Document No Revision No Project Nuoc Che HPP (2 x 15 MW) Document No NCHE – SI 002 Project code 1819 02 Revision no A No of pages 45 Date 01 05 2020 ERECTION INSTALLATION MANUAL VERTICAL FRANCIS TUR.
Project Nuoc Che HPP (2 x 15 MW) Document No NCHE – SI -002 Project code 1819 - 02 Revision no A No of pages 45 Date 01.05.2020 ERECTION & INSTALLATION MANUAL VERTICAL FRANCIS TURBINE NOUC CHE HYDRO POWER PROJECT (2 X 15 MW) CLIENT: NUOC CHE HYDROPOWER JOINT STOCK COMPANY HEMLET -1 (VIETNAM) INDEX DATE Prepared By NAME Date PARTICULAR Checked By DD-100-101 / 08 February, 2019 / Rev * Date Approved By Date Page of 46 FOREWORD The installation procedure mentioned herewith is proposed for Vertical Francis Turbines This procedure will show the assembly of components of Vertical Francis Turbine at site The method described is based on our experience, but it is by no means the only option Almost at every site, there are things and reasons, which can prevent the erection Engineer from following written instructions, and he must find his own solution This procedure shows the general guidelines for erection of Vertical Francis Turbines Drawings and sketches enclosed in this procedure have been taken from one similar vertical Turbine for reference only Detailed information is provided in respective drawings only and the erection Engineer should thoroughly study the drawings and make his own detailed plan accordingly for carrying out the erection work The erection plan is to be made well in advance, for which the following inputs are required 1) Contract agreement 2) All the necessary drawings required to execute the project 3) Installation time schedule 4) Safety requirements 5) Own Product and other materials packing lists 6) Tools and Plant 7) Instruction Manuals 8) Quality protocols 9) Skilled manpower While reviewing this procedure, the erection Engineer should remember the following details of activities, which are normally used for erection of Vertical Turbines Laying of Earth mat and first stage embedded parts are being done in the initial stage as per approved drawing 2) Draft tube, Turbine spiral casing, distributor assembly, pit liner Assembly and Main inlet valve, thrust relief assembly, shaft seal assembly, inflatable seal assembly are individual equipment assemblies and are classified under static water path equipment 3) Runner assembly with turbine shaft, Generator assembly, generator shaft and turbine shaft coupling, exciter rotor, air injection assembly and Water Collector Assembly are also individual assemblies classified under Rotary equipment 1) DD-100-101 / 08 February, 2019 / Rev * Page of 46 Installation of the auxiliary systems, Hydraulic system, wiring, terminations of cable in panels to control the operating system of the turbine and auxiliaries etc are to be generally performed after installation of turbine static & rotary parts 5) Insert plates should be left, if possible, on wall as well as on floor for clamping hydraulic and water Pipes, which are generally shown in drawings 4) DD-100-101 / 08 February, 2019 / Rev * Page of 46 CONTENTS 1) 2) Technical Particulars Pre‐Conditions & Preparations 2.1) Preliminary 2.2) Preconditions 3) Elevation of the unit 3.1) Main axis of the unit 3.2) Benchmarks 4) Assembly procedure First stage Embedments and concreting Erection & alignment of draft tube elbow and second stage concreting Draft tube cone -3 and cone -2 assembly Spiral case assembly with distributor and draft tube cone -1, if possible or in two parts First upper ring after lower assembly with guide vanes and draft tube cone -1 4.1) 4.2) 4.3) 4.4) 4.5) 4.6) 4.7) Main Inlet valve, pit liner and generator base frame (base plate) assembly Third stage concreting Installation of rails at MIV floor to dismantle and assemble Draft Tube, Runner, lower distributor ring, etc 4.8) Dismantling of draft tube cone -2 4.9) Dismantling of lower ring with draft tube cone -1 4.10) Assembly of bearing housing, lowering of turbine shaft and mounting of shaft holding fixture Generator assembly Runner Assembly Lower ring assembly with draft tube cone -1 Turbine guide bearing assembly Air Injection assembly Draft tube cone -2 assembly 4.11) 4.12) 4.13) 4.14) 4.15) 4.16) 5) Auxiliary system Hydraulic pumping unit Generator bearing lube oil Cooling water system Reference Drawings & catalogues 6.1) Layout of power house, Drawing No F3P1819-0230101 6.2) First Stage concrete and embedment plan and section, Drawing No F1P18195.1) 5.2) 5.3) 6) 0230502 DD-100-101 / 08 February, 2019 / Rev * Page of 46 6.3) Second stage concrete and embedment plan and section, Drawing No 6.4) 6.5) 6.6) 6.7) 6.8) 6.9) 6.10) 6.11) 6.12) 6.13) 6.14) F1P1819-0230503 Draft tube Assembly Drawing No F1C1819-0210101 Spiral Casing assembly Drawing No F1C1819-0211601 Pit Liner assembly Drawing No F1C1819-0212001 & F1C1819-0212101 Turbine Assembly Drawing No F1C1819-0214401 Distributor Assembly Drawing No F1C1819-0211201 Shaft Assembly Drawing No F1C1819-0212805 Main Inlet Valve Assembly Drawing No T1C6001-5420001 Assembly & Handling Fixture (Assembly) Drawing No F1C1819-0215638 Air injection assembly Drawing No F1C1819-0216501 Outline drawing of A.C Generator Drawing No 10006288581 Hyd Schematic control diagram for Turbine, bypass assembly and MIV 6.15) 6.16) Control (Drawing No F3C1819-02M0502) Cooling Water System Drawing No F3C1819-02M0601 Hydraulic Schematic control diagram (For generator lube oil system) Drawing No F3C1819- 02M0511 Compressed air system Drawing No F1C1819-02M0801 6.17) 1) Technical Particulars Type of turbine - Vertical Francis Turbine Installed capacity - X 15MW Rated Head - 104.50 m Rated speed - 600 RPM Runner diameter - Ø1280 MM Main inlet valve Generator - Ø1900 MM WEG make, Type SSW 250, 17648 KVA, 10.5 KV, 10 Poles, DD-100-101 / 08 February, 2019 / Rev * Page of 46 Sense of rotation - Counter Clock Wise (Viewed from DE Side.) Pre‐Conditions & Preparations 2) With regard to installation time schedule, the main erection of the Francis turbine can commence only after first stage concreting In first stage concreting the insert plates should be left for turbine draft tube foundation bolts locking and ensures all embedded components installed according to the reference drawings The generator is installed and aligned after turbine installations 2.1) • Preliminary checking Before starting the erection, make sure that powerhouse civil work is completed in all respects including all opening in Power House • Check the entire foundation cutout and foundation pocket as per drawing and free movement of the crane operation and its brake system If possible, conduct the load test of the crane • Check the elevation level of the all sole plates and finish floor level • Check the axis of penstock in respect to machine center-line The readings are to be recorded and to be compared with benchmark as given by civil team surveyor in the power house • Check all the materials availability in store, sequence wise for easy flow of erection • Check the availability of front readiness to erect the component as per sequence and erection team experience in their respective fields, contractor’s tools & plants and the skilled manpower of sub-contractor 2.2) • • Preconditions The following preconditions to be fulfilled before commencement of the turbine installation; Mark the center-line of each unit (XX and YY axis) and transfer one elevation point on the wall or at a fixed position to get reference for elevation Get the reference center-line from the penstock, which has been installed or ask the civil contractor to give the reference center-line To be recorded in a joint protocol with customer DD-100-101 / 08 February, 2019 / Rev * Page of 46 • Check the level of the turbine and generator sole plate and record the actual level Note 1: In order to achieve a flawless function of the assembly, cleanliness is of prime importance throughout the installation process For this reason, the turbine components have to be protected from dirt and dust by appropriate means (PVC‐sheeting, etc.) For instance: During the installation of the rotating parts, only workers along with clean clothes, clean shoes and with white color cotton waste to clean the parts during assembly are allowed 3) Elevation of the unit When the turbine suppliers begin with the erection work of the unit, the theoretical axis and elevations of the turbine unit in the power house are the coordinates and position of penstock only the references as per design The reference points which are existing, unit center-lines and elevation should be marked by surveying contractor and / or civil contractor are actual and handing over to E & M contractor with an official protocol should be done These reference points are taken as the basis for the further installation of E & M equipment 3.1) Main axis of the unit The positioning of the Turbine Housing dictates the precise elevation of all the other turbine and generator components Theoretically, the horizontal center-line of the turbine is the reference axis as well as the shaft center-line is the reference elevation Practically, however, the center-line is difficult to establish by measurements Important is the exact alignment of the Turbine Housing inlet pipe with regard to the penstock connection point in elevation and position The horizontal center-line of the Turbine Housing should be aligned with the horizontal center-line of the penstock Therefore, the deviations regarding the theoretical inlet pipe axis in horizontal and vertical direction should be measured and recorded 4) Assembly Procedure Before erection, erection agency is requested to go through all instructions, sequence of assembly procedure and guidelines for smooth operation and test the performance of crane Check the load test of crane before lifting heavy equipment DD-100-101 / 08 February, 2019 / Rev * Page of 46 Frist 4.1) • • stage embedment and concreting First of all, cast the first stage concrete, embed the foundation plates / anchor plate for draft tube mounting, drainpipes etc as per B.O.M mentioned in first stage embedment’s and concreting drawing This is the most important phase of concreting, so read carefully the B.O.M of embedment and align this embedment as per drawing Fix the pipes in proper slope for easy drainage as per drawing, the sketch -1 is just for reference of sequence only DD-100-101 / 08 February, 2019 / Rev * Page of 46 SKETCH -1 4.2) Erection, alignment of Draft tube Elbow and second stage concreting Refer draft tube Assembly Drawing No F1C1819-0210101 and second stage embedment and concreting Drawing No F1P1819-0230503 • Before the installation of draft tube, check the accessories as per packing list as well as drawings related to draft tube erection & ascertain any physical damages and check the level of all the sole plates for correct position • Principal axis of the generating set is fixed by reliably secured brackets and bench marks Lower the draft tube elbow with the help of mobile crane / EOT crane • First of all proper positioning of draft tube is to be done Since this is the basic part of generating unit, its correct positioning will determine the correct installation of entire generating set • • Draft tube elbow to be aligned with respect to the turbine centerline and its elevation with the help of leveling/ adjusting screws mounted on Draft tube elbow feet • Lateral movement to be done by using turnbuckles with temporary welding with side supports to make convenient for movement on concrete floor • After alignment of draft tube it should be properly supported by sufficient packing and fixed (Refer to sketch-2 and detail A) Lock the draft tube firmly on its sole plate and all the nuts used for positioning/adjustment to be welded as shown, to restrict misalignment of draft tube during concreting, weld additional anchor bar or supports if required for better stiffening • After alignment of the draft tube and before second stage concreting connect the MIV upstream, downstream drain pipe and thrust relief pipe with the draft tube elbow as shown in sketch -2 DD-100-101 / 08 February, 2019 / Rev * Page of 46 SKETCH-2 DD-100-101 / 08 February, 2019 / Rev * Page 10 of 46 Runner assembly for sequence purpose only SKETCH -18 4.13) Lower ring assembly with lower Cone-1 • Check the gaps between upper labyrinth and runner; if any correction is required, correct and then lower ring assembly 32 • • • • • If everything is found correct, then make a record and fill protocol of gaps as attached for reference only The original protocol will be provided by design department Now, proceed for assembly of lower ring with guide vanes, regulating rings draft tube cone-1 Put upon the trolley and fix with fasteners as per fixture assembly Lower ring assembly arrangement SKETCH-19 Before lifting the assembly, dismantle all the bushings of guide vanes and make proper arrangement of long studs M30x 1000 mm with nuts at least Numbers to make easy for this heavy assembly Fix the or Nos of chain pulley block to avoid swinging If the arrangement is ready, then proceed for assembly for more detail of assembly refer the drawing No F1C1819-0211201 and F1C18190215638 sheet of 33 Lower ring assembly with DT cone and guide vanes SKETCH -20 34 PROTOCOL FOR REFERENCE PURPOSE ONLY FOR THE GAP CHECK SKETCH -21 35 4.14) Turbine Guide bearing Assembly • • • • • • • Before T.G.B assembly, check all materials availability and fitness as per B.O.M of drawing F1C1819-0213201 Sheets and Weld the generator sole plates with base frame and weld all taper wedges; all checks to be done finally Assemble all auxiliary assemblies i.e oil cooler and other assemblies as per drawing as mentioned above Mount the housing cover, fully tighten all the bolts, mount the oil shield assembly inside of housing but connected with the housing cover internally Now shaft is completely aligned at the center of turbine We have to maintain H7 and f7 tolerances for the dia 560mm between turbine guide pads and turbine shaft collar According to this tolerance, the maximum gap required is 0.07 mm however to take confirmation from design This is the main and important part of assembly to maintain this tolerance by measurement with micrometer at points, from the housing slot to shaft and maintain the record; all measurements should be the same, if not so, then correct by adjusting the cover before doweling 36 TURBINE GUIDE BEARING ASSEMBLY FOR REFERENCE ONLY SKETCH -22 • As mentioned on page 40, given below is the procedure of measurement the thickness of shim 37 • • • This is to be recorded as a protocol filled unit wise and sent to design for approval It is required to have inside and outside micrometers at site to measure 50 to 75 mm to complete this critical exercise of assembly After filling the records of shims sizes and gaps as per actual, mount the other pending assemblies as per drawing of turbine guide bearing Turbine guide bearing assembly in boxed up form SKETCH -23 38 39 • 40 4.15) Air Injection assembly • • • It is the assembly mounted on the top of Generator shaft The housing is mounted upon the Exciters housing Reference the drawing No F1C1819-02116501 for detail to assist in assembly Air Injection assembly as reference only SKETCH -23 4.16) Draft tube cone -2 assembly 41 SKETCH -24 42 • • After completion of all major items concerned with the major assembly and final checks, box up the Draft tube cone -2 finally Sketch -24 is the reference showing the completed the assembly of generating unit Draft tube cone assembly procedure SKETCH -25 43 • • • • 5) 5.1) Earlier we have referred and assembled the Draft tube cone -2 and thereafter other assemblies Now, we can proceed to box up the entire unit by the assembly of draft tube cone -2 Before tightening the draft tube fix numbers dial gauges in position opposite to each diagonally The fixing of dial gauge shown in sketch -25 So first maintain the dismantling joint gap, then tighten the upper nuts slowly by monitoring all four dial gauges continuously The cone should not be in tension; after tightening, it should be identical in all four dial gauges Auxiliary Systems Hydraulic Oil Pumping unit (OPU) An oil pumping unit is provided for normal & emergency control operation of turbine and Main Inlet Valve (Ball Valve) This unit consists of a Motor pump arrangement mounted on the fabricated tank wherein the hydraulic oil is filled and different type of controlling valves, filters; pressure control switches, system pressure relief valve etc are mounted over the tank When the motor and pump arrangements is started, the set pressure develops in the system and pressurized oil passes through the different pipe routes to the required actuator to perform the opening and closing of the cylinder and thus the regulation of turbine takes place The oil pumping Unit is used for the following applications: • By Pass valve operation • Main inlet valve operation • Guide vane operation • Air injection Operation • Generator brake application Ref Drawing No F3C1819-10M0502 for Hydraulic schematic control diagram (Turbine and MIV Control) for detail information Also, please refer the separate 44 detailed manual supplied along with unit for operation and maintenance guidance 5.2) Generator Bearing Lube Oil System (GLOP) Generator bearing lube oil system is designed for continuous supply of lubrication oil to generator bearings Low pressure, filtered and cooled oil is used to provide lubrication for both the generator bearings Oil is pumped through the pump and motor arrangements mounted on the steel fabricated tank further oil passes through filters, different controlling valves to the bearings by suitable sizes of field piping to the bearings When oil enters the bearings, it extracts the heat from the bearings and returned back to the GLOP tank through the heat-exchanger system wherein the oil gets cooled and again the same oil goes to the bearings and process repeats Also, please refer the separate detailed manual supplied along with unit for operation and maintenance guidance 5.3) Cooling water system (CWS) The cooling water system is incorporated in the plant for water supply to the Heat-exchanger of Generator Lube oil system A common cooling water sump is made for the purpose and sump is connected to the tail race of both units with an embedded pipe in order to receive the water from tail race Three Centrifugal type pumps have been used (Two main+ one standby) for the water suction from sump and same can be mounted over the sump top slab Each pump is having separate suction pipes connected from pump inlet to the sump and delivery pipes from all the pumps is connected to a common header and a single pipe line is further connected to the duplex type coarse filter arrangement for trapping the foreign course materials like sand, stones, wood pieces, etc In delivery line of each pump, the pressure switches are provided to monitor the water pressure coming out from pump After filtering of water from coarse filter, the line is connected to the fine filter system same like coarse filter arrangements and here the small foreign items which remains during coarse filtration gets trapped and clean water is further supplied to the GLOP heat-exchanger and after heat-exchanger, the hot water can be released to the tail race channel 45 The several monitoring instruments like, pressure switches, pressure gauges, flow switches, flow control valves, etc are provided in the pipe lines to ensure and monitor the required flow and pressure to the heat-exchanger These instruments are connected to the Turbine control panel and an alarm and trip value can be set for alarm/stopping of the machine in case of low flow or pressure An overhead tank is provided in the system and which is directly connected to the water supply line to the heat-exchanger this water can be used in case of emergency like pump failure, severe leakage of pipes, etc.to ensure the continuous water supply to the heat-exchanger till the machine gets stand still condition For Piping and instrument mounting details please refer the drawing No F3C1819-10M0601 46 ... F3C1819-10M0502 for Hydraulic schematic control diagram (Turbine and MIV Control) for detail information Also, please refer the separate 44 detailed manual supplied along with unit for operation... prevent the erection Engineer from following written instructions, and he must find his own solution This procedure shows the general guidelines for erection of Vertical Francis Turbines Drawings... Turbine for reference only Detailed information is provided in respective drawings only and the erection Engineer should thoroughly study the drawings and make his own detailed plan accordingly for