installation hydroturbine

8/12/2019 Installation Hydroturbine

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GB/T 8564-2003

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 OriginalStandard 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, 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 magneticgenerator. 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 inapplication, 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.

Specification Installation of Hydraulic Turbine Generator Units

1Scope

This standard describes the requirements on the installation, commissioning and test of hydraulic turbine generator units and

their auxiliary equipment. It is applicable for the installation and acceptance test of hydraulic turbine generator units satisfying

one of the following conditions:

a)Single unit capacity no smaller than 15MW;b)Reaction turbine, with the nominal diameter of runner no less than 1.5m;


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GB/T8564-2003

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.2Normative 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 unitsJB/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, environmentprotection 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 standardsand the requirements given in the purchase order. After the equipment arriving at the destination, the installation enterprise canrequest to the owner for taking part in the open package inspection according to JB/T8660.


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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 theconstructional 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 inspectionreport 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 ofworkshop 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 50C, 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 orexplosive articles shall comply with the relevant safety requirements;

e)The installation shall be conducted according to the site regulations. The installation equipment, instruments, tools andconstruction 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 andrelevant 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, wedgeplates 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 thecentral line of bolt hole and that of foundation shall be no more than 10mm; The elevation and the depth of the bolt holes shall


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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 thedesign 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 requirementsshall 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 preembeddedreinforced 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 keycomponents, 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. Thesecond-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 thatunable 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 stagger 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, eachgenerator 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 meteringorganization.

b)The error in X and Y reference axes and reference elevation point for the installation of generator unit shall not exceed 1mmby 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 stressshall be no less than 1200MPa;


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

g)The impact of temperature change on the measurement precision shall be taken into consideration. The measured values shallbe 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. Aftercompleting 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. Thekeys 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 specialtraining 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 accordingthe 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 ofthe 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 withthe 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 thedelivery technical requirements.

4.17 The hydraulic turbine generator unit shall be kept clean during the component assembling and overall assembling and afterinstallation. 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 unitaccording 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 therequirements 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 relevantparticular requirements.

5 Installation of vertical reaction turbine5.1 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:


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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

Runner Diameter DNo. Item D2~3 >3~4 >4~6 >4~8 >8Points 1 2 3 6 10 15 25

E.1.3 See Table E. 3 for the defect dimensions not considering the point numbers.

Table E.3 Defect Dimensions not Considering the Point Numbers unit:mm

Thickness of base material, T Larger diameter of defectT25 50 10 25>T>15 50>T>25 100>T>50 T>100

Quality I 1 2 3 4 5 6grade II 3 6 9 12 15 18

III 6 12 18 24 30 36

IV The number of defect points exceeds the limit for Grade III

Table E.4 Rating of Circular Defects (determined according to the upper limit of defect points)


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The defects shall be rated based on the indicating length according to Table E.6.

APPENDIX F

(Informative appendix) Requirements on Steam Turbine Oil

Stipulated in GB11120-1989

Table F.1 Requirements on Steam Turbine Oil Stipulated in GB11120-1989Item Quality indexes Test

methodBest quality Firsts Qualified

Viscosity grade 32 46 32 46 32 46 GB 3141Kinematic viscosity (40 C),mm2/s

28.8~35.2 41.4~50.6 28.8~35.2 41.4~50.6 28.8~35.2 41.4~50.6 GB 265

Viscosity index a, no less than 90 90 90 GB 1995Pour point b, C, no higher than -7 -7 -7 GB 3535

Flash point (open end), C , nolower than

180 180 180 GB 3536

Density (20 C), kg/m2 Report Report Report GB 1884GB 1885

Acid number, mgKOH/g, nomore than

- - 0.3 GB 264

Neutralization value,mgKOH/g, no more than

Report Report - GB 4945

Mechanical impurities NA NA NA GB 511Moisture NA NA NA GB 260Demulsification number c,(40-37-3) L, 54C, min, no morethan

15 15 15 GB 7305

Air bubble test d, ml/ml 24 C, nomore than 93 C, no more thanLower than 24C , no more than

450/0100/0450/0

450/0100/0450/0

600/0100/0600/0

SY 2669

Oxidation stability e

a. Total oxidation products, %precipitate, %b. As acid number afteroxidation reaching2.0mgKOH/g, h, no less than

Report Report

3000

Report Report

2000

Report Report

1500

GB 8119

SY 2680

Liquid phase corrosion test(synthetic seawater)

No rust No rust No rust GB 11143

Copper strip test (100C,3h),grade, no more than

1 1 1 GB 5096

Air release value f(50 C) min,no more than

5 6 5 6 - SY 2693

a For the steam turbine oil produced from intermediate-base crude oil, the allowed viscosity index of L-TSA qualified

product shall not be lower than 70; and the viscosity index of the firsts no lower than 80, unless otherwise agreed by

manufacturer and user according to the experience in actual production and application. b The index of pour point can

be otherwise determined by manufacturer and user according to the experience in actual production and application.

Inspection grade A B CSheet thickness 8~15 8~300 8~300

Raging

grade

I 2/35, min. 12 5/2, min. 10, max. 30 5/3, min. 10, max. 20II 3/45, min. 12 2/35, min. 12, max. 50 5/2, min. 10, max. 30III


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c For military use, the demulsification number cam be determined by the army and the manufacturer through

negotiation.

d In the air bubble test, if bubbles have not completely covered the oil surface, the test result shall be "0". e As a

guaranteed item, oxidation stability shall be spot-checked once per year.

f For the firsts, air release value can be otherwise determined by manufacturer and user according to the experience in

actual production and application.

APPENDIX G

(Normative appendix) Description on Standard Wording The words used in the standard

according to the strictness of the requirements include:

G. 1 The words to represent the standard shall be strictly abided by and it's not allowed to deviate from the standard requirements

"shall" in the case of positive expression; and "shall not" in the case of negative expression. G.2 The word

to represent the requirements shall be abided under normal conditions

"should" in the case of positive expression; "should not" in the case of negative expression. G.3 The word

to represent it's allowed to select the requirements within a specified range

"can" in the case of positive expression; "need not" in the case of negative expression. G.4 The word to represent

the possibility or the potential capability of the causality of the matter "can" in the case of positive expression;"can not" in the case of negative expression.

installation hydroturbine

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