Dam Repair Process

PREFACE

Components of the hydroelectric dam, most notably the turbines may occasionally take damage to varying circumstances. Engineering personnel are expected to assess the issue, order necessary replacement parts, and use available systems such as the crane to carefully remove and install components. This dam repair process ensures the dam can return to full operation as quickly and safely as possible.

REPAIR PROCESS

This section outlines the full turbine repair process. While the exact procedures will be covered in training, all personnel should be familiar with each phase. The process is multi-step, labor-intensive, and requires coordination to properly execute the process.

While turbines can be prepared independently when necessary, performing the process alone is significantly more time-consuming, requiring frequent movement between locations. The repair process is designed to be collaborative due to the distance between the control room and the turbine hall. One personnel is typically stationed in the control room to operate the overhead crane via camera, while another is positioned on the turbine floor to attach and detach components.

STEP ONE: IDENTIFY THE DAMAGED TURBINE

Turbines will trigger an alarm when they begin taking damage. If not addressed in time, the turbine will eventually completely malfunction and explode, requiring the full repair process to begin.

Listen for alarms and keep an eye on the Turbine Control Panel for red alerts to identify the affected unit. Once confirmed, ensure the turbine is powered down before continuing. If it is left running, the system may automatically restart after repairs, causing immediate re-damage since oil resets to 0%.

STEP TWO: REMOVE DAMAGED COMPONENTS

Repairs are conducted using the Engineering & Technical Services overhead crane located in the turbine hall. This crane allows for authorized personnel to move and replace components of each turbine in an efficient manner.

To begin removal, the operator must enter the overhead crane and move it directly above the damaged turbine. While the process can be completed independently, it generally requires at least two people (one operating crane, one on the ground). The personnel on the ground must then attach the crane hook to the first turbine part. Once attached, the operator will then raise the part and move it to the parts elevator. The ground personnel will then detach the hook once positioned properly, and the part will be disposed.

STEP THREE: ORDER NEW PARTS
Similar to step two, once all damaged parts are removed, navigate to the dedicated OS computer and request the required turbine components one by one. These parts will appear in the same parts elevator, and must be attached to the crane hook. The operator will then navigate the new part over the empty turbine, lower it, and the ground personnel will detach the hook, anchoring the part into place.

This process will be repeated for each part in the proper assembly order, as listed in the section below. Each component must be removed in the correct sequence.

STEP FOUR: FINAL CHECKS

Prior to restarting and powering on the system, ensure the turbine is properly put together, all is anchored, and the oil level has been replenished. Following the repairs, the system may automatically restart if the system was not powered down prior to beginning the repair process, causing immediate re-damage since oil resets to 0%.

ASSEMBLY ORDER

Turbines are composed of multiple interconnected components that must be disassembled and reassembled in a specific sequence to ensure proper function and structural integrity. Refer to the order and photos below for more information. Following the correct sequence is essential to avoid damage, misalignment, or issues during operation.

For disassembly, components must be removed in the following order:

Upper → Floor → Lower

For assembly, the process is reversed:

Lower → Floor → Upper