply, Sanitary unit
Electrical Fittings & Fixtures
Special Repairs
• Repairs to roof / flooring / plaster / concrete
work
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Before Maintenance
Mhaisal L I S Stage 3
After Maintenance
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39Before Maintenance
Mhaisal L.I.S Stage 4
After Maintenance
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40Before Maintenance After Maintenance
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Before Maintenance
Mhaisal L.I.S Stage 4
After Maintenance
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Pump House Premises and Manifold Area
Periodical Repairs
Periodical Colouring & Painting to
building, delivery pipes, manifold area
Removal of Grass/ weeds
Maintenance of garden
Special Repairs
Structural Repair work – Compound
Wall, internal Roads
Landscaping
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Anti surge device
Periodical Repairs
Routine maintenance to keep
smooth operation of valves.
Colouring / painting
Special Repairs
Structural repair work
Valve/pipe replacement if required
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Rising main
Periodical Repairs
Internal epoxy painting & external guniting
Joints of pipe & manhole
Maintenance of Air Valve & Valve pipe
Special Repairs
Rising Main pipe joint repair work
Internal Anti corrosive painting of M. S. pipe
and external guniting
Kinetic air valve replacement
Vertical M.S. pipe replacement
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Delivery Chamber
Periodical Repairs
Colouring & Painting
Special Repairs
Structural repair work
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PumpPeriodical Maintenance
Cooling Valve Replacement
Bearing Housing Oil Top up
Gland packing filling
Pump Motor alignment
Hand rotation of pump
Special Repairs
Full Overhauling (Bellmouth, bowl
assembly, Impeller) repair/ replacement
Gland Sleeve replacement
Bearing Replacement
Shaft replacement
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Motor
Periodical Maintenance
Cleaning
Insulation Testing
Cable tightening
Bearing greasing
Special Repairs
Bearing Replacement
Motor Rewinding
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Valves(BFV/NRV/KAV)
NRV
KAV
Periodical Maintenance
Testing of valve
Top up of power pack Oil
Flange gasket replacement
Hydraulic cylinder Hose pipe replacement
Application of grease to gear box assembly
Kinetic Air valve replacement
Special Repairs
Replacement of hydraulic cylinder Tube
Limit Switch replacement of actuator
Cylinder pin replacement
Upgradation
Single door NRV to multi door NRV replacement
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Control Panel
L.T.PANEL
H.T.PANEL
Periodical Maintenance
Cleaning
Insulation Testing
Tightening
On-Off dummy testing
Special Repairs
Damaged parts replacement (Connectors, fuses,
relays)
Upgradation
Vacuum contactor is replaced by Vacuum Circuit
breaker (Retro fitting)
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Surge System
TANK
VALVE CONTROL ROOMPeriodical Maintenance
System Checking
Valve operation
Special Repairs
Valve replacement
Float replacement
Painting
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Allied components Rubber expansion joint (REJ),
Delivery piping, Manifold, Rising Main
Periodical Repairs
Tightening of flange bolts , Man hole
gasket replacement, KAV ball replacement
Special Repairs
Anti corrosive coating
Patchwork of Rising Main
Upgradation
Metallic Expansion Joint
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55
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Periodical Repairs
• Replacement of faulty insulators
Special Repairs
• Restringing of Line
Upgradation.
• Replacement of Porcelain insulators
by Polymer Insulator.
Transmission Line
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Periodical Repairs
• Transformer Oil Top Up.
• Tightening of Palm connectors
• Insulation testing
Special Repairs
• Total Oil Replace
• Major repairs of transformer
Upgradation
• Conversion of 'OFF' Load to ON load tap changer system.
• Replacement of conventional Earthing to maintenance free Chemical Earthing
Power Transformer
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Circuit Breaker
Periodical Repairs
• Topping of Sf 6 Gas.
• Replacement/ Tightening of connectors.
Special Repairs
• Replacement Connecting rod.
• Overhauling of operating Mechanism
Upgradation.
• Replacement of Vacuum Interrupter.
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Current & Potential Transformer
Periodical Repairs
• Top up of Oil.
• Replacement/ Tightening of connectors
Special Repairs
• Replacement of equipment
Upgradation
• Replacement with Dead tank to Live
tank.
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Isolator
Periodical Repairs
• Replacement of Palm connectors.
• Cleaning of connections
Special Repairs
• Alignment of Mechanism
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Lightning Arrester
Periodical Repairs
• Replacement / Tightening of Palm
connectors.
Special Repairs
• Replacement of equipment
Upgradation
• Replacement of conventional Earthing to
maintenance free Chemical Earthing.
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Control Panels
Periodical Repairs
• Replacement of connectors, fuses etc.
Special Repairs
• Replacement of Relay, Contactors.
Upgradation
• Replacement electro mechanical relay
with New Microprocessor based digital
relay.
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