FIELD SERVICE ENGINEERING IN HYDROPOWER AS A BUSINESS STRATEGY

Field Service Engineers (FSEs) in hydro construction are pivotal in ensuring the successful installation, commissioning, and operation of hydromechanical equipment. This article explores their critical responsibilities, including managing technical plans, ensuring compliance with safety standards, and supervising the assembly of components like penstocks, turbines, and valves. By integrating practical recommendations with insights from high-quality sources, this paper provides a comprehensive guide for FSEs operating in hydropower projects.

Personal reflections are structured using a novel argumentation methodology, emphasizing critical thinking and real-world application.

Introduction

In the rapidly evolving landscape of global energy, hydropower remains a cornerstone of sustainable electricity generation, offering both flexibility and reliability.

Hydropower remains a cornerstone of renewable energy, contributing 16% to global electricity production (IEA, 2021). The complexity of hydro construction demands specialized expertise, particularly from FSEs who bridge design, installation, and operational phases.

FSEs oversee critical components such as penstocks, turbines, and draft tubes, ensuring structural integrity, operational efficiency, and safety compliance.

These professionals serve as the pivotal link between design and reality, translating complex engineering schematics into operational assets. Their role transcends mere technical execution; it encompasses a rigorous commitment to precision, safety, and performance optimization within the unique and demanding environment of hydro construction.

This article provides practical recommendations for FSEs in hydro construction, delves into the multifaceted responsibilities of a Field Service Engineer, highlighting their engagement with technical documentation, their unwavering dedication to compliance and safety, and their direct supervision over the installation and commissioning of critical hydromechanical equipment.

The discussion is supported by industry best practices and authoritative sources to ensure reliability and applicability.

1. Technical Plans and 3D Modeling for Precision Execution

1.1 The Importance of 3D Modeling in Hydro Construction

Modern hydropower projects rely on 3D modeling and digital twins to optimize design, detect clashes, and simulate operational conditions before physical installation. According to EPRI (2023), digital twin technology enhances penstock performance monitoring, reducing failure risks during operation.

These models are essential for aligning penstock geometry with terrain constraints and turbine inlet conditions (AWWA, 2017).

 Recommendations for FSEs:

Utilize Building Information Modeling (BIM) for clash detection and spatial coordination.

Verify that as-built models match design specifications before fabrication.

Collaborate with design engineers to resolve discrepancies early, minimizing rework.

1.2 Commissioning Checklists for Systematic Validation

A structured commissioning checklist ensures no critical step is overlooked. The AWWA M11 (2017) guidelines emphasize systematic inspection protocols for steel pipe installations, applicable to penstocks and pressure conduits.

Commissioning ensures equipment operates as intended. The Electric Power Research Institute (EPRI) highlights the use of digital twins for penstock performance monitoring, which FSEs can leverage to validate system performance (EPRI, 2023). A robust checklist includes hydraulic testing, alignment verification, and control system calibration.

Key Checklist Items:

✔ Pre-installation checks: Material certifications, weld procedures, and coating integrity.

✔ Alignment verification: Laser-guided surveys for penstock and turbine positioning.

✔ Pressure testing: Hydrostatic and pneumatic tests per CECT standards.

Recommendation: Develop standardized checklists aligned with AWWA M11 guidelines for steel pipe installation (American Water Works Association, 2017). Include real-time data from digital twins to monitor stress and flow during commissioning.

2. Ensuring Technical Compliance and Operational Safety

2.1 Regulatory and Industry Standards

Hydropower components must comply with:

CECT guidelines for welding and fabrication.

IEA (2021) Hydropower Special Market Report recommendations for sustainable and safe designs.

AWWA M11 (2017) for steel pipe installation best practices.

FSE Responsibilities:

Conduct Non-Destructive Testing (NDT) on welds (UT, RT, MPI).

Verify bolting torque values on flanged connections.

Ensure corrosion protection (e.g., cathodic protection for submerged penstocks).

 2.2 Risk Mitigation in Hydromechanical Installations

Common hazards in hydro construction include:

Penstock bursts due to poor welding or material defects (NPEC Blog, n.d.).

Turbine misalignment, leading to vibrations and premature failure.

Mitigation Strategies:

Implement real-time strain gauges on penstocks (EPRI, 2023).

Enforce lockout-tagout (LOTO) during maintenance.

Conduct Fatigue Life Analysis on high-stress components.

3. Orchestrating Deployment: Supervision of Hydromechanical Equipment

The core of the Field Service Engineer’s duties lies in the direct supervision of the installation, assembly, commissioning, and inspection of a wide array of hydromechanical equipment.

This comprehensive oversight ensures that complex machinery functions seamlessly as an integrated unit.

Key components under the FSE's purview include:

Draft Tube: This critical component, located at the turbine outlet, efficiently recovers kinetic energy from the water exiting the runner, converting it into pressure energy.

The FSE supervises its precise alignment and watertight sealing, often involving intricate concrete pours and specialized jointing.

Turbine installation demands micron-level precision.

FSEs constantly supervises and verifies:

Rotor-stator alignment

Shaft runout measurements

Draft tube cone sealing and vibration damping

Spiral Case (or Scroll Case): Encircling the turbine runner, the spiral case distributes water uniformly around the turbine, minimizing hydraulic losses. Its fabrication and installation require extreme precision to ensure concentricity and structural integrity against immense pressure. The FSE meticulously checks welds, internal surface finishes, and bolting sequences.

FSEs constantly supervises and verifies:

Flange & joints alignments,

Dimensional checks

Stress-relieving welds.

 Penstocks: These large-diameter pipelines transport high-pressure water from the reservoir to the turbines. As detailed by NPEC, penstocks are vital conduits subject to significant static and dynamic pressures (NPEC, n.d.). The FSE oversees the installation of penstock sections, ensuring proper support, expansion joints, and corrosion protection. Their supervision includes hydrostatic testing to verify leak tightness and structural soundness before operation.

The Penstocks must distribute flow, FSEs validate:

Geometric conformity via laser scanning

Weld seam inspections using ultrasonic testing

Pumping unit priming and backflow prevention

Valves: Various types of valves (e.g., butterfly, spherical, needle) control water flow, isolate sections for maintenance, and provide emergency shutdown capabilities. The FSE ensures correct orientation, actuator calibration, and operational testing of each valve for reliable performance.

Turbines: The heart of the hydropower plant, turbines (e.g., Francis, Kaplan, Pelton) convert the hydraulic energy of water into mechanical energy. The FSE's involvement here is extensive, encompassing the precise alignment of the turbine runner, shaft, and generator, balancing, and initial spin testing. This phase requires an exceptional degree of accuracy to achieve optimal efficiency and minimize vibrations.

Pumping Units: In pumped-hydro storage plants, these units are crucial for moving water from a lower to an upper reservoir during off-peak hours. The FSE supervises the installation and commissioning of these powerful pumps, ensuring their efficient operation and integration into the plant's overall energy management system.

Business Leverage of Field Engineering in Hydropower

- Accelerated Commissioning = Faster ROI 

 Early and efficient commissioning led by skilled FSEs reduces time to energy production.

- After-Sales Intelligence 

 FSEs gather operational feedback and pain points from the field, feeding back into product development and client support services.

- Trust-Based Relationship Building 

 The on-site presence of a competent and communicative FSE reassures clients and reinforces the brand value of OEMs and service companies.

- Upselling and Embedded Business Development 

 By identifying operational inefficiencies or upgrade opportunities, the FSE becomes a strategic advisor, not just a technician.

Required Skills Beyond Engineering

To succeed in this new business-oriented role, the modern Field Service Engineer in Hydropower must combine technical depth with soft and commercial skills:

- Marketing Awareness: Understanding the value proposition of the company's solutions to promote upgrades and services effectively.

- Customer Communication: Ability to explain complex issues in simple terms, build trust, and manage client expectations under pressure.

- Digital Proficiency: Use of digital twins, condition monitoring tools, and AI platforms to support decision-making and reporting.

- Cross-Cultural & Multilingual Skills: Essential for multinational projects and cross-border collaboration.

 - Knowledge Transfer: Supporting training of operators and facilitating client independence—while maintaining a strategic support role.

Field Service as an Embedded Business Strategy

Companies that embed Field Service Engineering in their customer success strategy benefit from:

- Improved client retention 

- Higher conversion of maintenance contracts 

- Continuous innovation through client insight 

- Reduced legal risks and operational disruptions

Hervé YIMGNA MENGOUO,

MCIOB Construction Site Manager et Business Intelligence Analyst in EPC Projects