| 75th Anniversary
swiftly. For instance, in the Tala Hydro Electric Project in Bhutan, a water body was created downstream, facilitating the use of Burge crane for the installation of radial gate components.
How do you ensure the safety and reliability of hydromechanical equipment in hydro projects? Ensuring the safety of Hydro Mechanical Equipment entails implementing suitable measures at every stage, from planning to maintenance. Our designs adhere to guidelines outlined in relevant Indian Standards and are reinforced by FEA and CFD analysis. Hydraulic model studies are conducted as needed. Additionally, various safety devices are installed in all equipment to enhance reliability during operation. Maintenance plays a crucial role in ensuring
the reliability and safety of any structure. Consequently, gate structures should be designed and constructed with provisions for emergency bulkheads or stoplog gates upstream of the main gate. These facilities facilitate maintenance activities and allow for isolating the waterway in the event of an emergency or malfunction of the service gate. Conducting post-installation inspection and
maintenance is paramount to ensure the hydro- mechanical equipment operates effectively. It not only influences the performance of the civil structure but also determines the overall success or failure of the project. It is crucial that the inspection procedures and operating manuals adhere to sound engineering practices and align with the adopted design criteria. In my opinion, the overall design of gates should prioritize sturdiness and sufficient rigidity. It’s prudent not to overly prioritize cost- saving measures in the provisions for gates and hoisting equipment unless one is absolutely confident about the adequacy of design parameters. There’s a possibility that unforeseen and unpredictable circumstances could arise, and economical provisions may lead to unsatisfactory performance or even failure of the gate or its operating mechanisms.
What considerations are important when selecting hydromechanical equipment for a hydro project? The cost of hydro-mechanical equipment represents only a fraction of the total project expenditure, yet designers cannot afford to overlook their significance. Proper selection and meticulous planning of hydro-mechanical equipment are integral to the success of any hydro project. Guidelines from working groups stress the importance of specifying the type, size, and quantity of gates and their hoisting mechanisms during the planning phase. These components often constitute the most vulnerable aspects of a project, and their reliable performance is crucial for its success and safety. Many projects have faced setbacks, either partially or entirely, due to malfunctioning or inappropriate selection of hydro-mechanical equipment. These equipments are inherently site-specific; for instance, certain
gate types may not be suitable for water with heavy sediment loads. In the case of barrages, the cost of hydro-mechanical equipment significantly influences the overall project expenditure, and an improper gate selection can substantially inflate costs. In today’s era of water scarcity, the importance of these equipments has heightened as they regulate pond levels and discharge.
Have you worked on any projects involving the rehabilitation or retrofitting of hydromechanical equipment? If so, what were the main challenges and solutions? No, I haven’t previously been involved in projects concerning the rehabilitation or retrofitting of hydromechanical equipment. However, we are currently in the process of making estimates for the first time for the rehabilitation/retrofitting of five barrage radial gates, as well as several other vertical lift gates, all of which are over 75 years old.
How do you approach maintenance and troubleshooting of hydromechanical equipment during and after construction? In adherence to practical, sound, and best engineering practices, we develop and furnish both an Erection manual and a comprehensive Operation & Maintenance manual. These guides are intended to be followed meticulously during installation and for the systematic maintenance and operation of equipment, respectively. Ensuring the proper maintenance of hydraulic gates and hoists is paramount for achieving satisfactory gate operation and realizing the anticipated benefits of the project. Regular maintenance, including inspection and monitoring, is imperative for hydro-mechanical equipment. With diligent adherence under competent management, these equipment can continue to provide entirely reliable service long after their initially designed life cycle. We consistently advise our customers to hire adequately trained and experienced operating personnel who can exercise their initiative and judgment based on their past experiences to handle any situations that may arise during operation. Our team provides thorough training to these operators. It is essential that day-to- day experiences in operation, including any encountered difficulties, are faithfully recorded in the logbook. This ensures the availability of valuable data for studying the behavior of various structures and equipment. Additionally, detailed instructions for inspection, normal maintenance, and repairs of gate installations are provided in the operation and maintenance manual.
Can you share any lessons learned from past hydro projects that have influenced your approach to working with hydromechanical equipment? I cannot pinpoint just one, two, or three specific lessons learned, but I firmly believe that every day presents an opportunity for learning. Engineering, by its essence, is a creative profession, demanding more than eight hours a day, five to six days a week commitment. As industries become increasingly diversified, competitive, and
demanding, and clients seek greater transparency and accountability in delivered work, corporate professionals like us face mounting pressure to meet corporate demands swiftly and economically. As hydromechanical engineers, our greatest challenge often lies in balancing the workload against the available manpower. With a plethora of tasks and a limited workforce, it becomes imperative to devise strategies to achieve day-to- day goals efficiently. This involves anticipating future objectives, formulating and executing strategies accordingly, all while considering global competition and resource constraints.
In your opinion, what are the emerging trends or technologies in hydromechanical equipment for hydro projects?
For decades, significant leaps in hydromechanical equipment development have been scarce. In general, designers in this field tend to adopt a conservative approach, favoring proven gate types unless a new design demonstrates superior safety and cost- effectiveness. Nevertheless, advancements have occurred gradually over time, primarily in design and construction methodologies, and more recently in control systems and cloud- based data transfer during operation. As part of our research and development efforts,
we are currently exploring the development of new composite materials aimed at enhancing the longevity of gate structures. However, this initiative remains in the experimental stage.
How do you approach collaboration and communication with other stakeholders (engineers, environmental specialists, policymakers, etc.) in hydro projects involving hydromechanical equipment? In the realm of designing, manufacturing, and installing hydromechanical equipment, collaboration with environmental specialists or policymakers is typically not required. Project authorities often award hydromechanical packages to contractors after significant progress has been made in civil work. However, there are instances, particularly during the planning or detailed project report (DPR) stage, where it becomes necessary to engage with collaborators to recommend appropriate facility selections in terms of hydromechanical equipment.
About the author
Dr Mukulesh Debnath is an international expert in hydropower, with particular expertise in hydromechanical engineering. He is also experienced in the health inspection of various steel structure and material & port handling equipment and has expertise in their design, fabrication and erection. He received his B.E(Civil) from B.E College, Shibpur in 1995; M.E(Structure) from BESU, Shibpur in 2004 and PhD from IIEST, Shibpur in 2014. He has published more than a dozen research papers and more than 20 technical papers in various international journals.
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