GBT 8564-2003 Specification Installation of Hydraulic Turbine Generator Units.doc

4.18 The anti-corrosion paint on various parts of hydraulic turbine generator unit shall meet the following requirements: a Surface pretreatment and coating protection shall be conducted

5 Installation of Vertical Reaction Turbine

6 Installation of Through Flow Turbine

7 Installation of Reaction Turbine

8 Installation and Commissioning of Speed-Governing System

9 Installation of Vertical Hydraulic Turbine Generator

10 Installation of Horizontal Hydraulic Turbine Generator

11 Installation of Bulb Hydraulic Turbine Generator

12 Installation of Pipelines and Fittings

13 Installation of Butterfly Valve and Globe Valve

14 Electrical Tests on Hydraulic Turbine Generator Unit

15 Trial Run of Hydraulic Turbine Generator Unit

Appendix A (Informative Appendix): List of Hand-over Documentation

Appendix B (Normative Appendix): Installation requirements of mechanical hydraulic governor

Appendix C (Normative Appendix): Requirements on the drying of hydraulic turbine generator stator Appendix D (Informative Appendix): Pickling, Passivation and Rinsing of Pipe

Appendix E (Informative Appendix): Standards Related to Nondestructive Inspection of Welds

Appendix F (Informative Appendix): Requirements on Steam Turbine Oil Stipulated in GB11120-1989 Appendix G (Normative Appendix): Description on Standard Wording

Foreword

This standard covers the installation, commissioning and test for hydraulic turbine generator units and their auxiliary equipment It is also the main content involved in the acceptance test and examination for generator units It is applicable for the installation of various hydraulic turbine generator units and their auxiliary equipment

This standard is the revision of GB 8564-1988 Specification Installation of Hydraulic Turbine Generator

Units (The Original Standard in short hereafter) The Original Standard is a summary of Chinese

professionals on the installation of hydraulic turbine generator units and their auxiliary equipment based

on the accumulated experience by 1988 This standard has made some supplements, deletion and modifications on the basis of The Original Standard according to the requirements in the installation of numbers of newly-built large- and medium- scale hydraulic turbine generator units and their auxiliary equipment including the imported large-scale hydraulic turbine generator units, and at the same time assimilating some contents in the relevant foreign standards

Compared with the 1988 version of GB 8564-1988, this standard has made the following revisions:

— This standard is defined as a recommended standard;

— The applicable scope of this standard is revised, and the sections “Scope” and “Normative

References” are listed separately;

— New contents are added, including installation of cylinder valve, installation of reaction turbine and bearing assembly, assembly of welded rack of generator, on-site assembly of generator stator frame and iron core, welding of disc- rotor field spider, installation of excitation system, and trial operation of reversible pumped-storage generating unit so on;

— Some contents are supplemented, including governor installation, oil filling and adjustment test of speed-governing system, requirements on pipeline welding technology, and quality inspection so on;

— Some contents are deleted from the text, e.g installation of mechanical-hydraulic governor, exciter and permanent magnetic generator The contents on installation of mechanical-hydraulic governor and drying of stator winding are listed as appendices;

— The indexes and limits in some clauses are partially adjusted and improved

Internal water cooling or evaporative cooling stator windings have been applied in some generator units

in China However, these cooling methods are still immature in design and construction experiences and unlikely to be expanded rapidly in application, so we haven’t introduced them into this standard in this revision

This standard will replace GB 8564-1988 as of its effective date

Appendix B, Appendix C and Appendix G of This standard are normative appendices

Appendix A, Appendix D, Appendix E and Appendix F of This standard are informative appendices This standard are proposed and controlled by China Electricity Council Standardization Center

The enterprises participating in the drafting of This standard include: China Gezhouba (Group)

Corporation, China Water Conservancy and Hydropower Construction Corporation, China Yangtze Three Gorges Project Development Corporation, and Harbin Electrical Machinery Company Limited

The main drafters of This standard include: Fu YuanChu, Zhang Ye, Wang LongQuan, Qin XiXiang, Liu YongDong, Zhao ShiRu, Li ZhengAn, Zhang YaoZhong, Du QiChen, Zhang LianBin, Zhao GuiShan, Xu GuangTao, Gong DePing, Want Tian, Yang XiYin, Huang HongYong, Zhang ChengPing, Liu YanHua,

Jiang XiaoBin, Yin LongSheng, Liu ChanXue, and Tang WanBin

China Electricity Council Standardization Center reserves the ultimate right for the interpretation of this standard

a) Single unit capacity no smaller than 15MW;

b) Reaction turbine, with the nominal diameter of runner no less than 1.5m;

c) Mixed-flow turbine, with the nominal diameter of runner no less than 2.0m;

d) Axial, diagonal or through flow turbine, with the nominal diameter of runner no less than 3.0m

For the hydraulic turbine generator units of single-unit capacity smaller than 15MW and the generator units with turbine runner of nominal diameter less than the limits given in b), c) and d), This standard can serve as a reference

This standard is also applicable for the installation and acceptance test of reversible pumped-storage generator units

2 Normative References

The terms in the following documents are becoming an integral part of this standard by quoting All the modifications (excluding corrigenda) or revisions following the quoted documents marked with date are not applicable for this standard However, the parties involved in the standard are encouraged to search for the possibility to apply the new versions of these quoted documents As for the quoted documents without marked with certain date, the latest versions shall be complied with for the standard

GB/T 3323 Methods for radiographic inspection and classification of radiographs for fusion welded butt joints in steel

GB/T 7409.3 Excitation system for synchronous electrical machines Technical requirements excitation system for large and medium synchronous generators

GB/T 10969 Specifications for water passage components of hydraulic turbines

GB 11120 LTSA turbine oil

GB/T 11345 Method for manual ultrasonic testing and classification of testing results for ferritic steel welds

GB/T 18482 Start-up test code for reversible pump-storage units

GB 50150 Standard for hand-over test of electric equipment electric equipment installation

engineering

GB 50168 Code for construction and acceptance of cable levels electric equipment installation engineering

GB 50171 Code for construction and acceptance of switchboard outfit complete cubicle and

secondary circuit electric equipment installation engineering

DL/T 507 Start-up test code for hydraulic-turbine and generator units hydraulic turbine generator unit

DL/T 679 Code for welder technical qualification

DL/T 827 Start-up test code for through flow type bulb turbine generator units

JB/T 4709 Welding specification for steel pressure vessels

JB/T 6204 Code for insulation resistance and withstanding voltage test of large-scale high-voltage

AC generator’ stator

JB/T 8439 Anti-corona technical requirement for high-voltage generator used at high altitude

JB/T 8660 Specification on packing, transportation and preservation of hydraulic turbine generator units

3 General

3.1 The hydraulic turbine generator unit shall be installed according to the installation drawings and relevant design documents for the generator unit reviewed and confirmed by the design division and the manufacturer, as well as the requirements specified in this standard In the case of any special

requirements of the manufacturer, the requirements on the manufacturer’s relevant technical documents shall be complied with Supplemental provisions shall be made for the contents without requirements specified either in the standard or the manufacturer’s technical documents Should the manufacturer’s technical requirements conflict with the standard, generally the manufacturer’s requirements shall govern Otherwise, relevant agreement shall be reached with the manufacturer

3.2 Besides this standard, the relevant requirements given in the currently effective specifications on safety, environment protection and fire control etc issued by the state or relevant ministries shall also be complied with in the installation of generator units and their auxiliary equipment

3.3 The equipment of hydraulic turbine generator unit shall comply with the currently effective national technical standards and the requirements given in the purchase order After the equipment arriving at the destination, the installation enterprise can request to the owner for taking part in the open package inspection according to JB/T8660

The following documents shall serve as the base simultaneously for the installation and acceptance test

of generator units and their auxiliary equipment:

a) The instructions for equipment installation, operation and maintenance, and the relevant technical documents;

b) All drawings and data provided along with the equipment (including the equipment assembly drawing and the constructional drawings of parts);

c) Quality certificate, inspection and test records of the equipment;

d) Material certificates for main parts

3.4 Prior to the installation of generator unit, the design drawings, delivery inspection record and relevant documents provided by the manufacturer shall be read carefully and familiarized, and

reasonable construction organization design shall be made according to the actual construction

situation

3.5 Prior to the installation of generator unit, the installation enterprise shall read the relevant civil design drawings related to the installation and participate in the acceptance test of the civil work handed over for installation Any found defects shall be removed before starting the installation

3.6 All materials used for the installation of hydraulic turbine generator unit shall meet the design requirements The inspection report and quality certificate shall be provided for main materials

3.7 The installation site shall be planned uniformly and shall meet the following requirements:

a) The installation site shall be proof of wind, rain and dust The installation of generator unit can be started only after the roofs of workshop buildings in the generator unit section and the adjoining

generator unit sections have been closed completely;

b) The temperature at the installation site shall generally no lower than 50ºC, and the relative humidity of air no higher than 85%; The equipment and parts of special requirements on temperature, humidity or others shall be installed according to the design requirements;

c) Adequate lighting shall be provided for the installation site;

d) The installation site shall be supplied with facilities for construction safety protection The site for storing flammable or explosive articles shall comply with the relevant safety requirements;

e) The installation shall be conducted according to the site regulations The installation equipment, instruments, tools and construction materials shall be stocked in order, the site shall be kept clean, the passage shall be kept unblocked and the site shall be cleaned off after work

3.8 Upon the completion of the installation of hydraulic turbine generator unit, trial run shall be

conducted to comprehensively inspect the design, manufacture and installation quality of the generator unit according to the requirements given in the standard and DL/T 507 Following the passing of trial run, the acceptance test shall be carried out for the startup of generator unit, and relevant data shall be handed over referring to the requirement set forth in Appendix A

4 General Requirements

4.1 General cleaning and inspection shall be conducted before installing the equipment The main dimensions and fitting tolerances of key parts shall comply with the drawing requirements and shall be checked with the factory records

Records and relevant signatures shall be maintained for equipment inspection and defect treatment The supplied equipment delivered as assembled with the manufacturer’s quality warranty shall not be decomposed during the warranty period

4.2 The footplates of equipment foundation shall be embedded generally with the elevation deviation not exceeding -5mm~0mm, the deviation in center and position no more than 10mm, and the level deviation no more than 1mm/m

4.3 The embedded components shall be fixed reliably after being installed The foundation bolts, jacks, tensioners, wedge plates and foundation plates etc shall be fixed by spot welding The jointing planes between embedded components and concrete shall be free of oil stain or severe corrosion

4.4 The installation of anchor bolts shall meet the following requirements:

a) The position of anchor bolt holes shall be correct, and the burr on the inner wall shall be cleaned off The deviation between the central line of bolt hole and that of foundation shall be no more than 10mm; The elevation and the depth of the bolt holes shall meet the design requirements; The vertical deviation

of bolts hole wall shall be smaller than 10mm and no more than L/200 (L refers to the length of anchor bolt, mm, the same below);

b) The center and elevation of the anchor bolts buried directly or with conduit into the second-phase concrete shall meet the design requirements The center deviation shall be no more than 2mm, the elevation deviation no more than 0 mm~+3 mm, and the vertical deviation shall be smaller than L/450;

c) In the case that preembedded reinforced steel is applied for the welding of screws on anchor bolts, the following requirements shall be satisfied:

1) The material of preembedded reinforced steel shall be consistent with that of anchor bolt;

2) The sectional area of preembedded reinforced steel shall be larger than that of anchor bolt, and the preembedded reinforced steel shall be vertical;

3) Should double side welding be applied between bolt and preembedded reinforced steel, the weld length shall not be smaller than 5 times of anchor bolt diameter; In the case of single side welding, the weld length shall not be smaller than 10 times of anchor bolt diameter

4.5 The wedge plate shall be used in pairs and the jointing length shall be more than 2/3 For the wedge plates for bearing key components, 0.05mm feeler shall be used to check the contact after the

installation The contacting length on each side shall not be more than 70%

4.6 The equipment can be installed only after the strength of foundation concrete reaches 70% of the designed value The second-phase concrete for foundation plates shall be laid densely and solidly

4.7 The jointing planes of equipment shall be smooth and free of burr The jointing gap shall be check with 0.05mm feeler that unable to pass through; the allowed local gaps shall be check with 0.10mm feeler that the depth shall not exceed 1-3 of the jointing width, and the overall length shall not exceed 20% of the perimeter; No gap is allowed around the jointing bolts or dowels The step on the installing plane of jointing seam shall not exceed 0.10mm

4.8 The fitting marks shall be noticed during the part assembling As multiple generator units are being

installed, each generator unit shall be assembled with the parts marked with the same series number

The numbering for the same type of parts or measuring points in the installation record shall start from +Y in clockwise sequence (seen from the end of generator, the same below) for stationary parts; or start from the position of No.1 pole of rotor in clockwise sequence (expect the measuring points on the shaft

in turning, which is in anticlockwise sequence) for rotating parts; The consistency with the numbering rule of the manufacturer shall be checked

4.9 For the connecting bolts with pretightening force, the deviation in prestressing force shall not exceed ±10% of the specified value Without certain requirements specified by the manufacturer, the pretightening force shall not be smaller than 2 times of the designed working pressure, but not

exceeding 3/4 of the material yield strength

As installing the connecting bolts with teeth, lubricant shall be applied on the thread; The connecting bolts shall be evenly tightened in times; sampling inspection (about 20%) shall be made at normal temperature for the heat-tightened bolts for checking the pretension

After completing the installation of various parts, the dowel holes shall be bored and the dowels shall be fitted according to the design requirements

The bolts, nuts and dowels shall be locked firmly as the design required

4.10 The general measurement on generator unit shall meet the following requirements:

a) All measuring instruments shall have been qualified the regular inspection and calibration conducted

by authorized metering organization

b) The error in X and Y reference axes and reference elevation point for the installation of generator unit shall not exceed ±1mm by contrast with the workshop benchmark;

c) The measurement error in the elevation difference of various parts shall not exceed ±0.5mm; d) The measurement error in level shall not exceed 0.02mm/m;

e) The diameter of the steel wire used for center measurement is generally ranged between

0.3mm-0.4mm, and the tensile stress shall be no less than 1200MPa;

f) No matter which method is applied for measuring the center or roundness of generator unit, the measurement error shall normally no more than 0.05mm;

g) The impact of temperature change on the measurement precision shall be taken into consideration The measured values shall be corrected according to the temperature change

4.11 In the hydrostatic pressure test for measuring the strength of site-made bearing equipment and connectors, the test pressure shall be 1.5 times of the rated working pressure, but the minimum pressure shall not be smaller than 0.4MPa Maintain the test pressure for 10min, and no defects like leakage or crack shall occur

In the tightness breakdown test of the equipment and connectors, the test pressure shall be l.25 times of the actual working pressure and maintained for 30min, no leakage shall occur In the tightness test, the test pressure shall be the actual working pressure and maintained for 8 hours, no leakage shall occur Hydrostatic pressure test shall be conducted for single cooler at the designed test pressure Without relevant specification in the design, the test pressure shall be normally 2 times of the working pressure, but no lower than 0.4Mpa Maintain the test pressure for 30min, no leakage shall occur

4.12 In the kerosene leakage test for equipment vessels, the test shall be kept for at least 4 hours, no leakage shall occur After completing the leakage test, the vessel should not be disassembled in

general

4.13 The single keys shall be examined combinedly with the key ways The tolerance shall meet the design requirements The keys in pairs shall be examined combinedly and the parallelism shall meet the design requirements

4.14 The welding of generator unit and its auxiliary equipment shall meet the following requirements:

a) The welders taking part in the welding of generator unit and its auxiliary equipment shall have been received the special training and qualified the examination according to DL/T679 or the manufacturer’s requirements;

b) The length and height of all welding seams shall meet the drawing requirements Welding quality shall

be inspected according the requirements of design drawings;

c) For the welding of key parts, the welding procedure made on the basis of welding process

assessment or the welding code of the manufacturer shall be complied with

4.15 The code of turbine oil used by the generator unit and the speed-governing system shall meet the design requirements with the various indexes satisfying the limits given in GB11120 (refer to Appendix F)

4.16 All monitoring device and automation elements of the generator unit shall be inspected and

qualified according to the delivery technical requirements

4.17 The hydraulic turbine generator unit shall be kept clean during the component assembling and overall assembling and after installation After installation, the generator unit shall be cleaned internally and externally thoroughly to remove any abnormal materials or stains

4.18 The anti-corrosion paint on various parts of hydraulic turbine generator unit shall meet the following requirements:

a) Surface pretreatment and coating protection shall be conducted in the manufacturer’s factory for various parts of generator unit according to the requirements given in design drawings;

b) The top coating to be applied on the site (including on-site welding) shall be conducted according to the design requirements Should the applied paint color be inconsistent with the workshop ornaments, appropriate modification can be made except the color of pipelines;

c) Should the surface coating on some part be damaged locally during the installation, repair shall be conducted according to the requirements on the original coating;

d) The coatings applied on the site shall be even in thickness, homogeneous in color and free of bubble

or wrinkle;

e) The parts to be painted on the site as specified in the contract or owing to particular requirements shall meet the relevant particular requirements

5 Installation of vertical reaction turbine

5.1 Installation of embedded components

5.1.1 The steel lining at the nose of central pier for the draft tube shall be installed to meet the following requirements:

a) The distance tolerance from the top of steel lining at the nose to the X axis of the generator unit:

±30mm;

b) The distance tolerance from the top of steel lining at the nose to the Y axis of the generator unit:

±15mm;

c) The elevation tolerance of the top (or bottom) of steel lining at the nose: ±10mm;

d) The verticality tolerance of the steel lining at the nose: 10mm

5 1.2 The draft tube liner shall be installed with the tolerance meeting the requirements given in Table 1

Table 1 The Installation Tolerance of Draft Tube Liner unit: mm

1 Dimensions of elbow section ±0.0015H (B, r) ±0.001H (B, r) H- section height, B- section length, r- radius of arc section

2 Lower elbow nozzle Smoothly transited from the concrete nozzle

4 Elevation of upper elbow or

cone nozzle

0~+8 0~+12 0~+15 0~+18 0~+20 8~24 measuring points evenly distributed

5 Diameter of cone nozzle ±0.0015D

D- the designed nozzle diameter; 8~24 measuring points evenly distributed

The draft tube with flanges or

of inserting type shall satisfy the requirements given in Table 17

5 1.3 The installation tolerances of runner chamber, foundation ring and stay ring shall meet the

requirements given in Table 2 The design requirements shall be complied with in the case of particular

To measure the distance between the X and Y marks

on the embedded component to the X and Y reference lines of the generator unit

With out on-site

machining

0.05mm/m, the max not exceeding

0.60 Radial

measuremen

t With on-site

With out on-site

t

With on-site machining

0.35

The elevation difference between the highest and the lowest points

4 Roundness of runner chamber

The difference between various radii and the average radius shall not exceeding ±10% of the average designed clearance between the blades and the runner chamber

To measure the upper, middle and lower sections for axial turbine; to measure the upper and lower rabbets for diagonal turbine; 8~24 measuring points evenly distributed

5

Roundness of foundation ring

and stay ring, coaxiality of runner

8~24 measuring points evenly distributed; take the center of stationary wearing ring as the reference for mixed-flow turbine; take the center of runner chamber as the reference for axial turbine

5.1.4 The jointing planes of sectioned runner chamber, foundation ring and stay ring in the bolt-jointed structure shall be applied with sealant The jointing gaps shall meet the requirements given in Clause 4.7

In order to prevent leakage, the jointing gaps to be exposed to the flowing medium can be sealing welded, and the weld surfaces shall be ground to be smooth The assembly of runner chamber,

foundation ring and stay ring shall comply with the design requirement in the case of welded assembly structure

5 1.5 As installing the runner chamber ring and the stationary guide vane of post type stay ring, the orientation deviation between stay ring and foundation ring shall be consistent The end clearance of guide vane shall be ensured to meet the design requirements, and the height from the upper plane of foundation ring to the upper plane of stay ring shall be strictly controlled The distortion of stay ring caused by concrete laying, the error of measuring tools, and the decreasing of guide vane end clearance owing to the distortion of head cover during operation shall be taken into consideration The stay ring shall be reliably fixed in order to minimize the distortion in the concrete laying period

5.1.6 The assembly tolerance of spiral case shall meet the requirements given in Table 3

Table 3 The Assembly Tolerance of Spiral Case unit: mm

by line inspection method, the nozzle shall be on the same plane (a must item to be verified)

5.1.7 The installation tolerance of spiral case shall meet the requirements given in Table 4

Table 4 The Installation Tolerance of Spiral Case unit: mm

Distance to the Y axis

of the generator unit 0.003D D- The inlet diameter of spiral case Taking the steel pipe nozzle as the

reference if the steel pipe has been installed, the central deviation shall not exceed 15% of the thickness of spiral case sheet

1 Straight

tube

Elevation ±5

2 Elevation of the farthest point ±15

3 Tilting value of nozzle at the

positioning section

5

4 Deviation between the nozzle at

the positioning section and the

reference line

±5

5 Radius of the farthest point ±0.004R R- The designed radius of the farthest

point

6 Height of nozzle section ±0.002H H- The height of nozzle section (section

diameter) (a must item to be verified) 5.1.8 The welding of spiral case shall meet the following requirements:

a) The welding shall be carried out to meet the requirements given in Clause 4.1 4;

b) In generally, the gaps of butt welds connecting various sections and between spiral case and stay ring shall be ranged between 2mm~4mm The staggers exposing to the flowing medium shall not exceed 10% of the sheet thickness However, the maximum stagger of longitudinal seam shall not be more than 2mm, and the maximum stagger of ring seam shall not be more than 3mm;

c) The length of groove with local gap exceeding 5mm shall not exceed 10% of the weld length Repair welding is allowed at the groove

5.1.9 The welds on spiral case shall be conducted with visual appearance inspection and

non-destructive inspection In the case of lacking manufacture requirements:

a) Visual appearance inspection on welds shall meet the requirements given in Table 5 shall be satisfied;

Table 5 Visual Appearance Inspection for Welds on Spiral Case unit: mm

length shall not exceed 100, and the cumulative length of undercuts at two sides shall not more than 10% of the full length of the weld

b) Non-destructive inspection of welds:

With the ray detection, the length to be inspected: 10% for ring seams, 20% for longitudinal

seams or the butt welds between spiral case and stay ring According to GB/T 3323, the welding quality of ring seam shall meet the requirements of grade III, and that of longitudinal seams or the butt welds between spiral case and stay ring shall meet the requirements of grade II

With the ultrasonic detection, the length to be inspected: 100% for ring seams, longitudinal seams or the butt welds between spiral case and stay ring; According to GB/T 11345, the welding quality of ring seam shall meet the requirements of BII, and that of longitudinal seams

or the butt welds between spiral case and stay ring shall meet the requirements of grade BI For the positions with doubt, recheck by means of ray detection

c) For the steel lining of concrete spiral case, generally kerosene permeability test shall be conducted, in which the welds shall be free of penetrative defect

5.1.10 The worksite hydrostatic test on spiral case or the concrete laying for spiral case under pressure shall be conducted according to the design requirements

5.1.11 Prior to the concrete laying, the surface of spiral case shall be cleaned off angles or clamp plates Any burr shall be ground to be smooth, and the welds with damaged base shall be repaired and ground and detected by magnetic powder inspection

5.1.12 The measure shall be taken to prevent the stay ring from distortion during the installation, welding and concrete laying of spiral case The rising speed of concrete laying shall not exceed 300 mm/h The height of each concrete layer is normally 1 m~2 m, and the placement shall be symmetrical in pieces and layers The height of liquid concrete shall be controlled normally about 0.6 m During the laying, the stay ring shall be monitored to avoid distortion, and the concrete laying sequence can be adjusted at any time according to the actual situation

5.1.13 The roughness of the surfaces of embedded components exposing to the flowing medium shall satisfy the requirements given in GB/T 10969 The welds exposing to the flowing medium on draft tube liner, runner chamber and spiral case (or spiral case liner) shall be ground to be smooth The transition surfaces exposing to the flowing medium between the embedded components and the concrete shall be smooth

5.1.14 The installation tolerance of pit liner shall meet the requirements given in Table 6

Table 6 The Installation Tolerance of Pit Liner unit: mm

2 Diameter of upper hole ±5 ±8 ±10 ±12

3 Elevation of upper hole ±3 8~16 measuring points evenly distributed

4 Level difference of upper hole 6 8~16 measuring points evenly distributed 5.1.15 The installation tolerance of servomotor foundation shall meet the requirements given in Table 7

Table 7 The Installation Tolerance of Servomotor Foundation

a) No undercut in the welds of runner throat ring As the manufacturer required, flaw detection shall

be conducted to ensure the satisfaction of the requirements;

b) The joining gap of crown shall meet the requirements given in Clause 4.7;

c) The inferior fovea on crown flange shall not be more than 0.07mm/m, the superior hump shall not be more than 0.0 3mm/m, and the maximum shall not exceed 0.06mm For the main shaft in

a structure applying friction for momentum transfer, superior hump is generally not allowed; d) The staggers on band weld shall not be more than 0.5 mm;

e) After the blade sections and the blade packing are installed and welded, the blade shape shall meet the design requirements

5.2.2 Before the on-site welding of wearing ring, the roundness of runner at the positions for installing wearing ring shall meet the requirements given in Clause 5.2.8 After being welded, the wearing ring shall be tightly attached and the welding quality shall meet the design requirements If heat shrink is required for installing the wearing ring, the shrink-on process shall meet the design requirements 5.2.3 After the wearing rings of runner sections being ground, the measuring points shall not be less than

32 The dimensions shall meet the design requirements The roundness shall meet the requirements of

Clause 5.2.8

5.2.4 The static balance test shall be conducted according to Clause 5.2.5 after the runner sections being ground Distributing plate shall be supplied in the test and the clump weight shall be welded firmly

on the top surface of crown beneath the distributing plate

5.2.5 The static balance test of runner shall meet the following requirements:

a) The static balancing tool shall be concentric with the runner The concentricity deviation shall not

be more than 0.07mm The horizontal deviation of the supporting seat shall not be more than 0.02mm/m;

b) As applying steel balls or mirror plate for balancing, the sensitivity of the static balancing tool shall meet the requirements given in Table 8;

Table 8 Distances from the Ball Center to the Center of Runner Weight

Runner mass t, kg Max distance, mm Min distance, mm

Table 9 The Permitted Unbalance Tolerance eper for Unit Mass of Runner

Permitted unbalance tolerance

for unit mass of runner eper,

b) Hold the maximum testing pressure for 16 hours;

c) During the test, the full stroke of blade opening and closing shall be operated for 2~3 cycles per hour;

d) The jointing seams shall be free of leakage The oil leakage of single blade sealing device with

or without test pressure shall not exceed the limit given in Table 10, and not more than that in the

delivery test;

Table 10 Oil Leakage Limits of Single Propeller Sealing Device per Hour

Runner diameter D, mm D<3000 3000≤D<6000 6000≤D<8000 8000≤D<10000 D≥10000Oil leakage limit of

single propeller sealing

device per hour, mL/h

b) The bolt drop pit on the flange guard shall be filled to be flat;

c) The bolt of runner cone shall be firmly spot-welded Measures shall be taken for the guarding plate to prevent distortion The welds shall be ground to be smooth

5.2.8 The coaxiality and roundness of various parts of runner shall be checked taking the main shaft as the center The difference between the diameters and the average diameter shall meet the requirements given in Table 11

Table 11 Tolerance in Coaxiality and Roundness of Various Parts of Runner

1) Wearing ring 2) Installing surface of wearing ring

3) Outer edges of blade

±10% of designed clearance

The outer edges of blade shall be measured only if necessary and the external

1 Rated

head

<200m

4) Wearing ring on distributing plate 5) Similarly serving as the guard for flange

in sealing check

±15% of designed clearance

2 Rated

head

≥200m

1) Outer edge of crown

2) Outer edge of band

±5% of designed clearance The corresponding fixed parts are head cover and

bottom ring

3) Wearing ring of upper comb 4) Lower wearing ring

±0.10 mm

5.3 Preassembly of distributor

5.3.1 Before preassembling the distributor, pit test shall be conducted to detect the roundness of the bore hole on stay ring and thus to determine the center of the generator unit Measure the elevation and level of the upper surfaces of stay ring and foundation ring, and calculate the height difference, which shall meet the requirements given in Clause 5.1.3 and the relevant drawings

For the turbine design with cylindrical valve, the cylindrical valve shall be included in the

preassembly of distributor

5.3.2 The jointing planes of bottom ring sections, head cover and inner head cover shall be applied with sealant The jointing gap shall meet the requirements given in Clause 4.7 In the case that the wearing ring shall be inserted by shrink or mechanical pressure, the relevant design requirements shall be

complied with

5.3.3 The preassembly of distributor shall meet the following requirements:

a) In the case of mixed-flow turbine, the lower stationary wearing ring can be installed referring to the central measuring points determined by pit detection The center of the lower stationary

wearing ring is taken as the reference center of the generator unit The coaxiality and roundness

of various stationary wearing rings shall be checked referring to the reference center of the

generator unit The difference between the diameters and the average diameter shall meet the requirements for relevant parts given in Table 11 If the height of the working surface of wearing ring exceeds 200m m, both the upper and the lower rings shall be checked;

b) In the case of axial turbine, the center of runner chamber shall be taken as the reference center

of the generator unit The coaxiality of the front edges of sealing seat and bearing pedestal

flange shall be checked referring to the reference center of the generator unit The tolerance shall meet the requirements given in Table 12;

Table 12 Coaxiality Tolerance of the Front Edges of Sealing Seat and Bearing Pedestal Flange

as the reference center of the generator unit;

d) The preassembled quantity of guide vanes shall generally not be less than 1/3 of the total

guide vanes, no regular inclination is allowed The maximum overall clearance shall not exceed the designed clearance, and the distortion of head cover after being loaded shall be taken into consideration

Table 13 Adjustment Tolerance of Bottom Ring and Head Cover unit: mm

Coaxiality of holes

on guide vane

bearing bush Meeting the design requirements

5.3.4 The distributor directly for formal installation without preassembly shall also comply with the

requirements stipulated from 5.3.1 to 5.3.3

5.3.5 The installation of cylindrical valve shall satisfy the following requirements:

a) Upon the cylinder assembled and welded, the roundness of the cylinder under free condition shall meet the design requirements;

b) The installation and adjustment of servomotor and pipeline shall meet the design requirements, and the consistency of action time of various servomotors shall be guaranteed;

c) The welding of cylinder shall satisfy the requirements stipulated in JB/T 4709 and Clause 4.14;

d) The installation of synchronous scheme and stroke indicator shall meet the design requirements The actions all through the stroke shall be stable

5.4 The placement and installation of rotating parts

5.4 1 The placing elevation of main shaft and runner after being lifted into the pit shall normally be

slightly lower than the designed elevation A clearance ranged in 2 mm~6 mm shall remain between the upper flange face of the main shaft and the front edge of lower flange of the lifted generator shaft For the generator unit with the thrust collar installed on the main shaft of turbine, the placing elevation of the main shaft and runner after lifting into the pit shall be slightly higher than the designed elevation in order

to leave a clearance ranged in 2 mm~5 mm between the installed thrust collar and the mirror plate The verticality difference of main shaft shall generally not be more than 0.0 5mm/m

As aligning the turbine or generator according to a real object, the center and the main shaft of runner

shall be adjusted to be perpendicular to leave the clearance for wearing ring satisfying the requirements

of Clause 5.4.2 The vertical deviation of main shaft shall not be more than 0.02 mm/m

5.4.2 In the case of lacking the manufacturer’s instruction, the highest elevation of the installed runner, and the clearance tolerance between various wearing rings or between blade and runner chamber shall meet the requirements given in Table 14

Table 14 Tolerance in the elevation and clearance of runner installation unit: mm

Mixed-flow ±1.5 ±2 ±2.5 ±3 To measure the staggers between the stationary and

the rotating wearing rings

Axial 0~+2 +~+3 0~+4 0~+5 To measure the distance from the bottom ring to the

runner top face

a1

a2

The difference of various clearances and the actual average clearance shall not exceed ±10% of the average clearance

Note: The installed elevation of runner given in the table is the actual elevation having taken the sinking

of runner caused by water thrust into consideration

5.4.3 After the generator coupled, no gap shall be left in the jointing seam of two flanges Check with 0.03 mm feeler, which shall not be inserted

5.4.4 The installation of operating oil pipes and oil head shall meet the following requirements:

a) The operating oil pipes shall be cleaned strictly and connected reliably free of oil leakage; the measure shall be taken to lock the bolt-connected operation oil pipes;

b) The swing of operating oil pipe shall generally be no more than 0.20mm for fixed bowl structure,

and no more than 0.30mm for floating bowl structure;

c) The horizontal deviation of oil head shall not be more than 0.05mm/m measured on the plane of oil head seat;

d) The clearance between the oil rings of rotating sump and oil head seat shall be even, and shall not be less than 70% of the designed value;

e) The insulation resistance of oil head to the ground shall be no less than 0.5MΩ measured with the draft tube free of water

5.5 Installation adjustment of guide vane and servomotor

5.5.1 The end face clearance of guide vane shall meet the designed requirements The axial clearance

of the thrust ring of guide vane shall not be more than 50% of the upper clearance of the guide vane The guide vane shall rotate flexibly

5.5.2 At the position of the maximum opening, the distance between guide vane and stop block shall meet the designed requirements, to be ranged in 5 mm-10 mm in the case of no specified value

The link shall be connected and adjusted with the guide vane and the regulating ring placed with a small opening The gap of local vertical surface of guide vane shall be detected with the vane fully closed The link can also be connected with the guide vane fastened by steel wire and the regulating ring at the full closing position The deviation in the closing circle of guide vane shall meet the designed requirements The link shall be adjusted to be horizontal, with the height difference of two ends no more than 1 mm The distance between the two axle holes shall be measured and recorded

5.5.3 With the guide vane fastened by steel wire, the gap of local vertical surface of guide vane is checked with a 0.05 mm feeler, which shall be unable to pass through The local clearance shall not exceed the limit given in Table 15 The overall length of guide vane shall not exceed 25% of the height of guide vane The design requirements shall be complied with in the case of particular requirements

Table 15 Gap Tolerance of Local Vertical Surface of Guide Vane

Height of guide vane, h

no gap is permitted 5.5.4 The servomotor shall be installed to meet the following requirements:

a) For the servomotor to be disassembled on the site, after completing disassembly, cleaning, inspection and assembly, the jointing gaps shall meet the design requirements And the gaps between various jointing planes shall meet the requirements given in Clause 4.7;

b) Tightness pressure test shall be conducted for the servomotor according to Clause 4.11 In the test for swing servomotor, the oil distribution sleeve shall be turned for 3~5 cycles;

c) Regarding the horizontal deviation of servomotor installation, as the piston placed at full closing,

middle or full opening, the level difference of the sleeve or the piston rod shall not be more than 0.10 mm/m;

d) The clamping stroke of servomotor shall meet the design requirements provided by the

manufacturer, otherwise those given in Table 16 shall be complied with;

Table 16 Clamping Stroke of Servomotor unit: mm

Swing servomotor

With the guide vane placed at full closing, the movement of piston as the servomotor pressure rising from zero to 50% of working oil pressure is the clamping stroke

To determine according to the requirements on the straight cylinder servomotor

if it is convenient to adjust the limiting device

e) The position and opening size of throttling device shall meet the design requirements;

f) The servomotor piston shall move stably and smoothly The piston stroke shall meet the design requirements The stroke deviation between two pistons of straight cylinder servomotor shall not

be more than 1 mm;

g) After the oil pipelines for the oil distributor of servomotor is completed, the servomotor shall act flexibly

5.6 The installation of sealing for distributor and main shaft

5.6.1 The guide bearing shoe shall meet the following requirements:

a) The surface of runner guide bearing shoe shall be flat and free of defects like crack or scaling The guide bearing shoe made of Babbitt metal shall be free of defects like dense pores, crack, hard spot or scaling The roughness of bearing shoe surface shall be smaller than 0.8 μm;

b) The runner guide bearing shoe or the cylinder guide bearing shoe shall be assembled on trial in advance and the overall gap shall meet the design requirements Neither the difference between the maximum and the minimum overall gap at every end, nor the difference between the overall gap of upper and lower ends in the same orientation shall be more than 10% of the actually measured average overall gap

c) No further grinding is needed for the cylinder bearing shoe meeting the requirements of the above a) and b); for the sectioned shoe, whether grinding is needed shall be determined

according to the design requirements;

d) The surface of guide bearing shoe after grinding shall be jointed evenly At least one contact exists within every area of one square centimeter Every local non-contacted area in each bearing shoe shall not be larger than 5%, and the overall area shall not exceed 15% of the total area of guide bearing shoe

5.6.2 The guide bearing shoe shall be installed to meet the following requirements:

a) The guide bearing shoe shall be installed under the condition with the generator axis and thrust collar adjusted properly, and the gap of wearing ring of turbine and the air gap of generator meeting the specified requirements To facilitate checking the central position of the shaft, central measuring points shall be set at suitable positions on the stationary part of bearing and relevant data shall be measured and recorded;

b) The guide bearing shoe shall be installed referring to the central position of main shaft, and the gap shall be adjusted taking the swing direction and size of turning into consideration The overall installation gap shall meet the design requirements However, the swing can be

neglected in gap adjustment for the generators with only two guide bearings;

c) The gap tolerance for sectioned guide bearing shoe shall not exceed ±0.02mm; That for cylinder guide bearing shoe shall be ranged in ±20% of the specified gap The shoe plane shall be kept perpendicular

5.6.3 The bearing shall be installed to meet the following requirements:

a) The oil box of thin oil bearing shall be oil-tight Generally the gasoline leakage test shall be conducted according to Clause 4.12;

b) Pressure test shall be conducted for the bearing cooler according to Clause 4.11;

c) The oil shall reach the specified quality The oil level shall meet the design requirements, with the deviation not exceeding ±10 mm

5.6.4 The standstill seal of main shaft shall be installed to meet the following requirements:

a) The air shrouding shall be charged with 0.05MPa compressed air to conduct air leakage test in water before assembly No air leakage shall occur;

b) With the air shrouding installed, the radial gap shall meet the design requirements The deviation shall not exceed ±20% of the designed gap;

c) Air charging and venting test and pressure test shall be conducted for the installed air shrouding The pressure drop in the test shall meet the design requirements In general, keeping for one hour at a pressure as 1.5 times of working pressure, the pressure drop should not exceed 10%

of the rated working pressure

5.6.5 The working sealing of main shaft shall meet the following requirements:

a) The axial and radial gaps of the installed working sealing shall meet the design requirements, and the tolerance shall not exceed ± 20% of the actual average gap;

b) The sealing parts shall be able to move freely up and down, and contacted well with the sealing surface of revolving ring; The water supply pipeline shall keep unblocked

5.7 Installation of accessories

5.7.1 Action test and leakage test shall be conducted for vacuum break valve and aeration valve The

starting pressure and the maximum opening shall meet the design requirements

5.7.2 Tightness pressure test shall be conducted for the servomotor of gate valve or disk valve for the draining of spiral case and draft tube according to Clause 4.11

5.7.3 The horizontal deviation of the installed seat of disk valve shall not be more than 0.20mm/m

With the disk valve installed, the sealing surface shall leave no gap The valve group shall act flexibly, and the valve stem shall be sealed reliably

5.7.4 The aerating device at the central hole of main shaft shall be installed according to the design requirements If required by the design, barring examination shall be conducted for the aeration pipe at the center of main shaft The swing shall not exceed 20% of the actual average sealing gap, and the maximum swing shall not exceed 0.30 mm The connecting bolts shall be locked reliably The insulation resistance to the ground of the installed supporting seat shall be measured and generally no less than 0.5 MΩ Anti-dewing measures shall be taken for the naked pipelines

6 Installation of Through Flow Turbine

6.1 Installation of embedded components

6.1.1 The draft tube of through flow turbine shall be installed according to the tolerance requirement given in Table 17

Table 17 The Installation Tolerance for Draft Tube of Through Flow Turbine unit: mm

2 Center and orientation ±1.5 ±2.0 ±2.5 The elevation of level mark at nozzle, and the left/right deviation of

the verticality mark at the nozzle

3 Distance from the flange plane to the central line of

runner

(1) Taking the downstream-side flange as the reference in the case that the pipe saddle is preinstalled;

(2) To measure four points respectively at upper, lower, left and right positions

4 Verticality and levelness of flange plane 0.8 1.0 1.2 To measure the verticality of the flange plane referring to the central

line of the unit 6.1.2 The installation tolerance for the pipe saddle of through flow turbine shall meet the requirements given in Table 18

Table 18 The Installation Tolerance for Pipe Saddle of Through Flow Turbine unit: mm

1 Orientation and elevation ±2.0 ±3.0 ±4.0

1) The elevation of the level marks

on the upstream and downstream flanges

2) The distance from the X and Y marks on the part to the

corresponding reference line

2 Distance between the flange plane to the central line of

1) Take the flange as reference in the case that the draft tube is preinstalled

2) To measure four points respectively at upper, lower, left and right positions

3

Verticality and levelness of

the flange plane of the

Make conversion for other verticality and levelness based on the tolerance

5 Distance between the inner and outer flanges at

downstream side

0.6 1.0 1.2

6.1.3 The installation tolerance for the passage cover plate of through flow turbine shall meet the

requirements given in Table 19

Table 19 The Installation Tolerance for Passage Cover plate of Through Flow Turbine unit: mm

1 Center and position of silo hole of passage cover plate ±2 ±3 ±4

Deviation between the central line

of frame and the designed central line

2 Elevation of foundation frame ±5.0

3 Height deviation at four corners of foundation frame 4.0 5.0 6.0

4

Levelness of flange on the

silo hole of passage cover

6.1.4 The installation tolerance for the servomotor foundation of through flow turbine shall meet the requirements given in Table 7

6.1.5 The concrete laying shall be conducted according to Clause 5.1.11 and 5.1.12 after the

acceptance test on the installation of pipe saddle

6.2 Assembly of main shaft

6.2.1 The main shaft shall be assembled in the installation room generally Put the main shaft onto the supporting rack for assembly and adjust the levelness with the tolerance no more than 0.5mm/m 6.2.2 The operating oil pipes shall be cleaned strictly and connected reliably free of oil leakage The inner operating oil pipe shall move flexibly in the outer operating oil pipe

6.2.3 The check prior to the assembly of guide bearing shoe shall be conducted according to Clause 5.6.1; As mounting onto the main shaft, the gap tolerance of guide bearing shoe shall meet the design requirements The two ends of guide bearing shoe shall be well sealed so that the oil can be returned fluently

6.2.4 The fitting between guide bearing shoe and bearing case shall meet the requirement given in Clause 10.4.4; The gap between the jointing planes of bearing case, supporting ring and hydro cone shall meet the requirement given in Clause 4.7

6.2.5 As installing the guide bearing, the changes caused by the deflection of rotating parts shall be taken into consideration

6.2.6 The bearing specified with insulation resistance against ground shall be detected with a 1000V megohmmeter before filling oil The insulation resistance shall not be lower than 1MΩ

6.3 Assembly of distributor

6.3.1 The jointing planes between the sectioned outer guide rings, inner guide ring and regulating ring shall be applied with sealant or installed with sealing rods according to the design requirements The jointing seams shall meet the requirements given in Clause 4.7 The sealing rod shall be installed with a length ranged in 1mm~2mm exposed at two ends

6.3.2 The assembly of distributor shall meet the following requirements:

a) The coaxiality of the inner and outer guide ring shall be adjusted to keep the tolerance no more than 0.5mm;

b) The distance between the inner and outer flanges at the upstream side of distributor shall meet the design requirements, with the tolerance no more than 0.4mm;

c) The end plane gap of guide vane shall be adjusted The gap between the inner and outer end planes

at the closed position shall meet the design requirements The gaps at the guide vane head and tail ends shall be close to being equal, and the rotation of the guide vane shall be flexible;

d) The maximum gap at the vertical surface of guide vane shall not exceed 0.25mm The length shall not exceed 25% of the height of the guide vane

6.5 Installation of main shaft, runner and runner chamber

6.5.1 After the installation of runner, tightness breakdown test and action test shall be conducted and meet the requirements given in Clause 5.2.6

6.5.2 As adjusting the axes, the changes in axes caused by operation, and the actual tilting value of the flange plane of pipe saddle shall be taken into consideration, and the design requirements shall be satisfied

6.5.3 After completing the connection between runner and main shaft, the jointing plane shall be

detected with 0.03mm feeler, which shall not be able to pass through

6.5.4 The operating oil pipe of oil head shall be included in the turning check The swing of operating oil pipe shall generally be no more than 0.1mm The coaxiality between the oil head bowl and operating oil pipe shall be no more than 0.15 mm for fixed bowl structure, and no more than 0.2 mm for floating bowl structure;

6.5.5 The runner chamber shall be adjusted and installed with the runner as the center The gap

between runner chamber and blade shall meet the design requirements

6.5.6 The sealing installation of main shaft shall meet the requirements given in Clause 5.6.4 and Clause 5.6.5

6.5.7 After the installation of expansion joints, the reserved clearance of expansion joints shall meet the design requirements, and the tolerance shall not exceed ±3mm

6.6 The flow-passing planes and the jointing planes shall be installed with sealing parts and applied with sealant according to the design requirements Tightness check shall be conducted to avoid leakage 6.7 For the distributor with heavy hammer, following the completion of turbine assembly and the

formation of distributor operation system, the heavy hammer closing test shall be conducted on the generator unit under water-free or static water condition according to the design requirements The closing time shall be recorded

7 Installation of Reaction Turbine

7.1 Installation of water distribution pipeline

7.1.1 The distance tolerance between the inlet central line of water distribution pipeline and the

coordinate line of the generator unit shall not be more than ±2% of the inlet diameter

7.1.2 As welding the flanges of manifold, the flanges shall be controlled and detected to avoid hazardous distortion

7.1.3 After the completion of manifold welding, each supporting plane of flange and nozzle shall be checked in terms of the elevation, the horizontal distance to the coordinate line of generator unit, the mutual distance and verticality of each flange, and the angular position of holes, to ensure the tolerances

to satisfy the design requirements

7.1.4 Hydrostatic test shall be conducted for manifold and branch pipe The test pressure shall comply with the manufacturer’s requirements The welding seams on manifold and branch pipe shall be free of leakage, and the flanges of branch pipe shall be free of hazardous distortion

7.1.5 Should the concrete shall be laid under pressure for manifold and branch pipe, the water pressure

in manifold shall be controlled according to the design requirements

In the case of vertical generator unit, the elevation of various nozzle flanges on the housing shall be equal, with the tolerance no more than 1mm; The verticality of various flanges shall not be more than 0.30mm/m, and the distance to the coordinator lines of the generator unit shall meet the design

requirements

7.2.3 For the double runner horizontal turbine placed at two ends of generator unit, the relative elevation difference between two housings shall not be more than 1mm; The central distance shall refer to the position of thrust disc, and the addition of measured length of generator rotor and shaft plus the heat extension of generator rotor, with the deviation not exceeding 0mm~+1mm

7.3 Assembly of turbine bearing

7.3.1 The assembly of vertical turbine bearing shall meet the following requirements:

a) The bearing flange shall be measured to ensure the elevation deviation not to exceed 2mm and the horizontal deviation generally smaller than 0.04mm/m;

b) The guide bearing and its support shall be preassembled The central deviation between the center of bearing support and the center of generator unit shall not be more than 0.40mm After positioning the preassembly, location holes shall be bored and location pin shall be fitted for jointing it with the housing; c) Guide bearing shall be installed after the axes of generator unit being confirmed, and shall meet the following requirements:

1) The oil box of thin oil bearing shall be oil-tight The gasoline leakage test shall be conducted

according to Clause 4.12;

2) Pressure test shall be conducted for the bearing cooler according to Clause 4.11;

3) The oil shall reach the specified quality The oil level shall meet the design requirements, with the deviation not exceeding ±6 mm

7.3.2 The assembly of horizontal turbine bearing shall meet the following requirements:

a) Should the horizontal guide bearing require grinding on the site, the requirements given in Clause 10.1.1 and Clause 10.1.2 shall be complied with;

b) The clearance of bearing shall be adjusted to satisfy the requirements given in Clause 10.4

7.4 Installation of turbine shaft

7.4.1 Prior to the installation of turbine shaft, the smoothness and levelness shall be checked for the jointing flanges

7.4.2 In the case of vertical generator unit, the upper flange plane of turbine shaft shall be 20mm-25mm lower than the designed elevation For the structures of turbine shaft directly connected with generator rotor, the coaxiality between generator rotor flange and turbine shaft flange, the parallelism, and the elevation of generator rotor flange against nozzle axis shall be adjusted to meet the design

requirements

7.4.3 The deviation in levelness or verticality of main shaft shall not be more than 0.02mm/m

7.4.4 Prior to the installation of guide bearing, the axis of the generator unit shall be check to meet the design requirements

7.5 Installation of nozzle and servomotor

7.5.1 Before installing the nozzle and servomotor, tightness breakdown test shall be conducted

according to the manufacturer’s requirements

7.5.2 After assembling the nozzle and servomotor, the needle and servomotor shall act flexibly under 16% the rated pressure With the closing chamber of servomotor filled with oil of rated pressure, no gap shall remain between needle tip and nozzle tip ring If the needle servomotor is a built-in servomotor, the discharging chamber of oil-water mixture shall be checked and ensured to be free of oil or water

leakage

7.5.3 The installation of nozzle shall meet the following requirements:

a) The central line of nozzle shall be tangent to the runner pitch circle, with the radial deviation no more than ±0.2% d1 (d1 is the diameter of runner pitch circle), and the axial deviation with the diverting blade of bucket no more than ±0.5% W (W is the maximum width at the internal side of bucket);

b) The deviation between the deflector center and the nozzle center shall not be more than 4mm; c) The deviation of reduction length of buffer spring against the design value shall not exceed ±1mm; d) The synchronization deviation in the movement of various nozzle needles shall not exceed 2% of the designed stroke;

e) The axial and radial deviation of the central line of negative braking nozzle shall not be more than

±5mm

7.6 Installation of runner

7.6.1 The runner shall be installed to meet the following requirements:

a) The rotating plane of diverting blade of runner bucket shall pass through the center of the flange for installing nozzle on the housing, with the deviation no more than ±0.5%W;

b) The run out tolerance of runner end surface shall not be more than 0.05mm/m;

c) The gap between runner and water baffle shall meet the design requirements

7.6.2 The sealing of main shaft shall meet the requirements given in Clause 5.6.5

7.7 Installation and adjustment of control mechanism

7.7.1 The center deviation of various parts of control mechanism shall not be more than 2mm, the elevation deviation shall not exceed ±1.5mm, the horizontal and vertical deviation shall not be more than 0.10mm/m and the control mechanism shall act flexibly after installation

7.7.2 The opening hole of deflector shall be 3mm larger than the jetting radius, but shall not exceed 6mm Different deflectors shall act synchronously, with the deviation not exceeding 2% of the designed value

8 Installation and Commissioning of Speed-Governing System

8.1 Installation and commissioning of oil pressure unit

8.1.1 The foundation of return oil tank and pressure vessel and the equipment shall be installed to meet the requirements given in Table 20

8.1.2 The code and quality of oil used in the speed-governing system shall meet the requirements given

in Clause 4.15, and the working temperature oil shall be ranged in 10℃~50℃

Table 20 The Installation Tolerance of Return Oil Tank (Governor Oil Tank) and Pressure Vessel

on the equipment to the X and Y datum lines of the unit

3 Levelness, mm/m 1 To measure the elevation of the four

corners of return oil tank (governor oil tank)

4 Verticality of pressure

vessel, mm/m

1 To measure by the line arranged in X and

Y directions 8.1.3 Tightness breakdown test shall be conducted with qualified steam turbine oil for pressure vessel, oil pipeline or bearing element before put into operation according to Clause 4.11

8.1.4 The flexible coupling between the horizontal oil pump and the motor shall be installed and aligned, with both the eccentricity and the tilting value no more than 0.08mm With the axial play of oil pump at the axial motor side being zero, a gap ranged in 1mm~3mm shall remain between couplings After all dowels fitted, the couplings shall allow slight relative rotation Qualified steam turbine oil shall be filled in the oil pump chamber

8.1.5 The oil level at different parts of oil pressure unit shall meet the design requirements

8.1.6 The trial run of oil pump and motor shall meet the following requirements:

a) The inspection and test on motor shall meet the relevant requirements given in GB50150;

b) The oil pump shall be operated without load for one hour, and then 15 minutes respectively under 25%, 50%, 75% and 100% of the rated pressure No abnormity shall occur;

c) During operation, the vibration of the oil pump case shall not be more than 0.05mm, and the

temperature of bearing case shall not be higher than 60℃;

d) Under the rated pressure, the oil transmission rate of oil pump shall not be less than the designed value

8.1.7 The adjustment of various parts of oil pressure unit shall meet the following requirements:

a) Check the relation curve of the pressure and the output voltage (current) of the oil level sensor versus oil pressure and oil level The range with possible changes in working oil pressure and oil level shall present as linear, with the characteristics satisfying the design requirements;

b) The pressure transmitter for safety valve and operating oil pump, and that for backup oil pump shall

be adjusted to meet the requirements given in Table 21 unless otherwise specified in the design The action deviation of pressure transmitter shall not exceed ±1% of the setting value, and the returned value shall not exceed the design requirements;

c) The operating pressure of the overflow value for continuously operating oil pump shall meet the setting values for operating oil pump specified in Table 21 unless otherwise specified in the design;

Table 21 Setting Values of Pressure Transmitter for Safety Valve and Oil Pump unit: MPa

Setting value Safety valve Operating oil pump Backup oil pump

Pressure

of full opening

Pressure

of full closing

Starting pressure pressure Reset pressure Starting pressureReset

d) The safety valve shall cause no sharp vibration or noise as operating;

e) The setting values of low oil pressure in emergency shall meet the design requirements, and the action deviation shall not exceed ±2% of the setting value;

f) The oil level transmitter of the automatic air refilling device and return oil tank in pressure vessel shall act accurately and reliably;

g) The startup and shutdown action of pressure oil pump and leakage oil pump shall be correct and reliable Reversal shall not be allowed

8.1.8 With the pressure vessel at the working pressure and the oil level at the normal position, close various connecting valves and keep for eight hours, the oil pressure drop shall not be more than 4% of the rated working pressure Write down the descending value of oil level

8.2 Installation of governor

8.2.1 The mechanical cabinet, electrical cabinet and emergency control valve of the governor shall be installed to meet the following requirements:

a) The installation tolerance for the mechanical cabinet, electrical cabinet and emergency control valve

of electro-hydraulic governor shall comply with the requirements given in Table 22;

Table 22 Installation Tolerance for The Mechanical Cabinet, Electrical Cabinet and Emergency Control

Valve of Electro-hydraulic Governor

marks on the equipment and the X and Y datum lines of the unit

3 Levelness of mechanical

cabinet, mm/m 0.15 To measure the pedestal of electro-hydraulic switching device

4 Verticality or levelness of

emergency control valve,

mm/m

0.15 To measure the foundation plate of

emergency control valve

5 Verticality of electrical

cabinet, mm/m 1 To measure by the lines arranged in X and Y directions

b) For the combined electro-hydraulic governor, the installation shall take the driving gear support of regulating shaft as the reference, with the tolerance as the design required;

c) Refer to Appendix B for the installation of mechanical hydraulic governor

8.2.2 For the mechanical-hydraulic component to be disassembled, the cleaning, assembly and

adjustment of its elements shall comply with the requirements given in the manufacturer’s drawing

8.2.3 The indicators and levers in the mechanical cabinet of governor shall be adjusted according to the dimensions marked in the relevant drawings, with the position deviation between various mechanisms

no more than 1mm

8.2.4 With the servomotors of guide vane and impeller blade placed at the middle position (equivalent to 50% opening), the position of various regulating levers and links of reset mechanism shall meet the design requirements, with the horizontal or vertical deviation no more than 1mm/m; The coupling of reset mechanism shall be firm, and load test shall be conducted according to the design requirements

8.2.5 The loop connection of various systems in the electrical part shall be checked and meet the design requirements The measurement of insulation resistance and the withstanding voltage test shall be

carried out according to the relevant requirements in GB 50150 Standard for Hand-Over Test of Electric

Equipment

8.2.6 The output voltage of the stabilized voltage supply in the electrical part shall meet the design requirements The changes in output voltage shall generally not exceed ±1% of the designed value 8.2.7 The adjustable range of characteristics and adjustable parameters of various unit loops in electrical part, e.g permanent speed droop bp, slip ep, proportional gain Kp, integral gain K1, differential gain Kd (or temporary speed droop bt, time constant of damping device Td and acceleration time constant T0), shall meet the design requirements

8.2.8 The adjustable range of set values of opening, frequency and power shall meet the design

8.3 Oil filling and adjustment test of speed-governing system

8.3.1 Connect an oscillating current into the electro-hydraulic switching device and check the oscillating quantity according to the design requirements

8.3.2 Check the zero deviation of electro-hydraulic switching device and the zero drift of pressure The zero deviation shall generally not be more than 5% of the rated output quantity (current and voltage); within the range of working oil pressure, the zero drift of pressure shall not cause any obvious movement

of servomotor

8.3.3 Record the input frequency and the output movement of electro-hydraulic or electromechanical

switching device, and figure out the static characteristic curve The dead zone and the amplification factor shall meet the design requirements

8.3.4 Measure the output voltage (current) of feedback sensor and the servomotor movement, and figure out the relation curve Within the entire stroke range of servomotor, the curve shall be linear, and the characteristics shall meet the design requirements

8.3.5 The initial oil filling for the speed-governing system shall be carried out slowly The filled oil

pressure shall normally not exceed 50% of the rated pressure; Make the servomotor move in full stroke for several cycles, no abnormity shall occur

Switching test of different control methods (manual, automatic and others) shall be conducted for the governor The governor shall act normally without causing obvious swing of servomotor

Tightness test shall be conducted for oil pipelines and bearing elements according to Clause 4.11

8.3.6 Check the indication of pointer on the mechanical cabinet by manually controlling the opening limit device of guide vane servomotor The stroke indication shall be consistent with that of guide vane servomotor and impeller blade servomotor The deviation shall be no more than 1% of the full piston stroke against the guide vane servomotor and no more than 0.5º against the impeller blade servomotor

8.3.7 The emergency closing and opening time of guide vane and impeller blade, and the sectioned closing stroke and time of guide vane shall not deviate from the corresponding designed values by more than ±5%, and eventually they shall satisfy the requirements of the calculation of guaranteed regulation

The closing or opening time is normally evaluated as two times of the time required to move between the opening 75% and 25%

8.3.8 The time required for the emergency control valve to close the guide vane shall not deviate from the designed value by more than ±5%; and eventually they shall satisfy the requirements of the

calculation of guaranteed regulation

8.3.9 The dead stroke of reset mechanism shall generally be no more than 0.2% of the full stroke of servomotor

8.3.10 Figure out the relation curve of the movement of guide vane servomotor versus the opening of guide vane respectively in closing and opening directions The opening of guide vane at one point shall take the average of four to eight measured values; As the guide vane at full open, the opening value of all guide vanes shall be measured, and the deviation shall not exceed ±2% of the designed value

8.3.11 Figure out the relation curve and the closing/opening rules of the movement of guide vane

servomotor versus the movement of impeller blade servomotor respectively in closing and opening directions under different coupled relations with head, which shall meet the design requirements; The inaccuracy of impeller blade servo system shall be smaller than 1.5% of the full stroke

8.3.12 The practical open loop gain setting of servo system: the opening and closing time of servomotor has been adjusted and meet the design requirements With the amplification factor and lever ratio set at the maximum designed value, input a step signal equal to 10% of the full stroke of servomotor to the servo system, observe the movement of servomotor; Record the maximum amplification factor and lever ratio enabling the servo system to keep stable without overshooting, and take it as the practical open loop gain

8.3.13 Record and figure out the static characteristic curve of the speed-governing system with the permanent speed droop bp=6% Its static characteristic curve shall close to be a straight line, and the rotational speed dead zone shall be no more than 0.04%; For the speed-governing system of adjustable blade propeller turbine, the inaccuracy of impeller blade servo system shall not be more than 1.5%

8.3.14 With the spiral case free of water, write down the pressure of pressure vessel and the

descending value of oil level in the case of shutdown due to emergency low oil pressure

8.3.15 With the spiral case free of water, measure the minimum operating oil pressure of the operation mechanism of guide vane and impeller blade, which shall not be more than 16% of the rated oil

pressure

8.3.16 Oil filling and adjustment test shall be conducted for the speed-governing system of reaction turbine according to the relevant test items and standard given in Clause 8.3

8.4 Simulation test of speed-governing system

8.4.1 Simulate various faults of speed-governing system, in which the protection device shall perform reliably and the relevant alarm signals shall be correct

8.4.2 Carry out the simulation tests (startup, shutdown and emergency shutdown) of generator unit by means of manual or automatic methods, in which the speed-governing system shall act normally and the relevant alarm signals shall be correct

9 Installation of Vertical Hydraulic Turbine Generator

9.1 Assembly of frame

9.1.1 Check the jointing seams after assembling the arms of combined frame according to Clause 4.7

The top of bearing frame and the jointing seams of arms shall be detected by 0.05mm feeler The length uncontacted locally shall not exceed 10% of the overall length at the top

9.1.2 The assembly of welded frame shall meet the following requirements:

a) Support the central body firmly, and adjust it horizontal to ensure the horizontal deviation of upper jointing plane not to exceed 0.04mm/m;

b) Connect the arms with the central body, and check the following items to meet the design

requirements:

1) The staggers on the jointing planes between various arms and the central body;

2) The deflection of various arms (i.e verticality);

3) The height difference between the contacting planes of foundation plates of various arms and the jointing planes with the central body;

4) The middle ordinates of external edges of various arms;

c) Conduct welding according to Clause 4.14 unless otherwise specified by the manufacturer;

d) Carry out appearance check and nondestructive detection according to the manufacturer’s drawings and technical documents Without the specified requirement of the manufacturer, the requirements given

in Table 5 shall be complied with in the appearance check of welding seams, and the following criteria shall be adopted to evaluate the nondestructive detection:

1) In the case of ray detection, GB/T3323 shall be complied with The quality of tensile butt welds shall

be no inferior to grade II, and the percentage of welds to be ray detected shall be 50%; The quality of general butt welds shall be no inferior to grade III, and the percentage of welds to be ray detected shall

be 25%;

2) In the case of ultrasonic examination, GB/T11345 shall be complied with The quality of tensile butt welds shall be no inferior to grade BI, and the percentage of welds to be ultrasonic examined shall be 100%; The quality of general butt welds shall be no inferior to grade BII, and the percentage of welds to

be ultrasonic examined shall be 50%;

e) After completing the welding of arms, ensure the horizontal deviation of central body not to exceed 0.04mm/m Check the middle ordinates of key ways on the outer edges of various arms, and ensure their height difference against the contacting planes with the foundation plates of various arms and the planes on the central body to meet the requirements of design drawings

9.1.3 After assembling the sectioned thrust bearing pedestal, check the smoothness of the plane for installing the bearing, with the deviation not exceeding 0.2mm The gap of jointing seams shall meet the requirements given in Clause 4.7

9.1.4 For the sectioned bearing frame assembly, the assembly and welding of the central body and various arms shall be conducted according to Clause 9.1.3 and Clause 9.1.2

9.2 Grinding of guide bearing shoe

9.2.1 The thrust bearing shoe shall be free of defects like crack, slag blister or dense pores The overall area of local scaling raised on the surface material and the metal bottom surface of guide bearing shoe shall not exceed 5% of the overall area of bearing shoe surface Ultrasonic detection or other

examination shall be conducted if necessary

The thermometer and high-pressure oil lifting pipes shall be trial installed with the guide bearing shoe for inspection

9.2.2 The working surfaces of mirror plate shall be free of scratch or corrosion, and the roughness and hardness shall meet the relevant requirements The parallelism of two surfaces and the smoothness of working surfaces shall be checked according to the drawings if necessary

9.2.3 For the thrust bearing shoe to be ground on the site as the manufacturer required, the bearing shoes after ground shall meet the following requirements:

a) There shall be 1~3 contacting points per unit area of 1cm2 on the bearing shoe surface;

b) Each uncontacting area locally on the bearing shoe surface shall not be larger than 2% of the area of bearing shoe, and not exceed 16cm2, the overall area uncontacted shall not exceed 5% of the area of bearing shoe;

c) The edge for intaking oil shall be ground according to the manufacturer’s requirements;

d) For the thrust bearing shoe without pallet but being supported by screw, the requirements given in the above mentioned a) and b) shall be satisfied, and the middle of the bearing shoe surface shall be ground

to be lower A possible method is like this: Within the circle around the supporting screw with the

diameter equal to 2/3 of the length of bearing shoe, remove the contracting points (minor contacting points can remain), and grind the corrugations in one direction; Next, within the shrunk circle around the supporting screw with the diameter equal to 1/3 of the length of bearing shoe, grind the corrugations in the direction orthogonal to the first cycle;

e) After barring of the generator unit, draw out the thrust bearing shoe and check the contacting

condition, which shall meet the requirements given in the above-mentioned a) and b);

f) Check the lifted high-pressure oil chamber according to the design requirements Grind the surfaces if necessary;

g) For the thrust bearing of double bearing shoes, the contact surface between the thin shoe and the supporting shoe shall meet the design requirements Without specified design requirements, the contact surface between thin shoe and supporting shoe shall reach above 70%, and the contact surface shall be distributed evenly With the thrust bearing shoe in the stressed state, check the gap between thin shoe and supporting shoe with a 0.02mm feeler, which shall be unable to pass through

9.2.4 The guide bearing shoe required to be ground on the site shall meet the relevant requirements stipulated in Clause 5.6.1