Erection installation manual for hydroelectric turbines

Document No Revision No Project Nuoc Che HPP (2 x 15 MW) Document No NCHE – SI 002 Project code 1819 02 Revision no A No of pages 45 Date 01 05 2020 ERECTION INSTALLATION MANUAL VERTICAL FRANCIS TUR.

Project Nuoc Che HPP (2 x 15 MW) Document No NCHE – SI -002

ERECTION & INSTALLATION MANUAL

VERTICAL FRANCIS TURBINE

NOUC CHE HYDRO POWER PROJECT

(2 X 15 MW)

CLIENT: NUOC CHE HYDROPOWER JOINT STOCK COMPANY HEMLET -1

(VIETNAM)

This procedure shows the general guidelines for erection of Vertical Francis Turbines.Drawings and sketches enclosed in this procedure have been taken from one similarvertical Turbine for reference only Detailed information is provided in respectivedrawings only and the erection Engineer should thoroughly study the drawings and makehis own detailed plan accordingly for carrying out the erection work.

The erection plan is to be made well in advance, for which the following inputs are

required

1) Contract agreement

2) All the necessary drawings required to execute the project

3) Installation time schedule

4) Safety requirements

5) Own Product and other materials packing lists

6) Tools and Plant

3) Runner assembly with turbine shaft, Generator assembly, generator shaft andturbine shaft coupling, exciter rotor, air injection assembly and Water CollectorAssembly are also individual assemblies classified under Rotary equipment

4) Installation of the auxiliary systems, Hydraulic system, wiring, terminations ofcable in panels to control the operating system of the turbine and auxiliaries etc.are to be generally performed after installation of turbine static & rotary parts.

5) Insert plates should be left, if possible, on wall as well as on floor for clampinghydraulic and water Pipes, which are generally shown in drawings

3) Elevation of the unit

3.1) Main axis of the unit

3.2) Benchmarks

4) Assembly procedure

4.1) First stage Embedments and concreting

4.2) Erection & alignment of draft tube elbow and second stage concreting

4.3) Draft tube cone -3 and cone -2 assembly

4.4) Spiral case assembly with distributor and draft tube cone -1, if possible or intwo

parts First upper ring after lower assembly with guide vanes and drafttube cone -1

4.5) Main Inlet valve, pit liner and generator base frame (base plate) assembly

4.6) Third stage concreting

4.7) Installation of rails at MIV floor to dismantle and assemble Draft Tube,Runner, lower

distributor ring, etc

4.8) Dismantling of draft tube cone -2

4.9) Dismantling of lower ring with draft tube cone -1

4.10) Assembly of bearing housing, lowering of turbine shaft and mounting of shaftholding fixture

4.11) Generator assembly

4.12) Runner Assembly

4.13) Lower ring assembly with draft tube cone -1

4.14) Turbine guide bearing assembly

4.15) Air Injection assembly

4.16) Draft tube cone -2 assembly

5) Auxiliary system

5.1) Hydraulic pumping unit

5.2) Generator bearing lube oil

5.3) Cooling water system

6) Reference Drawings & catalogues

6.1) Layout of power house, Drawing No F3P1819-0230101

6.2) First Stage concrete and embedment plan and section, Drawing No

F1P1819-0230502

6.3) Second stage concrete and embedment plan and section, Drawing No.

F1P1819-0230503

6.4) Draft tube Assembly Drawing No F1C1819-0210101

6.5) Spiral Casing assembly Drawing No F1C1819-0211601

6.6) Pit Liner assembly Drawing No F1C1819-0212001 & F1C1819-0212101

6.7) Turbine Assembly Drawing No F1C1819-0214401

6.8) Distributor Assembly Drawing No F1C1819-0211201

6.9) Shaft Assembly Drawing No F1C1819-0212805

6.10) Main Inlet Valve Assembly Drawing No T1C6001-5420001

6.11) Assembly & Handling Fixture (Assembly) Drawing No F1C1819-0215638

6.12) Air injection assembly Drawing No F1C1819-0216501

6.13) Outline drawing of A.C Generator Drawing No 10006288581

6.14) Hyd Schematic control diagram for Turbine, bypass assembly and MIV

Control (Drawing No F3C1819-02M0502)

6.15) Cooling Water System Drawing No F3C1819-02M0601

6.16) Hydraulic Schematic control diagram (For generator lube oil system) Drawing

Sense of rotation - Counter Clock Wise (Viewed from DE Side.)

2) Pre‐Conditions & Preparations

With regard to installation time schedule, the main erection of the Francis turbine cancommence only after first stage concreting In first stage concreting the insert platesshould be left for turbine draft tube foundation bolts locking and ensures allembedded components installed according to the reference drawings

The generator is installed and aligned after turbine installations

• Check the elevation level of the all sole plates and finish floor level

• Check the axis of penstock in respect to machine center-line The readings are to berecorded and to be compared with benchmark as given by civil team surveyor in thepower house

• Check all the materials availability in store, sequence wise for easy flow of erection

• Check the availability of front readiness to erect the component as per sequenceand erection team experience in their respective fields, contractor’s tools & plantsand the skilled manpower of sub-contractor

• Check the level of the turbine and generator sole plate and record the actual level.

Note 1: In order to achieve a flawless function of the assembly, cleanliness is of prime

importance throughout the installation process For this reason, the turbinecomponents have to be protected from dirt and dust by appropriate means(PVC‐sheeting, etc.) For instance: During the installation of the rotating parts,only workers along with clean clothes, clean shoes and with white color cottonwaste to clean the parts during assembly are allowed

3) Elevation of the unit

When the turbine suppliers begin with the erection work of the unit, the theoreticalaxis and elevations of the turbine unit in the power house are the coordinates andposition of penstock only the references as per design The reference points whichare existing, unit center-lines and elevation should be marked by surveyingcontractor and / or civil contractor are actual and handing over to E & M contractorwith an official protocol should be done These reference points are taken as thebasis for the further installation of E & M equipment

3.1) Main axis of the unit

The positioning of the Turbine Housing dictates the precise elevation of all theother turbine and generator components Theoretically, the horizontal center-line

of the turbine is the reference axis as well as the shaft center-line is the referenceelevation Practically, however, the center-line is difficult to establish bymeasurements

Important is the exact alignment of the Turbine Housing inlet pipe with regard tothe penstock connection point in elevation and position The horizontal center-line

of the Turbine Housing should be aligned with the horizontal center-line of thepenstock

Therefore, the deviations regarding the theoretical inlet pipe axis in horizontal andvertical

direction should be measured and recorded

4.1) Frist

stage embedment and concreting

• First of all, cast the first stage concrete, embed the foundation plates / anchor platefor draft tube mounting, drainpipes etc as per B.O.M mentioned in first stage

embedment’s and concreting drawing

• This is the most important phase of concreting, so read carefully the B.O.M of

embedment and align this embedment as per drawing Fix the pipes in proper slope for easy drainage as per drawing, the sketch -1 is just for reference of

sequence only

SKETCH -1

4.2) Erection, alignment of Draft tube Elbow and second stage concreting

Refer draft tube Assembly Drawing No F1C1819-0210101 and second stageembedment and concreting Drawing No F1P1819-0230503

• Before the installation of draft tube, check the accessories as per packing list as well

as drawings related to draft tube erection & ascertain any physical damages andcheck the level of all the sole plates for correct position

• Principal axis of the generating set is fixed by reliably secured brackets and benchmarks

• Lower the draft tube elbow with the help of mobile crane / EOT crane

• First of all proper positioning of draft tube is to be done Since this is the basic part

of generating unit, its correct positioning will determine the correct installation ofentire generating set

• Draft tube elbow to be aligned with respect to the turbine centerline and its elevation with the help of leveling/ adjusting screws mounted on Draft tube elbow feet

• Lateral movement to be done by using turnbuckles with temporary welding with side supports to make convenient for movement on concrete floor

• After alignment of draft tube it should be properly supported by sufficient packing andfixed (Refer to sketch-2 and detail A) Lock the draft tube firmly on its sole plate and all the nuts used for positioning/adjustment to be welded as shown, to restrict mis-alignment of draft tube during concreting, weld additional anchor bar or supports if required for better stiffening

• After alignment of the draft tube and before second stage concreting connect the MIV upstream, downstream drain pipe and thrust relief pipe with the draft tube elbow as shown in sketch -2

SKETCH-2

• After final positioning of draft tube, all the nuts used for

positioning/adjustment to be welded as shown in detail A to restrict alignment of draft tube during concreting

mis-• After completion of above activities and found correct with all checks, we can

go ahead for the second stage concreting

• The embedment and concreting will be carried out with the reference of drawing No F1P1819-0230503

4.3) Draft tube cone 3, cone 2 Assembly.

Refer the drawing F1P1819-0210101

• After curing of the second stage concreting, lower the draft tube cone -3 fixthis cone with draft tube elbow with the C clamp (Dutchmen clamp) and tagweld on both side up and down of clamp, maintain the level and theelevation of top of the DT cone -3 during installation Maintain the gap forwelding to fix the rod in between as per site availability 10 mm or 8 mmdepend on rod size Cover the joint with cover plate if necessary

• Now lower the DT cone -2 with dismantling flange rest it over the cone-3.Maintain the dismantling gap 10 mm equally all around with the help of studand nuts as per detail B given in reference drawing the sketch -3 is asreference for sequence only

SKETCH -3

4.4) Spiral case assembly with distributor and DT cone -1

• Lower the bottom pit liner if it is supplied in single piece or weld with spiral

at service bay before spiral case installation

• Mount the DT cone 1 with spiral casing before lowering or installation Restthe DT cone 2 over the DT cone 3 flange, so that we can achieve 10 mm gap

to align the spiral casing easily

• Lower the spiral casing assembled with head cover, bottom ring and drafttube cone-1 and pit liner

• Rest the feet along with the adjusting screw of complete assembly over thesole plate embedded in second stage or on the concrete surface where soleplate not provided we can use or fix other alternate as per site requirements

• Align and level the complete assembly w.r.t embedded draft tube Check theorientation to match the inlet of penstock center line

SPIRAL CASING

SKETCH -4

Sketch -5

• If all checks are found correct, then connect upstream pipe with spiral

flange Maintain the dismantling gap as per drawing 10 mm, it should be maintained after welding of upstream pipe with penstock So, maintain the minimum gap including the shrinkage allowances considered for welding Use the proper C clamp (Cleats) between joint to reduce shrinkage Same exercise to be done for the welding joint of draft tube elbow and cone -3

• Recheck the alignment and leveling of complete assembly and make a record for the same

• If all checks found okay, then go ahead for welding of draft tube elbow and cone -3 and penstock with MIV pipe

• Now, lock the entire assembly with the help of adjusting nuts and provide additional locking by welding the bars, C-channels, etc

SKETCH -7

4.7) Installation of rails path for assembly and dismantling runner and other lower components.

• After proper curing of 3rd stage concreting and written clearance from civil in

charge, further assembly work to be done as per sequence

• As a first step, we need to dismantle the draft tube Cone -2, lower ring of

distributor with draft tube Cone-1

• For the above activities, we need to install rail track installation on MIV floor

• The installation details are given in the drawing, if not sufficient, ask for more info from design department

4.8) Dismantling of draft tube cone -2.

• To proceed for further assembly dismantle, the Draft tube cone first

• In Draft tube cone, there is arrangement of fixing wheel directly with the cone Putthe wheel over the rail track and tighten all the bolts of the wheel fixture Then, dismantle all the Flange mounting bolts

• Draft Tube cone-2 will be free to move after dismantling all bolts and easy to

remove out

As shown in sketch-11

Assembly after dismantling Draft tube cone -2

Sketch -10

Draft tube handling arrangement for assembly and dismantling purpose

SKETCH -11 4.9) Dismantling of lower ring with draft tube cone -1.

• The procedure of dismantling lower ring with guide vane and DT cone is a

heavy job Be careful during this exercise

• Remove the mounting fasteners of lower ring except 8 or 10 left to remove laterafter mounting fixture (Trolley with wheel) mount the trolley with DT cone tie the steel rope in the bottom of the trolley through hole given in trolley

• Hold this steel rope with the help of crane (Do check the capacity of rope and weight to handle prior to dismantle)

• Fix at least 3 or 4 chain pulley blocks or make any other alternative at site to avoid the swing of heavy load Remove all stop levers of guide vanes before lowering

• Now, remove all pending fasteners and let allow the load on steel rope Align the crane hook in the center of assembly

• Lower the complete assembly slowly and put over the rail track Now complete assembly will move out by pushing with hand

Assembly after dismantling lower ring with guide vanes and DT cone

SKETCH -12

Dismantling arrangement of lower ring with guide vane and DT cone -1

SKETCH -13

4.10) Assembly of Bearing housing, lowering of turbine shaft and mounting of shaft holding fixture.

• Next activity to the above sequence is assembly of bearing housing

• Bearing housing has ribs in bottom for strengthening the body it may foul with the top cover of distributor Ensure for any fouling during bolting with top cover If it fouls, trim the ribs suitably

• Fully tighten all mounting bolts as far as possible because this is the

• Sketch -14 is showing the arrangement of bearing housing

Bearing housing assembly

• Hold the shaft with shaft holding fixture properly and allow for the adjustment of height and shifting / aligning with the adjusting screw The sketch -15 is given as a reference of the arrangement.

• To confirm the location of shaft, check the height of shaft face from the labyrinth or any other suitable machined face as per design

requirement and adjusts the same accordingly

• These are the check points for the correct location of components So,

it is recommended to take the check point dimensions from the design wherever required accordingly

• Lower the shaft 25 mm further down from its normal position It will

be restored after coupling with Generator shaft As it is necessary to check the run out of generator shaft coupling flange before coupling with turbine shaft

• Align the shaft i.e centering w.r.t top cover’s circular machined surface

as convenient with the help of adjusting screw roughly

Sketch -15 provides a reference of the arrangement