Lắp đặt turbine GUGLER
Original Instructions Francis Turbine Dak Di Machine Nr.: 476-2 Year of Manufacture: 2021 Revision: 02 Page / 46 14.09.2021 Original Instructions Contents Installation and commissioning 6.1 Safety during installation and commissioning 6.2 Check list for readiness of power house .7 6.3 Installation 6.3.1 Draft tube 6.3.2 2nd Concreting (draft tube) 18 6.3.3 Release for 2nd Concreting (draft tube) 19 6.3.4 Preassembled Main Turbine Components 21 6.3.5 3rd Concreting (turbine) 31 6.3.6 Release for 3rd Concreting (turbine) 32 6.3.7 Generator 34 6.3.8 Pipes 43 6.3.9 Installation of the hydraulic power unit 44 6.3.10 Installation of the generator cooling circuit 45 6.3.11 Installation of the remaining equipment 46 Revision: 02 Page / 46 14.09.2021 Original Instructions Dak Di – T2 Installation and commissioning This manual shall serve as guide through the whole assembling and commissioning process From the very beginning until the operation start of the plant, this document should be used together with the daily work reports To correspond to the daily work reports, and to link this document with the reports, every finished work step must be marked, and the actual date must be noted This chapter of the manual is intended for personnel with the appropriate qualifications for "erection, installation, commissioning" 6.1 Safety during installation and commissioning Danger of life! Never work at any equipment while the turbine is running There are sudden but however slow movements of machine components, such as falling weights or the distributor mechanism Hazard of electrical voltage! Disconnect the machine from mains before opening the machine and start of any work inside the machine Installation and connecting of the machine must be carried out by qualified personnel Any work on the forced oil connections must only be carried out by, or under supervision of specialists with experience of forced oil connections and in accordance to the instructions! Hazard of high-pressure, pressure peak due to shut-off procedure Closing times to be adapted by GUGLER representatives only No manipulation on hydraulic system by unauthorized persons allowed The change of safety-relevant settings (e.g the closing times) is strictly prohibited! Hazard due to height above floor (fall and drop) due to the design of the building and/or during erection: Protect pits, shafts and any tipping points (e.g pipes) by safety equipment (grids, rails, ) and coloured marking, hazard signs or notes Anti-fall protection of pits (rail or cover) according to legal and static requirements Revision: 02 Page / 46 14.09.2021 Original Instructions Dak Di – T2 Avoid stumbling across cables, pipes or hoses Take care for the general order and cleanness on site to reduce the risk of stumbling All safety data sheets must be observed The Safety Data Sheets of turbine related substances are found in the external chapter “DATA SHEETS” Also observe those Safety Data Sheets of sub supplies (e.g Generator) Due to their weight or shape, machinery or components may be difficult to lift Transport and manipulation only with suitable transport equipment and lifting equipment! (e.g special devices) When working with an oil forced connection the hazard zone must be marked with barrier tape Keep oil binding media available! Work on electrical equipment must be carried out by qualified electricians or by instructed persons under direction and supervision of a qualified electrician and must be carried out in accordance with electrical safety regulations and when machine is switched off and secured against re-start Oil is inflammable! Avoid contact with hot machine parts and take special care when performing hot works Respect the legal requirements Danger of slipping on spilled oil In case of defilement clean site immediately Keep oil-binding media available Hazard of pointed or sharp edges during installation or service Although edges of assembled parts are deburred, use of appropriate personal protective equipment such as safety gloves Note that contaminated surfaces may be hot, and the reference to the hot surfaces is not visible due to this contamination Always use protective gloves when cleaning the machine, to prevent skin contact with contaminants and hot surfaces Hazard of rough or slippery surfaces Use of appropriate personal protective equipment such as safety footwear with non-slip sole Hazard of slipping due to leaking fluids Use of appropriate personal protective equipment such as safety footwear with non-slip sole Remove leaking liquids quickly! Moving machinery or components! When moving machinery or components no persons are allowed in the hazard zone Enough space in the surrounding area has to be kept free Revision: 02 Page / 46 14.09.2021 Original Instructions Dak Di – T2 Any works on energized parts or moving parts are strictly prohibited! Ignoring the installation and commissioning manual can result in malfunctions and risks for health and safety, equipment life expectancy and performance! The operating company must ensure adequate lighting on site, which corresponds to the national regulations The foundation forces are indicated in the installation plan On site the suitability of the foundation must be checked for plausibility Points on which the components may be set up are indicated at the relevant drawings in order to avoid tipping or similar hazards When overloaded electrical equipment can cause fire! Fire hazard due to hot works! Use the necessary protection according to legal requirements and protections (e.g railings, or fences) for hazardous locations (e.g tripping hazards, pits, shafts…) on the site Erect a scaffold to perform installation, revision, repair or maintenance activities in areas with poor accessibility! Apply warning label “P007” according to “EN ISO 7010” on the access door “No access for persons with implanted cardiac pacemakers or heard defibrillators” Gear oil and lubricant are dangerous for water They must be stored in prescribed containers Do not spill Spilled lubricants must be removed immediately with binder and disposed in the prescribed way Used old liquid must be disposed in the prescribed way, following the legal prescriptions The maximum allowed size of floating debris in the water is indicated in the general arrangement drawing An appropriate rack must be installed by the operating company In any case of any issues or doubts, always refer to GUGLER and await the written instructions given by GUGLER! Revision: 02 Page / 46 14.09.2021 Original Instructions Dak Di – T2 The calculation of the baseplate, as well as the safe design of all surrounding components, such as buildings, pressure pipes, steel construction for hydraulic engineering or stop logs are within the responsibility of the operating company, or its general contractor The structural separation of high voltage equipment, as well as all matters of explosion protection, are within the responsibility of the general contractor The evaluation of fire hazards and the installation of fire extinguishers is within the responsibility of the general contractor The operating company is obliged to set up rules for other parties who may come into contact with the machine (parties such as guided tours of external visitors, trainees or people who work in the vicinity) The operating company is obliged to prevent access by the public, for example by the installation of the machine in buildings The entrance doors shall be marked with the sign "No access for unauthorized persons" and " No access for persons with implanted cardiac pacemakers or heard defibrillators” All machine components must be grounded! Never tighten the connections above the allowed torque limit! Bending of pipes has to be the preferred solution for assembly! The national employee protection regulations are to be observed! Without the approval of the manufacturer of the machine no alteration of the machine is allowed Observe the relevant legal requirements for equipment as lifting equipment, scaffolding and ladders Flow controllers must be locked or sealed after adjustment to avoid unauthorised changes of important parameters (e.g water hammer) The operating company is obliged to comply with all applicable ordinances, laws, directives, rules and standards Revision: 02 Page / 46 14.09.2021 Original Instructions Dak Di – T2 6.2 Check list for readiness of power house ✓ Mark every finished checkpoint Before any installation work can start, the following arrangements must be made: □ □ □ □ □ □ □ □ □ □ □ □ □ □ □ □ □ □ □ All construction works completed Roofing of powerhouse completed All windows and doors installed in powerhouse First concrete and all recesses (cut-outs) according to installation plan Stairs and handrails between different floors finished (Especially down to turbine level) Power supply available “230/400V; 16A” Compressed air available Sufficient illumination inside powerhouse Heating available in cold season (below 10°C) Sanitary facilities available (toilet, bathroom etc.) Overhead crane with necessary equipment installed Overhead crane tested and approved and ready for operation Safety arrangements ready and complete Fire extinguisher and emergency medical pack available All GUGLER equipment available on site Free access into powerhouse available Cleaning of the entire powerhouse “well swept“ Lockable location for storage of expensive parts available All-risk insurance policy sent to GUGLER Comments: Date & Signature supervisor: Revision: 02 Date & Signature client: Page / 46 14.09.2021 Original Instructions Dak Di – T2 6.3 Installation ✓ Mark every finished checkpoint 6.3.1 Draft tube □ Determine the desired positions for the standing feet of the draft tube cone and drill holes for fixing the bottom plates of the standing feet to the ground (Level the plates accurately) □ Lift the draft tube cone (Client’s scope) into position in accordance with the general arrangement drawing □ Determine the desired positions for the standing feet of the draft tube elbow and drill holes for fixing the bottom plates of the standing feet to the ground (Level the plates accurately) □ Lift the draft tube elbow (Gugler’s scope) into position in accordance with the general arrangement drawing □ □ □ Adjust both parts to each other until that a smooth transition of the inside contour is reached □ Use the adjustment screws to adjust the upper flange to the foreseen height according to the drawing and level it perfectly in flow direction and in perpendicular to the flow direction □ □ Secure draft tube against any movement during concreting Weld the draft tube cone to the draft tube elbow (to be performed by a 3rd party!) Connect the pressure measurement pipes from draft tube elbow to the end of the draft tube cone (to be performed by a 3rd party!) Install/weld the dewatering pipe to the draft tube cone (to be performed by a 3rd party!) Revision: 02 Page / 46 14.09.2021 Original Instructions Revision: 02 Dak Di – T2 Page / 46 14.09.2021 Original Instructions Revision: 02 Dak Di – T2 Page 10 / 46 14.09.2021 Original Instructions Dak Di – T2 6.3.6 Release for 3rd Concreting (turbine) The previous installation steps were accomplished successfully, and the turbine is adjusted according to our drawings and secured against potentially moving during the concreting! Comments: Date: Signature of supervisor: Signature of client: Revision: 02 Page 32 / 46 14.09.2021 Original Instructions Dak Di – T2 6.3.6.1 Protocol – Turbine Alignment AFTER concreting □ Make sketches and fill Protocol before concreting in accordance with general arrangement drawing A (Alignment of axis of turbine shaft) = B (Height of turbine shaft) = C (Level of turbine shaft) = D (Orientation of spiral casing and bolt holes) = No displacements detected: Comments: Date: Signature of Supervisor: Revision: 02 Page 33 / 46 14.09.2021 Original Instructions □ □ Dak Di – T2 6.3.7 Generator In this chapter the generator is being coupled to the turbine Before lifting of generator make sure that the coupling is installed on the turbine shaft (No use of EOT crane possible after generator is placed) □ Now a modification of the tilting frame must be made: o Remove the welding between the base plates and the frame o Mount the base plates of tilting frame to the generator with M42 hexagon bolts o Weld the base plates back to the tilting frame again Pay attention to the location of terminal boxes so that there is no problem for tilting of generator □ Put the generator from horizontal to vertical position with the help of the tilting frame (see picture below) To control the tilting movement, secure the frame with logs so that the slings of EOT crane are always under tension □ □ □ □ Also check the generator documentation for instructions Disassemble the tilting frame from the generator Lift the generator and put it into position Mount the generator shaft to the coupling Revision: 02 Page 34 / 46 14.09.2021 Original Instructions Revision: 02 Dak Di – T2 Page 35 / 46 14.09.2021 Original Instructions Revision: 02 Dak Di – T2 Page 36 / 46 14.09.2021 Original Instructions Revision: 02 Dak Di – T2 Page 37 / 46 14.09.2021 Original Instructions Revision: 02 Dak Di – T2 Page 38 / 46 14.09.2021 Original Instructions Revision: 02 Dak Di – T2 Page 39 / 46 14.09.2021 Original Instructions Dak Di – T2 Comments: Date: Signature of Supervisor: Revision: 02 Page 40 / 46 14.09.2021 Original Instructions Dak Di – T2 6.3.7.1 Francis runner adjustment □ Move the draft tube cone below the runner so that the runner gaps are accessible □ Install/Start up the hydrostatic unit placed on the generator to lift the drive train to rotate the shaft and complete protocol in the next chapter For details refer to the generator documentation □ Put shim plates below generator and set pins according to the generator foundation drawing Don’t fix the pins until the complete drive train is adjusted according to the runner gaps! Refer to the foundation drawing of generator supplier □ □ □ □ □ Adjust the runner gaps by moving the generator in position Check runner gaps on draft tube side as well as on generator side and note down the values The gaps should be equal around the runner Adjust the Turbine guide bearing pads according to suppliers’ instructions After adjustment, grouting of the generator base plates can be done Check generator documentation for more details! Radial bearing pads gap Runner gap generator side Runner gap draft tube side Revision: 02 Page 41 / 46 14.09.2021 Original Instructions Dak Di – T2 Gap at draft tube side: Gap at generator side: Inlet Inlet Shim plates on generator base feet: Inlet Comments: Date: Signature of Supervisor: Revision: 02 Page 42 / 46 14.09.2021 Original Instructions Dak Di – T2 6.3.8 Pipes □ □ Apply the remaining pressure relief pipes Apply remaining dewatering pipes Comments: Date: Signature of Supervisor: Revision: 02 Page 43 / 46 14.09.2021 Original Instructions Dak Di – T2 6.3.9 Installation of the hydraulic power unit □ Put the hydraulic power unit into position, in accordance with the general arrangement drawing □ Make sure all assembly works are carried out according to the instructions of the manufacturer, attached to these instructions in external chapter “HYDRAULIC POWER UNIT” □ □ □ □ Connect the hydraulic pipes according to the hydraulic schema Fill in the specified oil Verify that the nitrogen filling of pressure accumulators is within the acceptable limits Lock or seal the flow valves after adjustment to make sure the closing times cannot be changed Attention Never tighten the connections above the allowed torque limit! Bending of pipes has to be the preferred solution for assembly! All pipes must be protected against rust (e.g zinc-coated) All pipes must be trimmed and cleaned after cutting to avoid contamination of the system Fittings may only be used if bending is not possible Hoses are only permitted on moving parts and where explicitly allowed by GUGLER Comments: Date: Signature of Supervisor: Revision: 02 Page 44 / 46 14.09.2021 Original Instructions Dak Di – T2 6.3.10 Installation of the generator cooling circuit □ □ Install the cooling circuit according to the general arrangement drawing and cooling schematic Fill in the specified liquids Attention Never tighten the connections above the allowed torque limit! All pipes must be protected against rust (e.g zinc-coated) All pipes must be trimmed and cleaned after cutting to avoid contamination of the system Comments: Date: Signature of Supervisor: Revision: 02 Page 45 / 46 14.09.2021 Original Instructions Dak Di – T2 6.3.11 Installation of the remaining equipment □ □ □ □ Make sure all assembly works are carried out according to the instructions of the manufacturer Connect the pipes and hoses in according to the general arrangement drawing Install all sensors and measurement devices according to the drawings and to the signal list Install the counterweight of the shut-off valve and the safety fence Comments: Date: Signature of Supervisor: Revision: 02 Page 46 / 46 14.09.2021 ... – T2 Page 13 / 46 14 .09.20 21 Original Instructions Revision: 02 Dak Di – T2 Page 14 / 46 14 .09.20 21 Original Instructions Revision: 02 Dak Di – T2 Page 15 / 46 14 .09.20 21 Original Instructions. .. 14 .09.20 21 Original Instructions Revision: 02 Dak Di – T2 Page 11 / 46 14 .09.20 21 Original Instructions Revision: 02 Dak Di – T2 Page 12 / 46 14 .09.20 21 Original Instructions Revision: 02 Dak Di – T2. .. 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