Topic:"Asset Management" in M12795

3.3.2 General Circuit Breaker Condition Indicator 2 – Operation and Maintenance History .36 3.3.3 General Circuit Breaker Condition Indicator 3 – Contact Resistance Tests37 3.3.4 General Circuit Breaker Condition Indicator 4 – Number of Op...

AI summary This document outlines condition indicators and assessments for various components of a power generation facility, including circuit breakers, governors, batteries, cranes, and emergency closure gates and valves. Each section details specific indicators related to age, maintenance, performance, and data quality.

6.2.1 Option A – Like for Like replacement90 6.2.2 Option B – New unit99 6.2.3 Option C – Full Decommissioning113 6.3 Summary - costed option analysis115 CONCLUSION116 Appendix 1 – Metallography and Metallurgical Study of the wicket gates1...

AI summary The document outlines three options for handling an asset: Like for Like replacement, New unit installation, and Full Decommissioning, followed by a summary of the costed option analysis and several appendices related to technical studies and risk assessments.

EXECUTIVE SUMMARY This report presents a comprehensive condition assessment and costed option analysis for the Factorydale Hydropower Plant, under the management of Berwick Electric Commission. The evaluation focuses on critical components...

AI summary This report assesses the Factorydale Hydropower Plant's critical components, identifying the turbine's irreparable damage and recommending replacement. The generator, though recently serviced, requires ongoing monitoring. Three costed options—replacement, new unit installation, or decommissioning—are proposed for investment decisions.

2.1 Assessment Criteria In this assessment, we will be utilizing the HydroAMP (Hydropower Asset Management Project) framework to systematically evaluate the condition of various components within the hydroelectric plant. HydroAMP provides...

AI summary The assessment uses HydroAMP to evaluate hydroelectric plant components like turbines and generators, excluding civil structures. It outlines a two-tier evaluation process, highlights the framework's statistical scoring system, and notes the need for separate structural assessments. HydroAMP was developed through collaboration between BOR, Hydro-Québec, and others starting in 2001.

2.2 Data Collection In our data collection phase, we conducted three site visits to thoroughly assess the plant's condition. The first visit on July 19 focused on evaluating the civil structures of the plant, where we inspected the dam, pe...

AI summary The data collection phase involved three site visits (July 19, July 25, August 8) to assess a plant's civil structures, electromechanical components, and penstock systems through inspections, 3D scanning, and photographic documentation. Detailed reports from these visits will be appended to the main report.

2.3 Scoring and Ranking The advantages of using HydroAMP is that it has a different scoring per system analyzed, and it is based on statistics. So each system will have different aspects to be looked at, and different scoring. We will pres...

AI summary The section discusses HydroAMP's scoring methodology, which uses system-specific statistical analyses to evaluate different systems individually. A HydroAMP guide will be uploaded for reference, with the report focusing on presenting scores and their rationale.

Table 1: HydroAMP - Turbine Age Scoring Turbine Age Scoring Age Age (New/Full (Partial Rehabilitation) Rehabilitation) Condition Indicator Score < 25 years < 15 years 3 ≥ 25 and < 35 years ≥ 15 and < 25 years 2 ≥ 35 and < 45 years ≥ 25 and...

AI summary Table 1 outlines the HydroAMP turbine age scoring system, where turbine age is categorized into different ranges with corresponding condition indicator scores. A score of 0 is assigned to turbines older than 45 years, indicating they are the oldest and potentially in the worst condition.

Results Condition Indicator Score Good Surface/Minimal Cavitation Damage 2 Fair Surface/ Moderate Cavitation Damage 1 Poor Surface/Severe Cavitation Damage 0 Total Physical Condition Score Sum of Cracks plus Cavitation and Surface Damage C...

AI summary The turbine and its mechanical components are in very poor condition, indicated by a score of 0, suggesting almost complete destruction or severe damage.

Runner In short, the runner is destroyed beyond repair. Figure 3: Runner Damage On the Root Cause Analysis of the failure of the machine we will elaborate a little bit more about the runner destruction. But there are a few aspects to keep...

AI summary The runner, originally installed in 1968, was coated with Belzona in the 1990s to address cavitation and corrosion. Despite this, corrosion weakened the blades over time, leading to destruction from high-speed impacts with wicket gate castings. Even a new replacement runner would not have withstood the damage.

Wicket Gate mechanism The mechanism is operated by a hydraulic governor, which operates a rotating shaft and moves two pairs of levers, a common arrangement on units of this age. Figure 7: Wicket gate mechanism in 3D Figure 8: Unit fully a...

AI summary The Wicket Gate mechanism is operated via a hydraulic governor and rotating shaft, with corrosion observed on components. A wooden branch found in the scroll case indicates potential foreign object intrusion, though it may not have caused the damage. Pins connecting arms to the operating ring show past replacement due to failures, with no current signs of deformation.

Wicket gates metallurgical tests On the appendix 1, the metallurgical report for the wicket gates is included. The report shows several aspects to be noted: - The sample consisted in two different wicket gates, both damaged, which were rem...

AI summary The metallurgical report on wicket gates reveals that two damaged gates, removed from a unit, showed poor quality control and materials weaker than ASTM A48 standards, indicating substandard manufacturing.

Wicket gate 01 Figure 11: Wicket gate 01 The wicket gate 01 appears to be "intact", even though it is just right next to the wicket gate 14, which was completely destroyed. The bronze link is not present; totally destroyed. The link pin is...

AI summary Wicket gate 01 is described as intact despite being near the completely destroyed wicket gate 14. The bronze link is missing, but the link pin remains in place. Visual evidence includes referenced images depicting the gate's condition.

Wicket gate 02 Figure 12: Wicket Gate 02 Both ends of the wicket gate are damaged, missing over 10% of its mass. The control pin and the control link are missing.

AI summary Wicket Gate 02 is reported to have both ends damaged, with over 10% of its mass missing. The control pin and control link are also missing, as illustrated in Figure 12. The condition of the gate raises concerns about structural integrity and operational reliability.

Wicket gate 03 Figure 13: Wicket Gate 03 The control link of Wicket Gate 03 was found broken, and the wicket gate rotated 180 degrees. This was the position it was found, which proves that the wicket gate could have been rotating freely du...

AI summary Wicket Gate 03's control link was found broken, allowing the gate to rotate 180 degrees freely during the failure event. Minimal damage was observed, with less than 1% material loss on the gate's lower tip. The position of the gate indicates potential operational issues during the incident.

Wicket gate 04 Figure 14: Wicket Gate 04 Missing control link and 180 degrees rotated was how we found Wicket Gate 04. No major damage, other than small amount (1% or less) of missing material on the lower tip of the gate. The link pin on...

AI summary Wicket Gate 04 was found with a missing control link, rotated 180 degrees, and a minor (1% or less) material loss on its lower tip. The link pin is also missing, though no major structural damage is reported.

Wicket gate 05 Figure 15: Wicket Gate 05 The top and bottom sections of the gate edge have damage, indication of impacts with a solid object. The control link is missed, but the control pin is there. Same as other wicket gates, it was foun...

AI summary Wicket Gate 05 exhibits damage to its top and bottom sections, indicating impact with a solid object. The control link is missing, though the control pin remains intact. The gate was found fully rotated 180 degrees, consistent with other wicket gates.

Wicket gate 07 Figure 17: Wicket gate 07 This wicket gate only suffered damage on the lower tip of the edge. Most definitively caused by impact. Was found rotated over 180 degrees of its expected position. Control link completely destroyed.

AI summary Wicket gate 07 sustained damage to its lower edge tip, likely from impact, and was found rotated 180 degrees from its normal position. The control link was completely destroyed, indicating significant structural failure.

Wicket gate 09 Figure 20: Wicket gate 09 - In the picture is marked as Wicket gate 10 We marked Wicket Gate 09 as 10 by confusion during our inspection. This wicket gate only suffered damage on the lower tip of the edge. Most definitively...

AI summary Wicket Gate 09 was mislabeled as 10 during inspection. It sustained damage from uncontrolled rotation, causing impact on its lower edge and destruction of the control link. The damage occurred during the gate's 180-degree rotation, leading to failure of the control link pin.

Wicket gate 10 Figure 21: Wicket Gate 10 Apart from a control link destroyed, there were no signs of damage on this wicket gate. Was found in the correct position as well.

AI summary Wicket Gate 10 was found undamaged except for a destroyed control link and was located in the correct position. No other signs of damage were observed.

Wicket gate 13 Figure 24: Wicket gate 13 This wicket gate only suffered damage on the lower tip of the edge. Most definitively caused by impact. Was found rotated over 180 degrees to its expected position. Control link completely destroyed.

AI summary Wicket gate 13 sustained damage to its lower edge tip, likely from impact, with the gate rotated 180 degrees from its normal position and its control link destroyed. Visual evidence includes photographs of the damaged structure.

Turbine Shaft, Guide bearing and generator bearing: We didn't have access to the bearings because that would require a disassembly of the unit, but we saw the condition of the shaft on the area closer to the guide bearing. Figure 26: Runne...

AI summary Inspection revealed scoring and friction lines on a turbine shaft above the guide bearing, which should be unscathed. Possible causes include sediment damage or Y-axis movement. Full assessment of shaft trueness requires disassembly or lathe use, which was not performed. The runner is damaged and cannot be repaired as-is.

Draft tube Figure 27: Draft tube exterior, corrosion present, but expected, no damage noticed There are signs of corrosion outside the draft tube, we may assume that the inside, if it is not coated, is in similar condition. Proper NDE is r...

AI summary The draft tube shows external corrosion, requiring non-destructive evaluation (NDE) to assess internal condition. Adjustment rods need replacement, and exposed rebar/concrete near the draft tube are deemed non-risky. The access platform is in poor condition and requires immediate replacement. Inspection was limited by darkness, preventing debris assessment at the draft tube's bottom.

Table 4: HydroAMP - Operational Limitations Scoring Maintenance Scoring Corrective Maintenance Condition Indicator Score No corrective maintenance 1.5 Small amounts of corrective maintenance (e.g., less than 3 staff days per unit per year)...

AI summary The table outlines scoring for corrective maintenance under the HydroAMP operational limitations framework. The unit is currently under a forced outage, resulting in a score of 0.

2 Physical Condition (Score must be 0, 1, 2, 3, or 4) 0 1.250 0 3 Operations (Score must be 0, 0.5, 1, or 1.5) 0 1.000 0 4 Maintenance (Score must be 0, 0.5, 1, or 1.5) 0 1.000 0 Tier 1 Turbine Condition Index (Sum of individual Total Scor...

AI summary The document presents a condition assessment form indicating that the unit requires a full refurbishment or replacement due to its current physical, operational, and maintenance scores being at the lowest levels.

Table 6: HydroAMP - Turbine Data Quality Scoring Turbine Data Quality Scoring Results Data Quality Indicator Score All Tier 1 inspections, tests and measurements were completed within the normal frequency. 10 One or more of the Tier 1 insp...

AI summary Table 6 outlines the HydroAMP turbine data quality scoring system based on the frequency of Tier 1 inspections, tests, and measurements. A score of 4 was assigned due to one Tier 1 inspection completed ≥24 and <36 months past the normal frequency, conducted by BI&I on the generator and electrical systems.

3.2 Generator Generator: 520 kVA, 2300 V, 131 A, 14 poles, Synchronous, Canadian General Electric, No 140147 Figure 29: Generator at Factordydale Powerplant The condition assessment methodology described by HydroAMP guideline: Generator Co...

AI summary The document details a 520 kVA generator at Factordydale Powerplant, manufactured by Canadian General Electric. It references HydroAMP guidelines for condition assessment, notes no visible mechanical damage, and mentions a 2023 rewind project. The generator's capacity (0.416 MW) is below the 2 MW threshold for HydroAMP's methodology, but the guidelines are still used as a reference.

Table 7: HydroAMP - Stator / Rotor Winding Operation & Maintenance History Scoring Stator / Rotor Winding Operation & Maintenance History Scoring Results Stator / Rotor Condition Indicator Score Operation and maintenance normal. 3 Some abn...

AI summary Table 7 presents a scoring system for evaluating the operation and maintenance history of stator and rotor windings in hydroelectric assets. The scoring ranges from 3 (normal operation) to 0 (major failures and end-of-life conditions).

Since there is no known consistent data and history of the generator up to the time of the operational failure, this with respect to Generator Electrical Maintenance data, then the Reference Guide recommends that when data is not available...

AI summary The text discusses the lack of consistent data on generator electrical maintenance and suggests assuming a mid-range score of 2 for condition indicators when data is unavailable, to avoid erroneous conclusions.

Table 8: HydroAMP - Stator / Rotor Winding Physical Inspection Scoring Stator / Rotor Winding Physical Inspection Scoring Results Stator / Rotor Condition Indicator Score Inspection results are normal. 3 Inspection shows some deterioration...

AI summary The table outlines a scoring system for assessing the condition of stator and rotor windings based on inspection results. It notes that humidity and lack of operations may lead to deterioration, and references a prior PdMA Testing Report from L&B that discusses how operations and energization could improve related parameters.

Table 10: HydroAMP - Stator / Rotor Winding Age Scoring Stator / Rotor Winding Age Scoring Age Stator / Rotor Condition Indicator Score < 20 years 3 ≥ 20 and < 30 years 2 ≥ 30 and < 40 years 1 ≥ 40 years 0 A project to rewind the generator...

AI summary Table 10 outlines a scoring system for the age of stator and rotor windings in generators, with higher scores for younger components. A 2023 rewinding project improved the score despite the generator's overall age.

Table 11: - HydroAMP - Generator Stator / Rotor Condition Summary Tier 1 Generator Stator / Rotor Condition Summary (For instructions on indicator scoring, please refer to condition assessment guide) No. Condition Indicator Score × Weighti...

AI summary Table 11 provides a condition assessment summary for a generator's stator and rotor, with scores calculated based on various indicators. The total condition index is 7.05, indicating that ongoing operations and maintenance can continue without restriction, with the need for periodic reassessment.

3.3 Circuit Breakers There is no exact and specific data of the electrical power installation, corresponding to Main Switch; therefore, to follow the protocol described in Appendix E2: Circuit Breaker Condition Assessment, It will be compl...

AI summary The document discusses the condition assessment of circuit breakers in a facility lacking specific installation data. It references L&B Electric's 2023 evaluation, highlights the absence of proper switchgear, and outlines four condition indicators (dielectric condition, maintenance history, contact resistance, operations count) for assessing breaker health. No electrical damage was visually detected.

Table 13: HydroAMP – General Circuit Breaker O & M History Scoring General Circuit Breaker O & M History Scoring Results Condition Indicator Score Operation and Maintenance are normal. 3 Some abnormal operating conditions experienced and/o...

AI summary Table 13 presents a scoring system for the general circuit breaker operation and maintenance history under the HydroAMP initiative. It evaluates the condition of circuit breakers based on their operation and maintenance, assigning scores of 3 for normal conditions and 2 for abnormal conditions or additional maintenance.

Table 15: HydroAMP – General Operations Scoring General Operations Scoring Results Condition Indicator Score < 1,000 normal operations < 250 normal operations (Oil Tank) 3 < 2,000 normal operations (SF6) ≥ 1,000 and < 3,000 normal operatio...

AI summary Table 15 presents a scoring system for general operations under the HydroAMP program, with different scores assigned based on the number of normal operations for oil tanks and SF6, indicating performance metrics for asset management.

Table 16: HydroAMP – Circuit Breaker Data Quality Scoring Circuit Breaker Data Quality Scoring Results Data Quality Indicator Score Al Tier 1 inspections, tests and measurements were completed within the normal testing frequency and the re...

AI summary The document presents a scoring system for evaluating the data quality of circuit breaker inspections and maintenance. It outlines different scoring levels based on the timeliness and reliability of inspection results and comparisons with short circuit study results. The lowest score is assigned when inspections are significantly overdue or data integrity is questionable.

2 Operation and Maintenance History (Score must be 0, 1, 2, or 3) 2 1.315 6 2.6312 3 Contact Resistance (Score must be 1, 2, or 3) 2 0.702 1.404 4 Number of Operations (Score must be 0, 1, 2, or 3) 2 0.439 0.878 Tier 1 Circuit Breaker Cond...

AI summary This section discusses the condition-based alternatives for general circuit breakers, including scores related to operation and maintenance history, contact resistance, and number of operations. A condition index is calculated based on these scores, which is used to evaluate the state of the circuit breakers.

Table 18: HydroAMP – Circuit Breaker Condition-Based Alternatives Circuit Breaker Condition-Based Alternatives Generator Condition Index Suggested Course of Action ≥ 7.0 and ≤ 10 (Good) Continue O & M without restriction. Repeat condition...

AI summary Table 18 outlines condition-based alternatives for circuit breakers based on the Generator Condition Index. Equipment with a 'Fair' condition requires an updated O&M plan, while 'Good' and 'Poor' conditions dictate specific maintenance and evaluation actions.

3.4 Governor The hydraulic governor is the original from 1968, when the plant was commissioned to its current state. Figure 31: Woodward Governor Figure 32: Woodward Governor, additional views We couldn't find technical specs of this gover...

AI summary The 1968 hydraulic governor has undergone undocumented modifications and repairs over 60 years, showing oil leaks and safety risks. Emerson still services these governors, but technical specs were unavailable during the report. The governor functioned properly before the 2023 failure, though maintenance records were incomplete.

Table 19: HydroAMP - Age Scoring - Mechanical Control System Age Scoring Mechanical Control System Age Condition Indicator Score < 25 years 3 ≥ 25 and < 40 years 2 ≥ 40 years 1

AI summary Table 19 outlines the age scoring for mechanical control systems under the HydroAMP program, assigning scores based on the age of the systems, with lower scores indicating older systems.

Table 21: HydroAMP - Availability of Spare Parts Availability of Spare Parts Scoring Availability Condition Indicator Score All necessary mechanical and electronic parts are available from original supplier. 3 Necessary mechanical and elec...

AI summary Table 21 outlines a scoring system for the availability of spare parts for HydroAMP, with scores ranging from 3 (all parts available from original supplier) to 0 (most parts unavailable and significant obstacles to reverse-engineering).

Tier 1 Governor Condition Index (Sum of individual Total Scores) 7.34 (Condition Index should be between 0 and 10) This score of 7.34 recommends: Continue O & M without restriction. Repeat condition assessment as needed.

AI summary A Condition Index score of 7.34 is reported, indicating that operations and maintenance (O & M) should continue without restriction, with the recommendation to repeat the condition assessment as needed.

Table 24: HydroAMP - Governor Data Quality Scoring Governor Data Quality Scoring Results Data Quality Indicator Score All Tier 1 inspections, tests and measurements were completed within the normal frequency. 10 One or more of the Tier 1 i...

AI summary The document outlines a data quality scoring system for HydroAMP Governor inspections, tests, and measurements. A score of 0 was assigned due to no records of inspections or maintenance in the last three years, except for personnel testimony.

Table 29: HydroAMP – Plant Battery Data Quality Scoring Plant Battery Data Quality Scoring Results Data Quality Indicator Score All Tier 1 inspections, tests and measurements were completed within the normal testing time interval and the r...

AI summary The document presents a scoring system for evaluating the data quality of plant battery inspections. The score is 0 due to the absence of inspection or maintenance records over the past three years, aside from personnel testimony.

3.6 Cranes There is one single crane in the plant, located on the first floor. It is a manual chain hoist. Has been certified recently as shown in documentation available. Figure 35: Chain hoist manual crane Crane Capacity: 9,991 kg. Crane...

AI summary The plant contains a single manual chain hoist crane with a capacity of 9,991 kg, recently certified. Although the certificate was lost, a plaque on-site indicates the capacity, placed by the certifier. Technicians confirm the plaque's origin from the certification process.

Table 32: HydroAMP – Cranes- Maintenance Requirements Scoring Maintenance Requirements Scoring Results Condition Indicator Score Small 3 Moderate 2 Excessive 1 As per HydroAMP guide: Small: A small amount of routine annual preventative mai...

AI summary Table 32 outlines the maintenance requirements scoring for cranes based on the HydroAMP guide, assigning scores of 3 for 'Small' maintenance needs, indicating minimal annual preventative maintenance is required.

Table 33: HydroAMP – Cranes- Age of Crane Age of Crane Results Condition Indicator Score < 20 years 3 ≥ 20 and < 35 years 2 ≥ 35 years 1 In this case, we give a score of 1, the crane is older than 35 years.

AI summary Table 33 outlines a scoring system for the age of cranes used in HydroAMP, assigning a score of 1 to cranes older than 35 years, 2 to those aged between 20 and 35 years, and 3 to cranes under 20 years old.

Table 35: HydroAMP - Crane Data Quality Scoring Governor Data Quality Scoring Results Data Quality Indicator Score The last crane periodic inspection was performed within the normal inspection frequency and results are reliable. 10

AI summary Table 35 outlines the data quality scoring for HydroAMP crane inspections, indicating that the last inspection was performed within the normal frequency and results are reliable, earning a score of 10.

3.7 Emergency Closure Gates and Valves It is important to understand that the emergency closure itself is not as fast as it may sounds. The only emergency closure mode existent now, is the closure of the wicket gates. The intake butterfly...

AI summary The emergency closure system relies solely on wicket gates, which are not as rapid as perceived. Intake butterfly valves and penstock gates are manually operated without automated controls, highlighting limitations in emergency response mechanisms.

Intake gate valve The intake gate valve is a typical 48 inch diameter butterfly valve, manually operated with a torque multiplier, and ith a bypass valve. Figure 36: Intake valve The valve is in very good condition, operates like it should...

AI summary The 48-inch intake gate butterfly valve is manually operated with a torque multiplier and bypass valve. Inspection confirms it is in good condition with no leaks or operational issues. Water in the scroll case is residual from drainage, and no concerns were identified.

Pressure relief valve Figure 37: Pressure relief valve The plant, instead of having a surge tank, has a pressure relief valve installed, with surge anticipation. This is a common system that it is used in small hydro plants to avoid the co...

AI summary The plant uses a pressure relief valve with surge anticipation instead of a surge tank to protect against water-ram effects during sudden valve closures. The valve is in good condition, properly maintained, but lacks formal registration. No concerns were identified during inspection.

Table 36: HydroAMP – Age of Gates, Valves, and Operators Age of Gate, Valve, and Operator Emergency Closure System Age of the Equipment Indicator Score < 20 years 3 ≥ 20 and < 35 years 2 ≥ 35 and < 60 years 1 ≥ 60 years 0 In this case, the...

AI summary Table 36 outlines the scoring system for the age of emergency closure system equipment in the HydroAMP project. Equipment is scored based on its age, with older equipment receiving lower scores. The equipment includes a mix of original 1968 components and newer pressure relief valves, with a score of 1 assigned due to the presence of older equipment.

Table 38: HydroAMP – Valve Physical Condition Valve Physical Condition Results Gate condition indicator score Limited corrosion on leaf/plug and water passage; coating is in good condition; seals and seats are in good condition and properl...

AI summary Table 38 details the physical condition of valves in the HydroAMP program, with two categories based on corrosion levels and maintenance status. The first category shows limited corrosion and good conditions, scoring 3, while the second shows moderate corrosion and adequate conditions, scoring 2.

Large areas of corrosion on leaf/plug and water passage; coating is less than adequate; seals and seats have some damage with minor leakage; bearing/pivot point lubrication is in adequate condition; the bypass has moderate corrosion; valve...

AI summary The document discusses the condition of intake gates and pressure relief valves, noting corrosion, inadequate coatings, and leakage. The intake gate is scored 2, while the pressure relief valve is initially scored 3 but adjusted to 2 due to infrequent exercise.

3.7.3 Condition Indicator 3 – Physical Condition of Operators Valves and gates are evaluated separately. HydroAMP uses Hydraulic and Electric operators only. The plant at Factorydale uses Manual mechanical operators, the closest evaluation...

AI summary This section discusses the evaluation of valves and gates, noting that HydroAMP uses hydraulic and electric operators, while the Factorydale plant uses manual mechanical operators, with the closest evaluation matrix being for electrical operators.

Table 39: HydroAMP – Gate Operator (Electric Hoist) Physical Condition, evaluating a mechanical operator Gate Operator (Electric Hoist) Physical Condition Results Gate condition indicator score Hoist surfaces and coatings are free of corro...

AI summary This table evaluates the physical condition of a gate operator (electric hoist) under the HydroAMP program. It provides details on the condition of various components, such as surfaces, couplings, lubrication, and brakes, with scores of 3 and 2 indicating good and minor issues, respectively.

Table 41: HydroAMP – Gates and Valves - Operations History Scoring Gates and Valves - Operations History Scoring Results Gate condition indicator score Meets original operational criteria, tested as required, no known design and operationa...

AI summary Table 41 outlines a scoring system for the operational history of gates and valves under the HydroAMP program. A score of 1 is assigned to valves and intake gates that function but require improvements. The scoring reflects the condition and operational criteria met by the equipment.

Table 42: HydroAMP – Gates and Valves - Maintenance History Scoring Gates and Valves - Maintenance History Scoring Results Gate condition indicator score Small 2 Moderate 1 Excessive 0 We will assign a score of 2. The systems do not need t...

AI summary The document assigns a score of 2 to the maintenance history of gates and valves under the HydroAMP program, indicating that the systems require minimal maintenance to operate properly.

Table 44: HydroAMP - Emergency Closure System Data Quality Indicator Scoring Emergency Closure System Data Quality Indicator Scoring Data Quality Years Since Last Condition Assessment Indicator Score < 8 years 10 ≥ 8 and < 17 years 7 ≥ 17...

AI summary The table outlines a scoring system for the data quality of emergency closure systems based on the years since the last condition assessment. A score of 4 is assigned for systems with ≥17 and <25 years since the last assessment. The text notes that a score of 4 was selected, assuming a condition assessment was conducted before installing a new penstock to ensure water control during construction.

3.9 Civil Structure General Condition As part of the condition assessment, we did an overall assessment of the condition of the civil aspects of the plant.

AI summary An overall assessment of the civil aspects of the plant was conducted as part of the condition evaluation process.

3.9.3 Gravel retainer wall: Figure 43: Gravel retainer wall Just below the building annex, a retaining wall is present, which looks like is original from the plant. The only drawing that we had access to does not shown this wall. It has a...

AI summary The gravel retainer wall near the building annex has a growing crack, splitting it into two parts. The wall retains gravel and a pressure relief valve pipe, which is normally empty. Although no immediate structural issues are present, the wall is referred to a structural engineer for assessment. The gravel stabilizes the area during water diversion events.

3.9.4 Turbine floor level: The turbine floor as well doesn't look in bad shape in general, considering the age of the plant (102 years). Most definitively can benefit from additional housekeeping, but it is in general good conditions. Now...

AI summary The turbine floor of a 102-year-old plant is generally in good condition despite its age, though it requires additional housekeeping. Three wall cracks and one column crack were identified during inspection.

North wall crack Figure 45: North wall crack The crack extends from the entrance door to the east corner. It can be seen from the outside as well, which means that the crack is not superficial. For a plant of this age is not uncommon.

AI summary A significant north wall crack extends from the entrance door to the east corner, visible externally and deemed non-superficial. The crack is described as typical for a facility of its age, suggesting it may be a result of normal wear and tear rather than an unusual structural failure.

East wall crack Figure 46: East wall crack This wall is fully below-grade, we cannot see the other side of the wall to evaluate if goes through the entire section, so we will assume that it goes through. What took our attention is that the...

AI summary The text describes cracks in the east wall of a below-grade structure, noting another crack extending to the southeast column. Due to the potential structural implications, a full structural engineering analysis of the plant is recommended.

South wall crack This is another crack in a wall that is fully below grade. We cannot see the other side of the wall so we will assume that it goes through the entire section of the wall. Figure 48: Crack on the South wall The crack ends c...

AI summary A crack in the south wall, fully below grade and near the penstock, is documented. The crack's full extent is unknown, but similar cracks near penstocks are described as common, raising potential concerns about structural integrity and maintenance practices.

3.9.5 Draft tube: Figure 49: Draft tube access hatch Figure 50: Draft tube exterior, corrosion present, but expected, no damage noticed Figure 51: Bolts that attach the curb plate/scroll case to the draft tube, nothing out of normal Figure...

AI summary Inspection of the draft tube revealed exposed rebar and concrete, likely removed during construction to facilitate installation. No structural risks were identified, though poor lighting hindered visibility of the turbine's lower sections. Corrosion and algae were noted but deemed normal.

3.9.6 Structural engineering observations To have an even more comprehensive analysis of the civil structure, we hired Pinto Engineering to conduct a high-level structural assessment of the plant. Their findings are in Appendix 2. Their co...

AI summary Pinto Engineering's assessment identified concrete wall cracks and foundation undermining, potentially caused by machinery vibrations. While cracks are not immediately risky, foundation repairs and discharge tube extensions are recommended. Floor slabs show no cracks, and the base level's condition is unclear but not critical.

3.9.7 Dam Inspection We had the opportunity to do a walkdown on the dam. Some of our observations: Figure 56: Dam Access points are unsafe The first observation is that it is not very safe to access the dam itself. From the west side, the...

AI summary The dam inspection highlights unsafe access points, debris accumulation, and maintenance needs. Stairs on the west side are obstructed by debris and vegetation, while the east side lacks proper steps for safe access. The trash rack is heavily clogged, and debris covers the dam, requiring cleaning. The rip rap and penstock show good external conditions, but internal inspections are recommended.

SECTION 4 - RISK ASSESSMENT In conducting the risk assessment for the hydroelectric plant, we systematically evaluated the potential risks associated with each major component of the facility. This process involved identifying operational,...

AI summary The risk assessment for the hydroelectric plant evaluated potential risks across operational, mechanical, electrical, safety, and environmental areas. The assessment was deferred for civil structures, circuit breakers, and transformers due to lack of information or scope limitations. A matrix based on impact and likelihood was used to evaluate risks.

Table 47: Some of the highest priority risks identified (table splits between pages) Risk Number System Component Risk Scenario Description Likelihood (1-5) Impact (1-5) Risk Level (Likelihood x Impact) Mitigation Measures 1.1.2 Turbine Ru...

AI summary Table 47 outlines two high-priority risks related to turbine runners: cavitation-induced cracking and cavitation erosion leading to blade thinning. Both risks are assessed as moderate in likelihood but high in impact, with mitigation measures including non-destructive testing, application of erosion-resistant materials, and operational adjustments.

Risk Number System Component Risk Scenario Description Likelihood (1-5) Impact (1-5) Risk Level (Likelihood x Impact) Mitigation Measures acidic, can weaken the scroll case and lead to leaks or failure. cathodic protection systems. Monitor...

AI summary The document presents a risk assessment for various components of a hydroelectric system, identifying potential risks such as hydraulic leaks, sensor failures, and inadequate maintenance. Each risk is categorized with likelihood, impact, and mitigation measures. A global recommendation for a comprehensive maintenance program is emphasized.

Implement Continuous Monitoring Systems: Install continuous monitoring systems for critical components such as the turbine, generator, and hydraulic systems. Focus on monitoring vibration, temperature, pressure, and flow rates. Immediate d...

AI summary The text advocates for installing continuous monitoring systems on critical infrastructure components like turbines and generators to track parameters such as vibration and temperature. This proactive approach aims to detect issues early, preventing failures and ensuring operational safety.

Establish Operational Limits: Define and enforce strict operational limits based on manufacturer recommendations and the specific conditions observed during the assessment. Ensure that all operators are trained and aware of these limits. O...

AI summary The text emphasizes defining and enforcing strict operational limits based on manufacturer guidelines and observed conditions, stressing the importance of operator training to prevent equipment failure from cavitation, wear, or other issues.

Initiate Immediate Inspections: Conduct thorough inspections of all critical components, particularly those identified as high-risk in the assessments (e.g., turbine seals, generator bearings, and hydraulic systems). Document any findings...

AI summary The text emphasizes conducting immediate inspections of high-risk infrastructure components (e.g., turbine seals, generator bearings) to identify issues early, prevent unplanned outages, and ensure operational reliability through timely interventions.

Operational Optimization Studies: Conduct studies to optimize plant operations, focusing on improving efficiency and reducing operational costs. This could include revisiting turbine settings, flow management, and energy consumption strate...

AI summary The document outlines the need for operational optimization studies to enhance plant efficiency and reduce costs through turbine setting adjustments, flow management, and energy consumption strategies. These studies aim to identify opportunities for equipment wear reduction and operational cost savings.

Remote Monitoring Capabilities: Begin upgrading systems to include remote monitoring capabilities, particularly for key components like the governor and hydraulic systems. This may involve installing new sensors and integrating them with a...

AI summary The text recommends upgrading systems with remote monitoring for key components like governors and hydraulic systems, involving sensors and central platforms to enable real-time analysis and improve plant management efficiency.

Modernization of Control Systems: Plan and execute the modernization of the plant's control systems, focusing on upgrading to stateof-the-art digital control technology. Ensure integration with predictive maintenance tools and advanced mon...

AI summary The document outlines plans to modernize plant control systems using digital technology, integrating predictive maintenance and advanced monitoring to enhance asset longevity and operational efficiency.

Urgent Inspections and Repairs: Install a new inspection platform on the draft tube chamber. Immediate intervention is necessary to properly understand the scope of work of a full refurbishment, even if it is a complete new unit or a like-...

AI summary The document emphasizes the urgent need for installing a new inspection platform on the draft tube chamber to assess the scope of a full refurbishment, highlighting the necessity of immediate intervention to determine whether the work involves a complete new unit or a like-for-like replacement/repair.

Implementation of a Preventive Maintenance Schedule: Establish and implement a comprehensive preventive maintenance schedule. This should include routine inspections, lubrication, cleaning, and testing of all critical components, based on...

AI summary The document emphasizes establishing a preventive maintenance schedule with routine inspections, lubrication, cleaning, and testing of critical components, aligned with manufacturer guidelines and plant-specific needs. It highlights the importance of regular maintenance in extending equipment life, reducing downtime, and preventing unexpected failures.

Critical Spare Parts Inventory Review: Review and update the inventory of critical spare parts, ensuring that all necessary components, especially those prone to wear and tear, are readily available. This includes seals, bearing components...

AI summary The review emphasizes maintaining a well-stocked inventory of critical spare parts, such as seals, bearings, and hydraulic components, to ensure readiness for repairs and minimize downtime during equipment failures.

Predictive Maintenance Tools Deployment: Deploy predictive maintenance tools such as vibration analysis, thermography, and nondestructive testing (NDT) to anticipate and address potential issues before they lead to failures. Focus on criti...

AI summary The deployment of predictive maintenance tools like vibration analysis, thermography, and NDT is proposed to monitor critical infrastructure components (turbines, generators, bearings), enabling early issue detection, reducing unexpected failures, and optimizing maintenance schedules.

Comprehensive Overhaul of Key Components: Schedule comprehensive overhauls for key components identified as high-risk, such as the turbine runner, generator, and hydraulic systems. This may include rebalancing, re-lubrication, and replacem...

AI summary The document emphasizes the need for comprehensive overhauls of high-risk components like turbine runners, generators, and hydraulic systems through rebalancing, re-lubrication, and replacement. Regular maintenance is highlighted as essential to restore equipment performance, extend lifespan, and prevent failures.

Enhancement of Maintenance Documentation and Record-Keeping: Improve the documentation and record-keeping of all maintenance activities. Implement a digital maintenance management system to track inspections, repairs, and part replacements...

AI summary The document proposes enhancing maintenance documentation through a digital management system to track inspections, repairs, and part replacements, emphasizing detailed records for equipment history tracking, issue identification, and future maintenance planning.

Routine Condition Monitoring Program: Establish a routine condition monitoring program that includes regular checks of operating parameters such as vibration, temperature, pressure, and lubrication levels. Ongoing condition monitoring help...

AI summary The document proposes establishing a Routine Condition Monitoring Program to regularly check operating parameters like vibration, temperature, pressure, and lubrication levels. This proactive approach aims to identify potential issues through trend analysis, enabling timely maintenance.

Lifecycle Analysis and Replacement Planning: Conduct a lifecycle analysis of all major components and develop a long-term replacement plan. This should include budgeting and scheduling for the replacement of components nearing the end of t...

AI summary The document emphasizes the need for lifecycle analysis of major components and long-term replacement planning to ensure operational continuity, budgeting, and scheduling for replacements, preventing unexpected breakdowns.

Advanced Maintenance Training Programs: Develop and implement advanced training programs for maintenance personnel, focusing on new technologies, advanced diagnostic tools, and best practices in maintenance. Continuous education and skill...

AI summary The document emphasizes the development of advanced maintenance training programs to equip personnel with new technologies, diagnostic tools, and best practices, enhancing maintenance operations' effectiveness through continuous education and skill development.

Periodic Overhauls and Upgrades: Plan for periodic overhauls and upgrades of critical systems, including the turbine, generator, and control systems, based on operational data and condition assessments. Regular overhauls and upgrades help...

AI summary The document outlines a plan for periodic overhauls and upgrades of critical systems such as turbines, generators, and control systems. These maintenance activities aim to ensure operational efficiency, prolong asset life, and minimize the risk of major failures.

Sustainability and Environmental Compliance: Integrate sustainability and environmental compliance into maintenance practices, including the use of eco-friendly lubricants and proper disposal of hazardous materials. Ensuring that maintenan...

AI summary The text emphasizes integrating sustainability and environmental compliance into maintenance practices by using eco-friendly lubricants and proper hazardous material disposal. It highlights that adherence to regulations ensures responsible plant operations and avoids fines or penalties.

5.3 Rehabilitation and Upgrade Recommendations

AI summary Section 5.3 outlines recommendations for rehabilitating and upgrading infrastructure, focusing on asset management and maintenance strategies. Specific details are not provided in the given text.

Inspection and Reinforcement of Structural Components: Conduct a detailed inspection of all structural components related to the turbine, including the scroll case, draft tube, and foundation. Reinforce or replace any components showing si...

AI summary The text emphasizes the need to inspect and reinforce turbine structural components like the scroll case, draft tube, and foundation to ensure safety and prevent failure. Non-destructive evaluation (NDE) and potential disassembly/sandblasting are recommended. Structural integrity is critical for safe operation.

Upgrade Control and Automation Systems: Following the turbine replacement, upgrade the control systems to include modern digital controls, remote monitoring, and automated safety shutdowns. Integrate these systems with the new turbine for...

AI summary The document outlines the necessity to upgrade control systems following turbine replacement, emphasizing modern digital controls, remote monitoring, and automated safety shutdowns. It highlights that the current system, installed in 2020 and tested in 2023, is outdated and lacks remote control capabilities, which could compromise operational efficiency, safety, and reliability.

Periodic Overhaul and Upgrades of Plant Equipment: Plan for periodic overhauls of the new turbine, generator, and associated systems every 5-10 years. This should include comprehensive inspections, non-destructive testing, and the replacem...

AI summary The document outlines a plan for periodic overhauls of turbine, generator, and associated systems every 5-10 years, emphasizing comprehensive inspections, non-destructive testing, and component replacement to maintain optimal plant condition and extend equipment lifespan.

Comprehensive Plant Modernization: Plan for a comprehensive modernization of the plant, including potential automation of manual processes, upgrading of safety systems, and integration of advanced analytics for predictive maintenance. Mode...

AI summary The document outlines plans for comprehensive modernization of a plant, including automation, safety system upgrades, and advanced analytics for predictive maintenance. The initiative aims to enhance competitiveness, efficiency, safety, and profitability in the evolving energy market.

The three options are: - Option A - Repair current assets: This option, after the condition assessment performed, is more a like-for-like replacement than a full repair. The main mechanical parts of the unit are totally destroyed, and the...

AI summary Three options are presented for managing aging assets: repairing current assets (Option A) with limited viability, replacing them (Option B) for improved efficiency, or decommissioning (Option C) with significant technical challenges. Repair is deemed impractical due to extensive damage, while replacement offers enhanced energy output and decommissioning involves complex infrastructure removal.

6.1 Methodology To obtain costs references for the three options, we went to the market and ask for quotes, as well as run short cost research to determine decommissioning costs of dams based on size. We consulted three OEMs to get us quot...

AI summary The methodology involved obtaining quotes from three OEMs (Norcan Hydro, Canyon Hydro, Dive Turbines) for repairs and replacements, using RETScreen Expert for energy and financial models for options A and B, and researching decommissioning costs for option C.

6.2.3 Option C – Full Decommissioning As it was explained in a previous section (6.1.2) we use the help of an advanced language model to research on several databases for costs of decommission. The majority of the data was referred to, in...

AI summary Option C involves full decommissioning, which was researched using an advanced language model. The costs are similar across Canada, with decommissioning only providing maintenance cost savings and no income generation.

CONCLUSION The condition assessment of the Factorydale Hydropower Plant reveals that while certain components remain operational, the plant's overall health is compromised by aging infrastructure and significant damage to critical componen...

AI summary The Factorydale Hydropower Plant requires urgent turbine replacement due to aging infrastructure and critical damage. While a generator rewind extends its lifespan, ongoing maintenance is vital. Three options are proposed: like-for-like turbine replacement, installing a modern unit, or decommissioning. The report advocates turbine replacement for continued efficient operation.

Readings (HRB) 1 2 3 4 5 Average O1 Wicket Gate Longitudinal 70.2 79.0 75.2 75.2 70.2 74.0 O1 Wicket Gate Transverse 77.4 75.7 76.4 81.4 70.3 76.2 O2 Wicket Gate Longitudinal 62.8 62.7 76.0 74.1 70.1 67.9 70.5 69.1 O2 Wicket Gate Transvers...

AI summary The document presents hardness readings for wicket gates (O1 and O2) in longitudinal and transverse directions, noting significant variation between O1 and O2 gates. Lower hardness in O1 gates may indicate lower casting strength, with hardness being used as a quality control measure.

e 5 O1 T etched microstructure showing pearlite, phosphides 500x Figure 6 O2 T etched microstructure showing pearlite, phosphides 500x The presence of phosphides weakens the microstructure along with the ferrite and larger graphite that is...

AI summary The document discusses microstructural analysis of materials, noting that phosphides and graphite in wicket gate materials reduce strength. It includes a structural review of the Factorydale Electrical Plant by HYSOVENT Sustainable Engineering, addressing concerns raised by J. Scott MacIntyre, P.Eng.

Ian Shea Technical Business Development Manager Norcan Hydraulic Turbine Inc. 50 Bruce Crescent, Carleton Place, Ontario, CA K7C 3V6 T: +1 (613) 257-4755 ext. 18 F: +1 (613) 257-4215 E: [email protected] From: Javier Ojeda Sent: Septem...

AI summary Ian Shea of Norcan Hydraulic Turbine Inc. and Javier Ojeda of Hysovent discuss the Berwick Hydropower plant's lie-for-like replacement and repair, noting the missing estimated power output for the new unit as a key unresolved detail.

Javier Ojeda P.Eng, MBA, PMP, CEM, REP Owner, Principal Engineer HYSOVENT Sustainable Engineering +1-902-2106828 [email protected] www.hysovent.com Book a meeting with me at your earliest convenience here! From: Javier Ojeda < javier@hys...

AI summary Javier Ojeda, a principal engineer at HYSOVENT Sustainable Engineering, discusses providing an estimate for the Berwick Hydropower plant's 'lie-for-like replacement and repair' to support energy and financial modeling for project progression. He confirms a follow-up call with Ian Shea.

Book a meeting with me at your earliest convenience here! From: lan Shea < [email protected] > Sent: Wednesday, September 18, 2024 11:17 To: Javier Ojeda < [email protected] > Subject: RE: Berwick Hydropower plant - lie-for-like repl...

AI summary Lan Shea apologizes for a delayed response to Javier Ojeda regarding the Berwick Hydropower plant project, citing emergency work in northern Ontario. She confirms availability for a meeting and shares preliminary cost estimates for the lie-for-like replacement and repair project, framing it as a long-term benefit for the customer.

Equipment Refurbishment Sandblast/Paint Existing Penstock Inlet & Pressure Case

AI summary The text outlines a specific equipment refurbishment task involving sandblasting and painting the existing penstock inlet and pressure case, indicating maintenance activities for infrastructure components.

Field Services - Equipment Disassembly, Removal, and Disposal - Removal of Existing Generator to local storage facility - Disposal of Obsolete Equipment - Embedment Alignment Inspection - On-site Machining (Contingency) - Equipment Install...

AI summary The document outlines field services procedures including equipment disassembly, removal, disposal, alignment inspections, on-site machining, installation, and unit commissioning as part of infrastructure maintenance and upgrades.

BACKGROUND This project involves the decommissioning of an earthen dam located in British Columbia, Canada. The dam in question stands 20 meters high and spans 150 meters in length, with an average crest width of 6.5 meters. Over time, the...

AI summary This project involves decommissioning a 20-meter-high, 150-meter-long earthen dam in British Columbia, Canada, due to its obsolescence and environmental risks such as sediment buildup and structural failure. The objective is to safely dismantle the dam and restore the site.

Factorydale Turbine Failure – Town of Berwick Electric CODE HSV - 2024 - 043 - RA01 CONDITION ASSESSMENT and COSTED OPTION ANALISYS Review Date August 2024

AI summary The document outlines a condition assessment and costed option analysis for the Factorydale Turbine Failure in the Town of Berwick Electric, with a review date in August 2024 and a reference code HSV - 2024 - 043 - RA01.

RISK ASSESSMENT Risk Number System Component Risk Scenario Description Likelihood (1-5) Impact (1- 5) Risk Level (Likelihood x Impact) Mitigation Measures 1.1.4 Turbine Turbine Runner and blades Runner Blade Fatigue: High Cycle Fatigue Rep...

AI summary The risk assessment identifies two turbine-related risks: high-cycle fatigue in turbine blades and fatigue failure at welded joints. Both risks are assessed as moderate to high in likelihood and impact, with mitigation strategies including monitoring, non-destructive testing, improved welding practices, and design modifications.

INTRODUCTION The main dam of Factorydale Hydropower Plant under the management of Berwick Electric Commission (BEC), is a concrete and earthen embankment structure raised to provide approximately 80 ft of head for the turbine/generator sys...

AI summary The Factorydale Hydropower Plant, managed by Berwick Electric Commission, suffered a 2023 incident causing permanent power loss due to a solid object damaging turbine components. A Condition Assessment and Root Cause Analysis (RCA) identified the failure's origin. The report evaluates refurbishment feasibility, including upgrading the turbine, generator, and infrastructure to improve efficiency and reliability.

SECTION 1 – PREVIOUS STUDIES For the incident, following a Condition Assessment and Costed Option Analysis, BEC conducted a Root Case Analysis to evaluate refurbishment feasibility. The proposed refurbishment includes installing a new, opt...

AI summary BEC conducted a Root Cause Analysis following a Condition Assessment and Costed Option Analysis to evaluate refurbishment feasibility. The proposed refurbishment includes installing a new Francis-type hydro turbine and related infrastructure to enhance efficiency, reliability, and sustainability.

1.1 Conditions Assessment Analysis: Conclusions - The condition assessment of the Factorydale Hydropower Plant indicates that while some components remain operational, the plant's overall health is compromised by aging infrastructure and s...

AI summary The Factorydale Hydropower Plant requires replacement of all electromechanical components due to aging infrastructure and turbine damage. Three options are outlined: like-for-like replacement, modern equipment installation, or decommissioning. The recommended action is component replacement to ensure continued efficient operation.

1.2 Root Case Analysis: Conclusions - The most likely scenarios were reviewed based on evidence gathered on-site, laboratory analyses, and computer simulations. The evaluation strongly indicates that a large object passed through the turbi...

AI summary The root cause analysis concludes that a large object caused catastrophic turbine failure, exacerbated by substandard cast iron and design flaws in wicket gates and blade attachments. The analysis highlights material inadequacies and engineering shortcomings that contributed to irreversible damage.

SECTION 1 – PREVIOUS STUDIES • Further inspection revealed deficiencies indicating the need for more rigorous maintenance and routine inspections. Although runner blades had been previously treated against corrosion and cavitation, no rece...

AI summary Inspection revealed infrastructure deficiencies, including corroded runner blades, seal and pipe joint leakages, and inadequate corrosion protection. Recent condition assessments were absent, and future replacement parts require rigorous engineering and quality controls.

2.1 Site Conditions The powerhouse building is constructed with reinforced concrete and brick. It includes concrete and metal pathways, passages, stairs, entrance/exit doors, and other common features typical of industrial applications. Th...

AI summary The Berwick Factorydale Hydroelectric Power Plant is located in Aylesford, Nova Scotia, with infrastructure including a concrete dam, reinforced fiberglass penstock, and a turbine room. The site features a reservoir-based system with a net head of 22.654 meters and a design flow rate of 3.39 cubic meters per second. The powerhouse is constructed with reinforced concrete and brick, and the surrounding rock consists of fractured slate.

2.2 Current Equipment The electric generator for replacement, operates at a constant speed of 514 rpm, synchronous AC, 416 kW (520 kVA – PF: 80%), 2300 V, 131 A, 14 poles, 60 Hz. Canadian General Electric, No. 140147. Figure 10: Descriptio...

AI summary The document details specifications of a 416 kW synchronous AC generator (Canadian General Electric, No. 140147) and a 12-blade Francis turbine (Barber Turbine & Foundries, 1968), both operating at 514 rpm. The system uses a Woodward HR hydraulic governor to maintain constant generator speed via mechanical linkage to wicket gates.

2.3 Proposed Equipment The project aims to fully upgrade all electromechanical systems, including the turbine, generator, balance of plant (BOP), transformer, and all associated systems at the Factorydale hydroelectric plant, increasing it...

AI summary The project proposes upgrading the Factorydale hydroelectric plant's electromechanical systems to increase capacity from 416 kW to 650-750 kW. Upgrades include new control systems, advanced condition-monitoring with machine learning for predictive maintenance, and modernization of components like turbines, generators, and transformers.

2.3.2 Scroll Case The proposed scroll case design adopts a spiral-shaped geometry concentrically surrounding the turbine, ensuring uniform flow distribution to each guide vane. This uniformity minimizes vibrations, torque fluctuations, and...

AI summary The scroll case design features a spiral geometry surrounding the turbine to ensure uniform flow, reduce vibrations, and enhance hydraulic efficiency. It is constructed with welded steel, epoxy coatings, and segmented for on-site assembly, adhering to IEC 60193 and ASME standards.

2.3.3 Turbine The proposed project involves the installation of a new Francis-type hydro turbine, designed to deliver a power output ranging between 650 and 750 kW, intended to replace the existing unit at the Factorydale hydroelectric pla...

AI summary The project involves installing a new Francis-type hydro turbine at the Factorydale hydroelectric plant, replacing the existing unit. It requires efficiency under variable flow conditions, integration with existing systems, compliance with IEC/ASME standards, corrosion protection, and rigorous testing. The turbine must withstand harsh coastal climates and sediment-laden flows, with a 50-year service life and 90% efficiency under nominal conditions.

2.3.5 Generator The proposed project involves the replacement of the existing electric generator at Factorydale with a new synchronous AC generator, rated between 650 kW and 750 kW, operating at 2300 V, 514 rpm, with 14 poles and 60 Hz fre...

AI summary The proposal involves replacing Factorydale's existing generator with a new 650-750 kW synchronous AC generator, enhancing efficiency and sustainability while adhering to IEC/CSA standards. Key requirements include humidity control, corrosion resistance, SCADA integration, and compliance with environmental and operational standards for reliability under transient conditions.

2.3.6 Switchgear The Factorydale hydropower project includes the replacement and upgrade of the existing switchgear system, ensuring comprehensive protection, control, and isolation of electrical systems associated with the new hydro-gener...

AI summary The Factorydale hydropower project involves upgrading switchgear to ensure electrical system protection, control, and isolation. Compliance with IEC and CSA standards is mandatory, with advanced protection mechanisms and detailed maintenance protocols. Grounding systems and surge protection are emphasized for reliability.

2.3.7 SCADA, Control, Automatization, Protection and Measurement The proposed Factorydale hydropower project involves upgrading the existing SCADA, Control, Automation, Protection, and Measurement systems. The upgrade will include a comple...

AI summary The Factorydale hydropower project proposes upgrading SCADA, control, automation, protection, and measurement systems. Key upgrades include PLC-based panel replacement, remote communication, machine learning for predictive maintenance, multifunctional relays, advanced power quality meters, redundant SCADA infrastructure, and compliance with IEC standards to enhance operational efficiency, reliability, and safety.

2.3.8 Power Transformer The complete and detailed proposal for this equipment will be defined following the closing of submissions by the Hydrogenerator System manufacturers. The proposed project involves replacing the existing 600 kVA pad...

AI summary The proposal involves replacing the existing 600 kVA ONAN transformer at Berwick's Factorydale hydropower facility with a more efficient unit. The current transformer operates at 2300 V (Delta) and 12470 V (Wye), with 4.3% impedance. The new transformer will require updated cabling, controls, and monitoring systems to ensure compliance with modern safety and efficiency standards.

2.3.9 Excitation System The proposed project involves supplying and installing a new Static Excitation System (SES) to support the new generating unit rated between 650 kW and 750 kW. The SES will be designed to ensure structural compatibi...

AI summary The proposed project involves installing a Static Excitation System (SES) for a 650-750 kW generating unit, featuring advanced cooling, microprocessor control, multiple operational modes, and compliance with IEC/CSA standards. The system will integrate with the plant's CADA system for remote monitoring and undergo Factory/Site Acceptance Testing to ensure performance and safety.

2.3.10 New Trash rack in penstock entry With the current trash rack in poor condition as mentioned on Section 2.2, we decided to add to the scope of work a new trash rack, in this case made not made in steel but in HMWPE – high molecular w...

AI summary The document proposes replacing the existing steel trash rack in the penstock entry with a high molecular weight polyethylene (HMWPE) alternative due to its advantages, including reduced head loss, lightweight, corrosion resistance, and lower costs for small spacing. A mechanically assisted cleaning system with minimal maintenance requirements is also planned.

3.2 Financial models per Scenario The Berwick Electric Commission (BEC) sells its energy directly to customers in their grid. The rates established by the Nova Scotia Utility Regulator are as follows (in summary): • Domestic Service: $0.17...

AI summary The Berwick Electric Commission (BEC) sells energy directly to customers at regulated rates, using a conservative 25% discount on the highest kWh rate ($0.1789) to determine the Electricity Export Rate ($0.1311). Financial models incorporate turbine replacement scenarios, OEM cost quotes, and extrapolated water flow data. Table 2 summarizes cost, revenue, ROI, and ROE for new units.

Table 5: Risk Evaluation. Key Risks Probability Impact Risk Mitigation Strategies Technical Risks Integration of new turbine with existing civil infrastructure Medium High Detailed civil and structural assessment already completed; design...

AI summary The document outlines key technical risks associated with the integration of a new turbine, including structural compatibility, design assumptions, component availability, SCADA communication, cooling performance, vibration, and cybersecurity. Mitigation strategies include detailed assessments, conservative design parameters, redundancy, and adherence to cybersecurity standards.

Key Risks Probability Impact Risk Mitigation Strategies Unrealistic Initial Schedule Commitments Low High Perform detailed schedule development during engineering; validate timelines with suppliers and contractors; include float in critica...

AI summary The document outlines key risks and mitigation strategies for a project, including unrealistic schedule commitments, supply chain disruptions, and environmental risks. It also addresses regulatory, demand forecasting, and asset management risks, with emphasis on using conservative modeling and planning for long-term operations.

Response: - (a) BEC Employees complete daily operational checks on the generator at Factorydale while in service. They complete monthly visual checks on the backwoods dams and spill ways looking for signs of washout and general condition o...

AI summary BEC employees perform regular maintenance and operational checks on the Factorydale generator and associated infrastructure. Currently, four full-time employees handle both distribution and hydro operations. The proposed modern design is expected to reduce maintenance hours, though the detailed maintenance plan is still under development as part of Phase 3 of the project.

- Visual inspection of the transformer. Then, at least once every year, when water levels are low enough to guarantee a 2-3 day outage: - Visual inspection of the turbine, through the scroll case, including inspection of the wicket gates a...

AI summary The text outlines a basic inspection schedule for transformer and turbine components, including visual inspections and insulation tests. It clarifies that this is not a comprehensive maintenance program and that a detailed one will be developed once the final design is established.

Response: BEC recognized that the runner blades were corroding and contracted out a coating system that was applied many years ago (HSV-2024-043-RCA01). This coating system was reaching the end of its life when the last failure occurred. Y...

AI summary BEC acknowledged corrosion on runner blades and had previously discussed potential replacements with vendors, but no changes were implemented before an incident occurred. Hysovent proposed a maintenance program to address corrosion through inspections and reapplication of systems with new equipment.

Nova Scotia Energy Board Staff Interrogatory IR-24 Interrogatory: Question(s): Page 76 of Condition Assessment states: "…there is one global recommendation: a proper maintenance program for the entire facility and its assets." Will this pr...

AI summary The Nova Scotia Energy Board Staff Interrogatory IR-24 asks whether a maintenance program will be prepared as part of the proposed project, based on a recommendation from Page 76 of the Condition Assessment. The response confirms that a detailed maintenance program will be developed and is part of the project deliverables.

Question(s): In several sections of Condition Assessment, Hysovent noted that consistent maintenance records and technical specifications for various equipment were not available. - (a) Please describe BEC's routine maintenance schedule an...

AI summary The document requests BEC to provide details on its maintenance schedules, record-keeping methods, and procedures for generating facilities and equipment. It also asks for copies of maintenance reports and explanations for any unavailability of records.

Structure Name Previous Recommended Recommended Recommended Classification Classification IDF EDGM Factorydale Dam and Spillway High Significant Q 1,000 (123 m 3 /s) AEP 1,000 (PGA 0.046g) Factorydale Dam and Spillway was evaluated based o...

AI summary The Factorydale Dam and Spillway were assessed on August 8, 2024, and found to be in Fair condition with minor deficiencies. The evaluation included a visual inspection and review of design adequacy, and no imminent failure was observed.

2 SYSTEM DESCRIPTION AND BACKGROUND Factorydale Dam is located at 2545 Harmony Road, within the limits of the Town of Berwick. The dam and spillway were rehabilitated in 2008 with post-tensioned anchors and rockfill buttressing at the left...

AI summary Factorydale Dam, located in Berwick, was rehabilitated in 2008 with post-tensioned anchors, rockfill buttressing, and an upgraded spillway crest with a concrete overlay.

4.5.3 MANAGEMENT DEFICIENCIES Management deficiencies identified during the 2024 Dam Safety Review and their corresponding recommended mitigation are summarized in [Table 4.9.](#page-0-36) There are four (4) notable design adequacy deficie...

AI summary The 2024 Dam Safety Review identified four design adequacy deficiencies, with two classified as high priority and three as medium priority, along with recommended mitigation strategies.

Based on current digital terrain maps, the dam controls a catchment area of approximately 92.3 square kilometers, including regulation structures at South River Lake Dam and Burnt Flowage. There is also a structure at Randall Canal that ma...

AI summary The Factorydale Dam and Spillway were assessed in August 2024 and found to be in fair condition. The dam's maximum flood level during an intense storm event is slightly higher than previously estimated, and some structural elements, such as the right abutment, remain at risk. Recommendations include addressing deficiencies and ensuring proper dam operation.

INTERNAL STABILITY A traditional assessment of piping and internal erosion potential for an earthfill dam requires conjecture and judgment to assess zoning in the dam, filters (if present), and quality of construction, foundations and perf...

AI summary The text discusses the assessment of internal erosion potential in earthfill dams, emphasizing the need for judgment in evaluating dam design, construction quality, and risk factors such as geometry and material types. The Guidelines provide qualitative commentary but lack quantitative criteria for erosion protection.

Table 1.2 Condition Rating System for Project Components Condition Rating Condition Definition G Good Will function as intended. Little wear, deterioration, or damage. Maintenance is up-to-date. F Fair Will function as intended. Normal wea...

AI summary The document presents a condition rating system for project components, categorizing them into Good, Fair, Poor, and Unsatisfactory based on their functionality and maintenance status. It also introduces a section on site inspection overview, which likely details the methodology or findings of inspections related to these components.

Other notable deficiencies; The horizontal crack repair on the dam section between the penstock intake and the spillway should be repaired properly with injection grouting techniques if this has not already been done. Where spalls and unde...

AI summary The document highlights deficiencies in dam maintenance, including the need for proper horizontal crack repair using injection grouting and adherence to ACI RAP Bulletin 4 for spall and undermining repairs. It also emphasizes the importance of monitoring seepage on the right side of the dam to detect potential internal erosion.

Note that the wave runup equation was not developped for dams with a vertical upstream slope, even though it is steeper than a 5H:1V slope. For concrete dams with vertical slopes, the freeboard is verified on the earthfill embankment. This...

AI summary The wave runup equation is not suitable for concrete dams with vertical upstream slopes. Freeboard is verified on the earthfill embankment, as concrete dams are more forgiving for waves passing over their crest compared to earthfill structures.

Table 4 presents the relevant dam characteristics and assumpations used for freeboard calculations and Table 5 presents the Wave Characteristics Calculations. Object : Factorydale Freeboard Analysis Date : December 17, 2024

AI summary The document provides a summary of freeboard analysis for Factorydale Dam, referencing Table 4 for dam characteristics and Table 5 for wave characteristics calculations, with the analysis dated December 17, 2024.

Note that the wave runup equation was not developped for dams with a vertical upstream slope, even though it is steeper than a 5H:1V slope. For concrete dams with vertical slopes, the freeboard is verified on the earthfill embankment. This...

AI summary The text discusses the wave runup equation not being developed for dams with vertical upstream slopes, noting that freeboard is verified on earthfill embankments. Concrete dams are considered more forgiving for waves over their crest compared to earthfill structures. The analysis was reviewed by Perry Mitchelmore, P.Eng, for the Berwick Electric Commission.

Results of the sliding stability analysis are presented in [Table 3.4.](#page-0-97) The dam complies with the standards-based criteria in the CDA guidelines for "Usual", "Unusual", and "Extreme" loading conditions for concrete structures.

AI summary The sliding stability analysis results show that the dam meets CDA guidelines for concrete structures under 'Usual', 'Unusual', and 'Extreme' loading conditions.

Results of the sliding stability analysis are presented in [Table 3.6.](#page-0-43) The section complies with the standards-based criteria in the CDA guidelines for "Usual", "Unusual", and "Extreme" loading conditions for concrete structur...

AI summary The document presents results of a sliding stability analysis in Table 3.6 and states that the section complies with CDA guidelines for concrete structures under 'Usual', 'Unusual', and 'Extreme' loading conditions.

Results of the sliding stability analysis are presented in [Table 3.12.](#page-0-95) The spillway complies with the standards-based criteria in the CDA guidelines for "Usual", "Unusual", and "Extreme" loading conditions for concrete struct...

AI summary The spillway's sliding stability analysis results show compliance with CDA guidelines for various loading conditions, including 'Usual', 'Unusual', and 'Extreme', for concrete structures.

Sensitivity analysis was performed on the spillway to assess the significance of soil conditions beneath the section. The structure found on bedrock, but the condition of the underlying rock may vary. The potential failure mode was sliding...

AI summary A sensitivity analysis was conducted on a spillway structure to evaluate the impact of varying soil and rock conditions beneath it. The analysis identified sliding stability as the critical failure mode, particularly when the friction angle between the concrete base and underlying rock drops below 36°, leading to potential instability during 'Usual' and 'Unusual' loading conditions.

4.0 SUMMARY & RECOMMENDATIONS Areas of the right gravity dam that were not post-tensioned in 2008 remain at risk of deformation. There were no observations to indicate the area is experiencing deformation to-date. The analysis concluded th...

AI summary The analysis identifies potential risks to the right gravity dam and Factorydale Spillway if certain conditions occur, such as relaxation of rock anchors or deterioration of the concrete-bedrock interface. However, no current deformation or deterioration has been observed, and both structures comply with safety standards under normal and extreme scenarios.

Types of Analysis Sliding Overturning Load Conditions Load Combinations FoS Usual D+H+I+Sh+U 1.5 one-third Usual (No Ice) D+Hf+Sh+U 1.5 one-third Unusual (Flood) D+Hf+Sh+Uf 1.3 one-half Unusual (Temperature) D+H+I+Sh+U+T 1.3 one-half Extre...

AI summary The text presents a table outlining different load conditions and their corresponding factors of safety (FoS) and overturning stability ratios for various scenarios, including usual, unusual, and extreme conditions. It includes load combinations and stability criteria for structural engineering analysis.

System Total Score Data Quality Indicator Turbine 0 4 Generator 7.05 7 Circuit Breakers 6.6672 0 Governor 7.34 0 Batteries 10 0 Cranes 8.133 7 Emergency Closure Gates and Valves 5 4 Hysovent concluded that "the plant is in relatively good...

AI summary Hysovent's Condition Assessment Report indicates that the plant is in relatively good condition, except for the turbine and its mechanical components, which are destroyed. The report recommends a proper maintenance program for the entire facility and its assets, as well as additional recommendations related to operations, maintenance, rehabilitation, and upgrades.

21 and $5.89 million, excluding tax. BEC further explained that the two options have similar estimated costs. However, compared with Option A, Option B would provide the following additional benefits: …The proposed new unit provides increa...

AI summary BEC is evaluating two options for a new turbine, noting similar costs but additional benefits from Option B, including increased capacity and efficiency. The rate impact of the project remains uncertain, and BEC plans to file a General Rate Application in 2026. The document also highlights the absence of an OMS manual at Factorydale Dam, with a need for documented standard practices.

Conclusion The project was evaluated under three options: Option A, a like-for-like replacement; Option B, replacement with a new, larger system and improved control and operation systems; and Option C, decommissioning the facility and pur...

AI summary The Board approved BEC's application to replace the damaged system with a larger, more efficient one (Option B). The decision was based on cost-effectiveness and long-term benefits, including reduced O&M costs and better monitoring. The Board emphasized the need for improved maintenance and record-keeping practices.

Request IR-1: - Please compare the technical specifications of the existing transformer and the proposed new - transformer.

AI summary Request IR-1 seeks a comparison of technical specifications between the existing transformer and the proposed new transformer.

Request IR-4: - On page 1 of the Application under introduction, BEC noted that there have been several major - incidents that happened on the system that damaged the turbine and wicket gates, including - incidents in 2006 and 2023. Paragr...

AI summary Request IR-4 seeks clarification from BEC regarding past turbine damage incidents (2006, 2023), including mitigation measures, protective device efficacy, inspection protocols, and root cause investigations. Questions focus on system reliability, infrastructure safeguards, and corrective actions.

Request IR-11: - What is the expected useful lifespan of the following items listed in the cost estimate on page 3: - (a) turbine 650 kW; - (b) 600 kW Generator, 600 RPM; - (c) hydraulic power unit, servos and field piping; - (d) controls...

AI summary Request IR-11 seeks clarification on the expected useful lifespan of eight specific equipment components listed in a cost estimate on page 3, including turbines, generators, transformers, and hydraulic systems, to inform capital expenditure planning and asset management strategies.

Request IR-19: - With respect to the three dams: - (a) What is the expected remaining useful life of each of the three dams and how was this determined? - (b) When were the dams last assessed in accordance with the Canadian Dam Association...

AI summary Request IR-19 seeks information about three dams, including their remaining useful life, assessment history per Canadian Dam Association Guidelines, and financial viability of refurbishment versus turbine replacement. Questions focus on infrastructure planning, asset management, and cost-effectiveness considerations.

Request IR-23: - Will the project replace the batteries or cranes? If so, given their Tier 1 condition index score, - why?

AI summary Request IR-23 inquires whether a project will replace batteries or cranes, citing their Tier 1 condition index score, and seeks justification for such replacement decisions.

Request IR-24: - Page 76 of Condition Assessment states: "…there is one global recommendation: a proper - maintenance program for the entire facility and its assets." Will this program be prepared as part - of the proposed project?

AI summary The Condition Assessment recommends a comprehensive maintenance program for the facility and its assets, raising a question about whether this program will be included in the proposed project.

Request IR-27: On page 93 of Condition Assessment, in referring to the like-for-like replacement, it states, "There is no government aid on these scenarios, because we are not increasing the output." What is the - least amount of output in...

AI summary The document contains six regulatory requests (IR-27 to IR-32) seeking clarifications on government aid thresholds, O&M cost calculations, financial analyses under different debt rates, evaluation scenarios for replacement options, freshet season timing, and equipment differences between refurbishment and like-for-like replacement options.

Request IR-35: - In several sections of Condition Assessment, Hysovent noted that consistent maintenance records and technical specifications for various equipment were not available. - (a) Please describe BEC's routine maintenance schedul...

AI summary Request IR-35 seeks details on BEC's maintenance schedules, record-keeping practices, and procedures for its generating facilities and proposed new systems, citing incomplete maintenance records and technical specifications as noted in the Condition Assessment.

System Total Score Data Quality Indicator Turbine 0 4 Generator 7.05 7 Circuit Breakers 6.6672 0 Governor 7.34 0 Batteries 10 0 Cranes 8.133 7 Emergency Closure Gates and Valves 5 4 Hysovent concluded that "the plant is in relatively good...

AI summary Hysovent's Condition Assessment Report indicates that the plant is in relatively good condition, except for the turbine and its mechanical components, which are destroyed. The report recommends implementing a proper maintenance program for the entire facility and its assets, along with additional recommendations for operations, maintenance, rehabilitation, and upgrades.

21 and $5.89 million, excluding tax. BEC further explained that the two options have similar estimated costs. However, compared with Option A, Option B would provide the following additional benefits: …The proposed new unit provides increa...

AI summary BEC is evaluating two options for a new turbine, noting that Option B offers increased capacity, efficiency, and reliability, along with a 22% reduction in O&M costs. However, the rate impact of the project remains uncertain, depending on future GRA filings and Board decisions. Additionally, BEC lacks an OMS manual for Factorydale Dam, though standard practices are in place.

Conclusion The project was evaluated under three options: Option A, a like-for-like replacement; Option B, replacement with a new, larger system and improved control and operation systems; and Option C, decommissioning the facility and pur...

AI summary The Board approves BEC's application to replace the damaged system with a larger, more efficient unit (Option B) over other alternatives. The decision is based on cost-effectiveness, better financing opportunities, and improved operational performance. The Board emphasizes the need for improved maintenance and record-keeping practices moving forward.