tiêu chuẩn lắp đăt GB8564-2003 Specification for installation of hydraulic turbine and generator units

GB/T18482 Start - up test code for reversible pump - storage units; GB50150 Emending explanation of Standard for hand-over test of electric equipment electric equipment; GB50168 Code for

ICS 27.140

F 22

NATIONAL STANDARD OF THE PEOPLE’S REPUBLIC OF CHINA

中华人民共和国国家标准

中华人民共和国国家标准

GB/T 8564-2003 Replace GB/T 8564-1988

Specification for Installation of Hydraulic Turbine Generator Units

水轮发电机组安装技术规范

水轮发电机组安装技术规范

Issued on September 15, 2003 Implemented on March 1, 2004

Issued by General Administration of Quality Supervision, Inspection and Quarantine of the People's Republic of China and Standardization

Administration of the People's Republic of China

NATIONAL STANDARD OF THE PEOPLE’S REPUBLIC OF CHINA

Electric Machinery Co., Ltd

Implementation date: March 1, 2004

Standards Press of China

中国标准出版社 中国标准出版社

Beijing 2004

Contents

1 Scope 7

2 Normative standards 7

3 General principles 8

4 General regulations 9

5 Installation of vertical type reaction turbine 12

5.1 Installation of built-in fitting 12

5.2 Runner installation 21

5.3 Preassembling of the guide apparatus 24

5.4 Emplacement and installation of rotatable parts 26

5.5 Installation and adjustment of guide blade and/or servomotor 27

5.6 Installation of water conduit and main shaft seal 29

5.7 Installation of fittings 30

6 Installation of tubular turbine 31

6.1 Installation of built-in fitting 31

6.2 Installation of principal axes 34

6.3 Installation of guide apparatus 34

6.4 Installation of guide apparatus 34

6.5 Installation of the principal axes, runner and runner chamber 35

7 Installation of impulse turbine 35

7.1 Installation of diversion conduit 35

7.2 Installation of case 36

7.3 Installation of the bearing of turbine shaft 36

7.4 Installation of turbine shaft 36

7.5 Installation of sprayer and servomotor 37

7.6 Installation of runner 37

7.7 Installation and adjustment of control mechanism 37

8 Installation and debugging of speed regulating system 37

8.1 Installation and debugging of oil pressure devices 37

8.2 Installation of speed governor 39

8.3 Oil filling adjustment test of speed regulating system 41

8.4 Simulation test of speed regulating system 42

9 Installation of vertical type hydrogenerator 42

9.1 Combination of framework 42

9.2 Grounding and scraping of bearing shell 43

9.3 Stator installation 44

9.4 Rotor installation 50

9.5 Overall installation 56

9.6 Installation of excitation system and devices 64

10 Installation of horizontal hydraulic generator 65

10.1 Grounding and scraping of bearing bush 65

10.2 Installation of bearing pedestal 66

10.3 Installation of stator, rotor and/or fitment 66

10.4 Checking of each part of the bearing and clearance adjustment 67

11 Installation of bulb-type hydraulic generator 68

11.1 Installation of stator 68

11.2 Installation of rotor 68

11.3 Installation of principal axes and composition bearing 68

11.4 Generator installation 69

12 Installation of pipelineand and fitments 70

12.1 Fabrication of pipe fittings and fitments of pipeline 70

12.2 Pipeline welding 72

12.3 Installation of pipeline 73

12.4 Treatment of the inner wall of pipeline 75

12.5 Test of the conduit and pipe fittings 75

13 Installation of butterfly valve and ball valve 75

13.1 Installation of butterfly valve 75

13.2 Installation of ball valve 76

13.3 Installation of flexible connector 77

13.4 The installation of hydraulic control valve and air valve 77

13.5 Installation of operating mechanism 77

14 Electrical test of water-turbine generator set 78

15 Trial run of water-turbine generator set 82

15.1 General specifications 82

15.2 Water filling test of assembling unit 83

15.3 Zero load trial run of unit 83

15.4 Test over paralleling in of unit and under load 86

Annex A 90

Annex B 94

Annex D 96

Annex E 98

Annex F 101

Annex G 104

Foreword

This standard provides basis for the installation, debugging and testing of hydraulic turbine generator units and relevant auxiliary facilities and main content for unit acceptance and examination This standard is applicable to the installation of all types of hydraulic turbine generator units and relevant auxiliary facilities

This standard is the revision of GB 8564-1998 Specification for Installation of Hydraulic Turbine Generator Units (hereinafter referred to as "the original standard") The original standard summarizes technologies for installation of hydraulic turbine generator units and relevant auxiliary facilities in and before 1988 On the basis of the original standard, this standard contains supplements, deletions and amendments to specifications for installation of large and medium hydraulic turbine generator units and relevant auxiliary facilities including those imported since 1989, and makes references of some relevant content in foreign standards

Compared with GB 864-1988, the following changes are made herein:

The standard is clearly classified to be a piece of recommended standard; Application scope of original standard is changed and "Scope" and

"Normative References" are stated separately herein;

The following contents are supplemented, such as installation of cylindrical valve, aqueduct installation and bearing assembly of action turbine, assembly of welded generator engine frame, assembly of generator stator base and iron core, welding of disc-type rotor, installation of excitation system and commissioning of reversible pump-storage unit

Partial contents of installation of speed regulator, adjustment test of oil charging for speed regulating system, technical requirements of pipeline welding and quality inspection;

Installations of mechanical hydraulic speed regulator, initiator and permanently-magnetic machine are deleted from the text of original standard, and installation of mechanical hydraulic speed regulator and drying of stator winding are stated in annex;

Indices and limit values of some articles are partially adjusted and increased Although stator windings of internal water cooling and evaporative cooling have already been adopted in some units in China, experiences in design and construction

of these cooling types are immature and these cooling types may not be promoted in the future Therefore, these two cooling types are not covered herein

This standard will replace GB 8564-1988 from the implementation date of this standard

Annexes B, C and G attached hereto are normative

Annexes A, D, E and F attached hereto are informative

This standard is proposed by and under the jurisdiction of China Electricity Council Standardization Center

Chief Development Department: China Gezhouba (Group) Corporation,

Sinohydro Corporation, China Gorges Project Corporation and Harbin Electric

Machinery Co., Ltd

Chief Drafting Staff: Fu Yuanchu, Zhang Hua, Wang Quanlong, Qin Xixiang,

Liu Yongdong, Zhao Shiru, Li Zheng'an, Zhang Yaozhong, Du Qichen, Zhang Lianbin, Zhao Guishan,

Xu Guangtao, Gong Deping, Wang Tian, Yang Xiyin, Huang Hongyong, Zhang Chengping, Liu Yanhua, Jiang Xiaobing, Yin Longsheng, Liu Canxue and Tang Wanbin

China Electricity Council Standardization Center is responsible for interpretation

of this standard

Specification for Installation of Hydraulic Turbine Generator Units

1 Scope

This national standard regulates the installation, debugging of hydraulic turbine generator units and the requirements of test It is applicable to the installation and/or acceptance of hydraulic turbine generator units in compliance with the following conditions:

a) Unit capacity of 15MW and/or higher

b) Impulse hydraulic turbine with its nominal diameter of runner at 1.5m and/or above

c) Radial-axial flow turbine with its nominal diameter of runner at 2.0 m and/or above

d) Axial flow, mixed flow variable pitch turbine, and tubular turbine, with nominal diameter of runner at 3.0m and/or above

Hydraulic turbine generator units with unit capacity smaller than 15MW and units with nominal diameter of turbine runner smaller than that specified in b), c), and d) This national standard is applicable to the installation and/or acceptance of reversible pump storage unit

2 Normative standards

The following normative documents contain provisions, which, through reference

in this text, constitute provisions of this national standard For dated reference, subsequent amendments to, or revisions of, any of these publications do not apply However, it is recommended parties reaching agreement according to this national standard carry out a study on if the most updated version of these documents may be applied or not For undated reference, the latest edition of the normative document referred to applies

GB3323 Methods for radiographic inspection and classification of radiographs for fusion welded butt joints in steel

GB/T7409.3 Excitation system for synchronous electrical machines-Technical requirements of excitation system for large and medium synchronousgenerators;

GB/T7894 Fundamental technical requirements for hydraulic turbine generators; GB/T9652.1 Specifications of governors and Pressure oil supply units for hydraulic turbines;

GB/T9652.2 Test acceptance codes of governors and pressure oil supply units for hydro-turbines;

GB/T10969 Specifications for water passage components of hydraulic turbines; GB/T11120L-TSA Turbine Oil;

GB11345 Method for manual ultrasonic testing and classification of testing results for ferritic steel welds;

GB/T18482 Start - up test code for reversible pump - storage units;

GB50150 Emending explanation of Standard for hand-over test of electric equipment electric equipment;

GB50168 Code for construction and acceptance of cable levels electric equipment installation engineering;

GB50171 Acceptance of switchboard outfit complete cubicle and secondary Circuit Electric Machine;

DL/T507 Start-up test code for hydraulic-turbine and generator units;

DL/T679 Code for welder technical qualification;

DL/T827 Start-up test code for bulb tubular hydraulic-turbine and generator units; JB/T4709 Welding specification for steel pressure vessels;

JB/T6204 Specification for withstand voltage test on stator coil and winding insulation of high voltage AC machines;

JB/T8439Technical requirements on suppress corona of high-tension machines used in high altitude areas

JB/T8660 Standard for hydroelectric set packing, transportation and preservation

3 General principles

3.1 Installation of water-turbine generator set shall proceed according to this national standard in compliance with the installation drawing approved by design organization and manufacturer as well as related technical documents Special requirements raised by the manufacturer shall be satisfied according to related technical documents Supplementary provisions for requirements not listed in this standard and technical documents of manufacturer shall be specified additionally In case of a conflict between the technical requirements from the manufacturer and this standard, generally, the requirements of the manufacturer shall proceed Otherwise, consult with the manufacturer for a settlement

3.2 Other than this national standard, installation of unit and its auxiliary facilities shall also comply with current related specifications on safety, environmental protection, fire control, and so on issued by the state or related authorities

3.3 Equipment for water-turbine generator units shall be in accordance with the regulations of current national standard and purchase contract After the equipment arrives at the acceptance spot, the installation party may participate in unpacking, counting, checking the supply list and random packing list, and then operate according

c) Certificate of analysis, inspection and test records;

d) Material quality and performance certificate of vital parts

3.4 Before the installation, read design drawing, factory inspection record and related technical documents carefully and be familiar with them, and then make out a logical construction design in compliance with the actual conditions

3.5 Before the installation, read related civil design drawing and participate in the acceptance of the delivered civil construction parts For places with flaws, the installation must be carried out after treatment

3.6 All materials used in the installation of water-turbine generator unit shall be in accordance with design requirements Primary materials must possess inspection certificate and certificate of analysis

3.7 Plan the installation field integrated The following requirements shall be met: a) Installation field shall be windproof, rainproof and dustproof Unit installation must proceed after the completion of the factory building roofs of this unit and adjacent units are sealed

b) Generally, the temperature shall not be lower than 5°C Relative humidity of air shall not be higher than 85% For other equipments and parts that have requirements over temperature, humidity and other special conditions, the installations shall be implemented according to the design specifications

c) Enough illumination shall be provided on the construction field;

d) Safety facilities for construction in compliance with requirements must be equipped on site Places to put flammable, high explosive items must have corresponding safety provisions;

e) Civilize production Installation equipment, construction tools and materials shall be placed in order The construction site shall keep clean Passage remains to be smooth Clear the site on the completion of work

3.8 After the completion of the installation of water-turbine generator set, proceed the test run according to this national standard and DL/T507 Comprehensively check the quality of design, fabrication and installation After the test run is proved qualified, proceed the acceptance of the unloading phase of this unit Hand over related materials according to the requirements of Annex A

4 General regulations

4.1 Before installation, clear and inspect the equipment overall Check the main dimensions and/or tolerance of primary parts according to the drawing requirements as well as ex-factory records

Equipment inspection and flaw treatment shall have records and licenses

Packed equipment under warranty may not have to be dis-integrated

4.2 Generally, deviation of the elevation of entombment of equipment foundation bedplate shall not exceed - 5mm ~ 0mm Deviation of the center and azimuth distribution shall not be greater than 10mm Horizontal deviation is no greater than 1mm/m

4.3 After fitting entombment part, reinforce it Foundation bolt, lifting jack, fastener, wedge, and floor plate shall all be spot-welded and fixed The built-in fitting and the concrete binding surface shall be free of oil sludge and serious rustiness 4.4 Installation of the anchor bolt shall comply with the following requirements:

a) Check if the anchor bolt hole is in the right position The inner wall of the hole shall be roughened and cleaned Deviation of the screw center line and base center line shall not be greater than 10mm; the elevation and depth of the bolt shall be in compliance with the design requirement; squareness deviation of bolt hole wall shall not be greater than L/200 (L refers to the length of anchor bolt mm, the same for the following context) and shall be smaller than 10mm

b) Centre of second phase concrete direct burial and casing flush type anchor bolt shall comply with design requirement The deviation of center shall not be greater than 2mm The discrepancy in elevation shall not be greater than 0mm ~ +3mm Squareness deviation shall be smaller than L/450

c) Anchor bolt adopts embedded bar Welding of screw on it shall conform to the following requirement:

1) Material quality of embedded bar shall agree with the material quality of anchor bolt basically;

2) Cross-sectional area of embedded bar shall be greater than that of bolt, and the embedded bar shall be upright;

3) When the bolt and embedded bar adopts double side welding, the weld length shall not be smaller than 5 times the diameter of the anchor bolt When single side welding is adopted, the weld length shall not be smaller than 10 times the diameter of anchor bolt

4.5 Use wedge plate pairs and the overlapping length shall be 2/3 upwards For the wedge plate that bears important parts, inspect the contact situation with 0.05mm feeler gauge The contact length of each side shall be greater than 70%

4.6 Install the equipment after the substructure concrete intensity reaches 70% of the design value Second term concrete on the floor plate shall be poured and

compacted

4.7 The coupling surfaces of equipment shall be smooth and burr free For joint close clearance, measure with 0.05mm feeler gauge and the gauge shall not pass through Partial clearance is allowed Check with 0.10mm feeler gauge and the depth shall not exceed 1/3 the width of plane of composition The total length shall not exceed 20% of the perimeter No clearance shall exist around the assembling bolt and pin bolt

Generally, fitting surface at the combination slot staggering shall not exceed 0.10

mm

4.8 Match marks shall be considered during component installation When a lot of machines are installed together, each machine shall be assembled with the part marked with the same series design

The serial numbering in the installation record of same kind of installation or survey points for fixed parts shall begin from +Y and be numbered clockwise (begin from generator end, same for the following context); for rotating installation, begin from the position of No.1 polar of rotor Except that the survey point on the jigger is numbered counterclockwise, others are all numbered clockwise Attention shall be paid

to the above numbering regulations of the manufacturer

4.9 For connecting bolt with pre-tightening force requirement, the pre-tightening force deviation shall not exceed the 10% of the set value If not specified by the manufacturer, preliminary tension shall not be smaller than twice the design work stress and shall not exceed 3/4 of the yield strength of materials

During the installation of closely-pitched connecting bolt, the screw thread shall

be applied with lubricant Connecting bolt shall be fastened evenly by many times Adopt thermal state screwed bolt After fastening, spot check the pretension of around 20% bolt

After each part is installed, drill hinge pin tack hole and fit pin bolt according to design requirement

Lock and fasten the bolt, bolt cap, and pin bolt according to design requirements 4.10 Universality measurement of the unit shall conform to the following requirements:

a) Check and adjust all measuring tools in the qualified metrological examination departments

b) Deviation of X, Y datum line and height point used in the installation of unit against the data mark of factory building shall not exceed±1mm

c) Measuring error of the height deviation of each part shall not exceed±0.5mm d) Horizontal survey deviation shall not exceed 0.02mm/m

e) Generally, diameter of the steel wire used by the center is 0.3mm ~ 0.4mm Its tension stress shall not be smaller than 1200MPa

f) No matter which method to take in measuring the center or roundness of the unit, the measuring error shall not be greater than 0.05mm;

g) Pay attention to the impact on the surveying accuracy by temperature fluctuation Amend the measured number according to the changes of temperature during the measuring

4.11 In the intensity waterproof test for field manufactured bearing equipment and bridge pieces, the test pressure is 1.5 times the nominal operating pressure, but the minimal pressure shall not be smaller than 0.4MPa Sustain for 10 minutes, no leakage

or crackles, and so on

During the tightness compression test of equipment and its bridge pieces, the test pressure is 1.25 times the actual working pressure Sustain for 30 minutes, no leakage phenomena During the leakage test, the test pressure is actual working pressure, sustain for 8 hours, no leakage phenomena

Carry out the waterproof test of single cooler according to design requirement If not regulated, the test pressure shall be twice the working pressure, but no lower than 0.4Mpa Sustain for 30min, no leakage phenomena

4.12 In the kerosene leakage test of vessel, sustain at least 4h If no leakage phenomena, do not dismantle the vessel after finishing the leakage test

4.13 Single keystroke shall coordinate with keystroke for the examination The tolerance shall comply with design specification Keystrokes in-pair shall be checked in pair The parallelism shall meet the design requirements

4.14 Welding of assembling unit and its auxiliary facilities shall comply with the following requirements:

a) Welders of assembling unit and its auxiliary facilities shall attend special item training and examination regularly as required by the manufacturer They must hold certificate to take the position after they pass examinations and are licensed

b) All the length and height of the welding seams shall meet the drawing requirements Welding quality shall be checked as required by the design drawing c) For important components, welding shall proceed according to the welding process or welding procedure specification specified by the manufacturer after the qualification of welding procedure

4.15 Trademark of turbine lubricating used by assembling unit and speed-regulating system shall comply with the design regulations See Annex F 4.16 All monitoring equipment and automation components of the assembling unit shall be check and qualified according to the ex-factory specifications

4.17 Assembling and general installation of the water-turbine generator as well as installation shall all be kept clean After the installation of assembling unit, clean and check carefully both inside and outside the unit No impurities or nastiness shall exist 4.18 Antisepsis painting of each part of the water-turbine generator set shall satisfy the following requirements:

a) Each part of the assembling unit shall be pre-treated and painted in the manufacturing factory according to the design drawing

b) Installation (including site-welding seams) needs to be painted with final coating on site shall proceed according to the design requirements If the color and factory building ornament do not agree, except for the tube color, colors of other parts are changeable

c) During the installation process, if the finish coat is damaged partially, fix it according to the requirements of original coating

d) Coating of the site operation shall be homogeneous, bubble free, wrinkle free and with the same color

e) Installation that needs to be varnished on site according to contract or required specially shall comply with regulations

5 Installation of vertical type reaction turbine

5.1 Installation of built-in fitting

5.1.1 Installation of the steel liner on the nose of the splitter wall of draft pipe shall comply with the following requirements:

a) Range deviation from the top of nose steel liner to the X-axis of assembling unit

d) Squareness deviation of the nose steel liner 10mm

5.1.2 Permissible deviation of installation of draft tube liner shall conform to the requirements of Table 1

Table 1 Permissible deviation for Installation of Draft Tube Liner Unit: in millimeter

Runner diameter D Serial No Item

H – Section height; B –section length; r – arc radius of section

2

Lower tube

mouth of elbow

Smooth transition of the down tube mouth of elbow pipe and concrete pipe mouth

3

Elbow pipe,

top tube mouth of conical tube and/or

azimuth

Distance from X,

Y marks of the measured tube mouth to X, Y reference line of unit

4

Elevation

of the top tube mouth

of shaft tube and conical tube

Evenly divided into 8~24 points for the measurement

5

Diameter of

the pipe orifice of conical

±0.0015D

D – Design value

of tube diameter; equally divided into 8~24 points

tube

6

Perimeter difference

of the neighboring

pipe orifice

inwalls of conical tube

of conical tube without elbow pipe

liner

Measurement or examination with plumbing bobs; smooth transition with the concrete pipe mouth

5.1.3 Permissible variation of the installation of throating ring, foundation ring, and stand ring shall comply with the requirements of Table 2 Special requirement of design shall be met

Table 2 Permissible deviation for Runner chamber, foundation ring, and the stand ring

installation Unit: in millimeter

X and Y marks on the built-in fitting and X, Y datum line of unit

No machinework

at the site

0.05 mm/m, maximal no greater than 0.60 Radial survey

Site machinework 0.25

Elevation difference of the highest point and the lowest

point

No machinework

Site machinework 0.35

4 Roundness of runner

chamber

Difference between each radius and the average radius shall not exceed ±10% of the design average clearance of the paddle and runner chamber

Measure the three upper, middle and lower sections with axial flow; measure upper spigot and lower spigot with mixed flow

variable pitch turbine; evenly divide it into 8 ~ 64 measuring points

5

Foundation ring,

socket ring roundness

and/or its right

5.1.4 Split runner chamber, foundation ring, socket ring plane of composition of screw-in structure shall be applied with sealant, and the combination slot clearance shall be in compliance with the requirements of Article 4.7 To prevent leakage, combination slot of waterway surface may be sealed and welded Weld surface shall be burnished and polished Combination if throating ring, foundation ring and socket ring of group weld shall meet the design requirements

5.1.5 During the installation of the upper ring of pillar socket ring and fixed guide vane, direction of the azimuth deviation of socket ring and foundation ring shall be identical To guarantee end clearance of the guide blade is in accordance with the design requirements, height from the foundation ring surface to the socket ring surface shall be controlled critically The distortion of socket ring caused by concrete pouring, deviation of measuring tool, as well

as the decreasing value of the end surface clearance caused by the tectorial distortion in service

To reduce the distortion in the process of concreting, socket ring shall have reliable reinforcement measures

5.1.6 Permissible deviation for spiral casing erecting shall conform to the requirements of Table 3

Table 3 Permissible deviation of spiral casing erecting, unit as millimeter

6 Pipe orifice

flatness

3 Combination on the steel

platform or guy wire inspection tube mouth shall be on the same surface (belonging to the inspection project)

5.1.7 Permissible deviation for spiral casing assemble shall conform to the requirements

of Table 4

Table 4 Permissible deviation of spiral casing installation, unit as millimeter

Distance to

Y axle of the unit

0.003 D

of the straight pipe Elevation ±5

D - Inlet diameter of spiral case If the steel pipe is well assembled, then the steel pipe is taken as the reference and the deviation shall not

5 Ultima thule radius ±0.004 R R - Design value of

ultima thule radius

6 Pipe orifice knot

height

±0.002 H H - Pipe orifice knot

high (section diameter),

(belonging to inspection project)

5.1.8 The following requirements shall be met for spiral casing weld:

a) Weld shall conform to the regulations of Article 4.14;

b) Generally, clearance between internodes, spiral cases and butt welds connected to the socket ring is 2mm ~ 4mm Unevenness of the waterway surface shall not be greater than 10%

of the slab thickness, but the maximal unevenness of longitudinal seam shall not be greater than 2mm and the maximal unevenness of circumferential seam shall not be greater than 3mm; c) If local clearance of groove is over 5mm, its length shall not exceed 10% of the weld length It is permitted to make overlay welding treatment at the groove

5.1.9 Spiral case welding seam shall accept visual examination and non-destructive examination If not regulated by the manufacturer, the following requirements shall be met: a) Weld appearance inspection shall conform to the regulations of Table 5;

Table 5 Appearance inspection unit of spiral welding seam Unit: in millimeter

dimension

3 Undercut Depth not greater than 0.5;

continuous length not greater than 100; accumulated total length of the undercut on both sides not greater than 10% of the overall length of welding seam

4 Not fully welded Not allowable

5 Surface porosity Not allowable

Submerged arc welding Cover 2~7 of the width of

the groove of each side and the transition is smooth

9 Welding beading Not allowable

b) Non-destructive test of welding seam

Non-destructive test of welding seam adopts radiographic inspection, the inspection length is: For circumferential seam, it is 10%; for longitudinal seam and butt weld connecting

spiral case and socket ring, it is 20%; for the inspection of weld quality, according to the GB3323 standard, circumferential seam shall reach Grade III, while the longitudinal seam and butt weld connecting spiral case and socket ring shall reach the requirements of Grade II During non-destructive test, if supersonic flaw detecting is adopted, the inspection length is: For circumferential seam, longitudinal seam and butt weld connecting spiral case and socket ring, it is 100%; for the inspection of weld quality, according to the GB11345 standard, circumferential seam shall reach Grade BII, while the longitudinal seam and butt weld connecting spiral case and socket ring shall reach the requirements of Grade BI For skeptical parts, radiographic inspection shall be applied for double check

c) Generally, steel liner of concrete spiral casing shall have kerosene permeability examination and welding seam shall be free from penetrability defects

5.1.10 Hydraulic site test of spiral case or pressure maintaining pouring spiral casing floor concrete shall proceed according to the design requirement

5.1.11 Before concrete pouring, clean the angle iron and pressure plate from spiral case surface Burr shall be planished If the base material is injured, it shall be welded up and planished, and magnetic particle inspection shall be taken

5.1.12 Spiral case installation, welding and/or concrete pouring shall have measures to prevent distortion of socket ring Ascending velocity of concrete pouring shall not be greater than 300mm/h Generally, the height of each layer is 1m ~ 2m The pouring shall be symmetric, stratified and partitional Generally, liquid concrete height is controlled at around 0.6m During the pouring course, the stay ring distortion shall be monitored According to the actual conditions, adjust the concrete pouring order according to the practical situation

5.1.13 Roughness of waterway surface of built-in fitting shall comply with the regulations

of GB/T10969 Waterway surface welding seam of throat liner, runner chamber, and spiral case (or spiral case underboarding) shall be planished Waterway surface of built-in fitting and concrete shall transite smoothly

5.1.14 Permissible variation for the installation of pit liner shall comply with the requirements of Table 6

Table 6 Permissible variation of the installation of pit liner Unit: in millimeter

part of holder; evenly divide it into 8~16 points

5.1.15 Permissible variation for the installation of servomotor foundation shall be in accordance with the requirements of Table 7

Table 7 Permissible variation for the installation of servomotor foundation

a) Welding seam of throating ring disallow undercut phenomena Defect detecting test shall proceed as required by the manufacturer and shall be in compliance with the following requirements;

b) Runner crown combination slot clearance shall comply with requirements of Article of 4.7;

c) Runner crown flange inferior fovea value shall not be greater than 0.07mm/m Epirelief value shall not be greater than 0.03mm/m The maximum shall not be greater than 0.06mm For principal axes, friction carry-over moment structure shall be adopted Generally, no convexity is allowed;

d) Undercut of welding seam at the lower ring shall not be greater than 0.5mm;

e) After the erection welding of differentiate paddle and/or paddle fillet, blade profile shall be in compliance with the design requirements

5.2.2 Before the site welding of seal ring, runner roundness at the part to install seal ring shall be in compliance with requirements of 5.28 After the welding, seal ring shall be closely jointed and the weld quality shall be in compliance with the design requirements If hot jacket

is required for the seal ring, it shall be in compliance with the design requirements

5.2.3 When the split runner seal ring is rounded, the measuring points shall be at 32 points and the dimension shall be in compliance with the design requirements The roundness shall conform to the requirements of 5.2.8

5.2.4 After the rounding, static balancing test shall be carried out on the split runner according to requirements of Article 5.25 Diversion board shall be fitted during the test Clump weight shall be welded on the runner crown superface under the diversion board The welding shall be solid

Roughness of waterway surface of built-in fitting shall comply with the regulations of GB/T10969 Waterway surface welding seam of throat liner, runner chamber, and spiral case (or spiral case underboarding) shall be planished Waterway surface of built-in fitting and concrete shall transite smoothly

5.2.5 Runner static balancing test shall be in compliance with the following requirements: a) Static balance instrument shall be concentric to runner Deviation shall not be greater than 0.07mm Horizontal deviation of bearing base shall not be greater than 0.02mm/m;

b) When iron shot or rotating plate balanced method is adopted, sensitivity of static balance instrument shall be in compliance with the requirements of Table 8

Table 8 Distance from spherical surface center to the gravity center of runner

Quality of the runner - t

no requirements are raised, requirements of Table 9 shall be met:

Table 9 Allowable imbalance value of the unit mass of runner e per

b) Maintain 16h under the maximum test pressure;

c) During the test, during the test, switch on and off the paddle two or three times per hour

d) No leakage phenomena are allowed for each combination seam oil leakage limit for each single paddle package under or without test pressure shall not exceed the limit regulated

in Table 10, and be no greater than fuel oil leakage quantity during the ex-factory test;

Table 10 Oil leakage limit of each single paddle package per hour

Runner

diameter D

(mm)

D<3000 3000≤D<6000 6000≤D<8000 8000≤D<10000 D≥10000

f) Plot the relation curve of runner servomotor stroke and paddle rotor angle

5.2.7 Joint of principal axes and runner shall be in compliance with the following requirements:

a) Flange plane of composition shall be free of clearance Check with 0.03mm clearance gage and it shall not fill in;

b) Drop pit of screw bolt of flange shield shall be filled and leveled up

c) Runner boss screw bolt shall be spot welded and fastened Frame cover weld shall adopt measures to prevent distortion Welding seam shall be planished

5.2.8 Right alignment and/or roundness of each part of the runner shall be examined with principal axes as the center The difference between each radius and average radius shall meet the requirements of Table 11

Table 11 Permissible variation of right alignment and/or roundness of each part of the

runner

1) Seal ring 2) Fitting surface of seal ring

3) Tip of blade

±10% design clearance

Tip of blade is measured only when it is necessary, and when the quantity flow is

0

1 Nominal head <

200 m 4) Wearing ring

of diversion board

5) Flange protection cover also serves as sealing cover during overhaul

±15% design clearance

2 Nominal

head≥200 m

1) Exterior margin of upper

±5% design clearance

Corresponding fixed parts are

canopy 2) Exterior margin of lower ring

coping and/or base ring

3) Seal ring of upper claw tooth 4) Runner band seal

±0.10 mm

5.3 Preassembling of the guide apparatus

5.3.1 Before the preassembling of guide apparatus, measure the unit pit and determine the roundness of bore opening at of socket ring to determine the unit center Determine the surface elevation and level of stay ring and foundation ring Calculate height difference Article 5.1.3 and the drawing requirements shall be met

If the design includes water turbine with cylindrical valve, the cylindrical valve shall attend the preassembling of guide apparatus

5.3.2 Spread sealant on the plane of compositions of leaf type base ring, top cover, inner top cover and so on and the clearance on the plane of composition shall be in compliance with the requirements of Article 4.7 If shrinking or mechanism driving-in is needed for seal ring, design requirements shall be met

5.3.3 Preassembling of guide apparatus shall meet the following requirements:

a) Lower stay column seal ring shall be installed on the radial-axial flow turbine according to the centering measuring point given after the determination of unit pit The center

of lower stay column seal ring shall be taken as the fiducial center of the unit Examine the right alignment and roundness of each fixed sealing ring according to fiducial center of unit The difference between each radius and the average radius shall meet the requirements of permissible variation of corresponding parts listed in Table 11 When the workface height of seal ring exceeds 200mm, the upper and lower circles shall be checked

b) Centre of axial wheel and runner chamber shall be taken as the unit fiducial center Check the right alignment of sealing socket and bearing block flange spigot according to the unit fiducial center line The permissible variation shall meet the requirements of Table 12

Table 12 permissible variation for the right alignment of sealing socket and flange

spigot of bearing block Unit: in millimeter

d) Preassembling quantity of guide blade shall not be less than 1/3 of total;

e) After the adjustment of base ring and top cover, the quantity of symmetric, screwed fitting-up bolts shall not be less than 50% and shall meet the requirements of Table 13 Check the clearance of guide blade sections Clearance left on both sides of the header and end of each guide blade shall identical No regular inclinations are permitted The maximal total clearance shall not exceed the design clearance Deformation value of the bearing rear head cover shall be taken into account

Table 13 Permissible variation of base ring and top cover Unit: in millimeter

Runner diameter D Project D<3000 3000≤D

of seal ring

distribute 8~24 measuring points Check the

surface level

of base ring

0.35 0.45 0.60 The number of

circumferential measuring points shall not

be less than the number of guide vanes Adopt the difference of elevation

between the culmination and nadir point Right

alignment of

wicket gate

housing

In compliance with the design requirements

5.3.4 Guide apparatus without preassembling but directly installed formally shall also meet related requirements of 5.3.1 ~ 5.3.3

5.3.5 Installation of cylindrical valve shall meet the following requirements:

a) After the group welding of tunnel body, roundness of tunnel body under free condition shall meet the design requirements;

b) Installation and adjustment of servomotor and pipeline shall meet the design requirements Consistency of the actuation time of each servomotor shall be guaranteed;

c) Welding of tunnel body shall meet the provisions of JB/T4709 and 4.14;

d) Installation of synchronizing mechanism and stroke indicator shall meet the design requirements Movement during the total excursion shall be stable

5.4 Emplacement and installation of rotatable parts

5.4.1 Placement elevation of the principal axes and runner after being suspended into unit pit shall be slightly lower than the design elevation Between the flange face on the upper part

of principal axes and the subface of lower flange spigot of the generator shaft, 2mm ~ 6mm clearance shall be left For unit with bearing collar installed on the water turbine, the placement elevation after the principal axes and runner are suspended into unit pit shall be slightly higher than the design elevation to leave a 2mm ~ 5mm clearance between the bearing collar and rotating plate after the installation of bearing collar Deviation of the principal axes squareness shall not be greater than 0.05mm/m

When the water turbine or generator are centered according to objective, adjust the centre and/or principal axes plumbness of runner to make the wearing ring clearance in compliance with the requirements of Article 5.4.2 Squareness deviation of principal axes shall not be greater than 0.02mm/m

5.4.2 Permissible variation for the ultimate elevation of the installation of runner, each wearing ring clearance or clearance between paddle and runner chamber shall meet the requirements of Table 14 if no requirements are given by the manufacturer

Table 14 Permissible variation of runner level and/or clearance Unit as millimeter

Runner diameter D Item

±1.5 ±2 ±2.5 ±3 Measure the high and low

undercuts of fixed and rotation seal ring

0~+5 Measure the distance from base

ring to the top surface of runner hub

- - - Measure the inside clearance

between paddle and runner chamber

Clearance Nom Difference between each clearance Measure the three parts at the

inal

head

<200

m

and actual clearance shall not exceed±

20% of the average clearance

influent, water outlet and middle

at their complete shutdown position

a1

a2

Difference between each clearance and the actual average clearance shall not exceed ±10% of the design clearance value

Difference between each clearance and the actual average clearance shall not exceed± 10% of the design clearance value

Note: Runner elevation listed in the table has taken into account the actual elevation value due

to the runner subsidence resulted by hydraulic thrust

5.4.3 Zero clearance between the combination seams of two flanges after the coupling of the unit Check with 0.03mm clearance gage, and the gage shall not fill in 5.4.4 Installation of oil supply line and oil-supply head shall meet the following requirements

a) Oil supply line shall be rinsed critically Joints shall be secure, with no leakage Screwing oil supply line shall have locking measures

b) Generally, for fixed tile structure, swing of oil supply line shall not be greater than 0.20mm; for floating tile structure, it shall not be greater than 0.30mm

c) Horizontal deviation of oil-supply head shall not be greater than 0.05mm/m if measured on the surface of oil receiver holder

d) Oil deflector ring clearance between the rotating sump and oil receiver holder shall be even and shall not be smaller than 70% of the design value

e) Grounding insulation resistance of oil receiver shall not be smaller than 0.5MW during the measuring when draft pipe is anhydrous

5.5 Installation and adjustment of guide blade and/or servomotor

5.5.1 End clearance of guide blade shall meet the design requirements Axial clearance of guide blade thrust ring shall not be greater than 50% of the gap width on the upper part of the guide blade The guide blade shall be able to rotate flexibly

5.5 2 At the maximum opening position, the distance between the guide blade and bearing plate shall meet the design requirements When there is no regulation, 5 mm ~ 10 mm shall be left

Link rod shall be linked and adjusted on occasions that the guide blade and control loop are located in a small opening position Vertical plane clearance inspection of guide blade shall proceed under complete shutdown position The connection of link rods shall proceed when the guide blades are fastened by steel wires or control loop is completely shut down Deviation

of the circle of gate closure shall meet the design requirements The link rod shall be leveling off and the difference of height of both ends shall not be greater than 1mm Measure and record the distance between the two axial holes

5.5.3 The clearance of vertical plane of guide blade shall be checked with 0.05mm clearance gage when it is tightened by rope coil and the gage shall not pass through Partial clearance shall not exceed the limit required by Table 15 Total length of its clearance shall not exceed 25% of the height of guide blade When the design has a special requirement, it shall meet the design requirements

Table 15 Allowable vertical clearance of guide blade Unit as millimeter

a) After the decomposition, rinsing, checking and assembling of the servomotor at the site, each fit clearance shall meet the design requirements The clearance between each plane of composition shall meet the requirements of Article 4.7;

b) Servomotor shall have tightness compression test as required by Article 4.11 During the test of wobble servomotor, oil separator sheath shall rotate back and forth 3~5 times

c) When the plunger is in complete shutdown, middle or fully open position, as for the horizontal deviation of the installation of servomotor, the sleeve shaft or actuator rod level shall not be greater than 0.10mm/m;

d) Clamping stroke of servomotor shall meet the design requirements of manufacturer When no requirement is raised by the manufacturer, determine according to Table 16

Table 16 Clamping stroke value of the servomotor Unit as millimeter

ng steel ribbon

4~7 6~8 7~10 8~13 10~15 After the

filling in

of stamping steel ribbon, check the

Guide blade withou

t stampi

ng steel ribbon

3~6 5~7 6~9 7~12 9~14 vertical

plane of guide blade, zero clearance

Wobble servomotor When the guide blade is in complete shutdown position,

servomotor ascend to 50% of the loading oil pressure from non pressure, its plunger shift value is the clamping stroke

If the caging device adjustmen

t is convenien

t, it can also be determine

d according

to the requirements of linear type servomot

or

e) Position of orifice set and opening dimension shall meet the design requirements; f) Servomotor piston shift shall be calm and flexible The piston stroke shall meet the design requirements Deviation of the two piston strokes of linear type servomotor shall not be greater than 1mm;

g) Behind the oil separator tubing of wobble servomotor, servomotor movement shall be flexible

5.6 Installation of water conduit and main shaft seal

5.6.1 Bearing shell shall meet the following requirements:

a) Rubber bearing shell surface shall be leveling off, flawless and/or no peel-back Babbitt metal bushing shall be free of flaws like concentrated porosity, crackle, hardpoint and/or peel-back Tiling roughness shall be smaller than 0.8mm;

b) Try the assembling of rubber tile and spool tile with axle Total clearance shall meet the design requirements The difference between the maximal and minimal total clearance at each side and the difference of the total clearance of the upper and lower ends in the same azimuth shall both be no greater than 10% of the average total clearance according to the actual survey

c) When spool tile conforms to the two requirements of a) and b), it does not have to be grounded and scraped any more The grounding and scraping of sectional type tile shall be determined according to design requirement;

d) After the grounding and scraping of bearing shell, the tiling osculation shall be even

At least one contact point shall be set on per square centimeter; each of the partial non-contact area of each piece of tile shall not be greater than 5% The sum shall not be greater than 15%

of the total area of bearing shell

5.6.2 Installation of guide-block shall conform to the following requirements:

a) Guide-block shall be installed under the conditions that the unit axial line and stress over thrust pad is adjusted to be eligible and the wearing ring clearance of water turbine and air interstice of generator meet the requirements To facilitate the countercheck of the central position of rotor shaft, establish central measuring point at proper parts of the fixed section of bearing Measure and record related data;

b) Generally, during the installation of guide-block, gap adjustment shall be made according to the spindle center; also, the swing, direction and dimension of jigger shall be taken into account The total installation clearance shall meet the design requirements For units with only two guide bearings, swing may be neglected during the gap adjustment;

c) Permissible variation of sectional type guide-block clearance shall not exceed± 0.02mm; permissible variation of sausage type guide-block clearance shall not be greater than±20% of the assigned clearance value Tiling surface shall be kept vertical

5.6.3 Bearing installation shall meet the following requirements:

a) Oil leakage is not permitted for thin oil bearing tank Generally kerosene leakage test is required in accordance with Article 4.12;

b) Bearing cooler shall have tightness compression test as required by Article 4.11

c) Oil quality shall be eligible The oil level shall meet the design requirements Generally, the deviation shall not exceed± 10mm

5.6.4 The overhauling and installation of principal axes shall meet the following requirements:

a) Before the assembling of the air lashing strip, 0.05MPa compressed air shall be filled in

In the air leakage test in the water, no air leakage phenomena shall exist

b) After the installation, diametral clearance shall meet the design requirements The deviation shall not exceed 20% of the design gap width

c) After the installation, air charging test, air discharge test and pressure maintaining test shall be carried out The pressure drop shall meet requirements Generally, under 1.5 times working pressure, the pressure shall be maintained for 1h The pressure drop should not exceed 10% of the nominal working pressure

5.6.5 The working, pressurizing and installation of principal axes shall meet the following requirements:

a) Axial and radial clearance of the working pressurized installation shall meet the design requirements Permissible variation shall not exceed±20% of the actual average gap width; b) The sealing element shall be able to shift up and down freely The contact with swivel sealing surface shall be good Drainage system shall go smoothly

5.7 Installation of fittings

5.7.1 Vacuum breaking valve and gulp valve shall have actuation test and leakage test and its initial actuating pressure and maximum opening shall meet the design requirements

5.7.2 Spiral case and drainage gate valve of draft pipe or servomotor of disk valve shall all have tightness compression test as required by Article 4.11

5.7.3 For installation of the valve base of disk valve, horizontal deviation shall not be greater than 0.20mm/m

After the installation of disk valve, check the sealing surface, which shall be free of clearance The actuation of valve box shall be flexible and the pressurizing of valve stem shall be secure

5.7.4 Device installation for the admission of air of spindle center hole shall meet the design requirements If required by the design, the spindle center aeration pipe shall attend the jigger checking The swing value shall not exceed 20% of the actual average value of sealing clearance The maximal value shall not exceed 0.30mm Connecting bolt shall be secured After the installation of fulcrum bearing, grounding insulation resistance shall be measured Generally, it shall not be smaller than 0.5MW Exposed pipeline shall have moisture condensation resistant facilities

6 Installation of tubular turbine

6.1 Installation of built-in fitting

6.1.1For the installation of draft pipe of tubular turbine, the permissible variation shall meet the requirements of Table 17

Table 17 Permissible variation for the installation of tubular turbine draft pipe Unit as

millimeter Runner diameter D

D< 3000 3000≤D<6000 6000≤D<8000 Notes

1

Difference between the maximal and the minimal diameters at the pipe orifice

Structure with foundation ring refers to the flange on foundation ring

2 Centre and

elevation ±1.5 ±1.5 ±2.5

Left-right deviation of elevation at the pipe orifice level and its vertical label

3

Distance between the flange face and runner

±2.0 ±2.5 ±3.0

(1) If stay ring is installed first, then its

centerline downstream

side flange is taken as reference; (2) Measure four points:

up and down, right and left

4

Vertical plane of flange face

Measure the squareness of flange face to the unit center line

6.1.2 For the installation of tubular turbine stay ring, the permissible variation shall meet the requirements of Table 18

Table 18 Permissible variation for the installation of tubular turbine stay ring

Y marks on the installation and corresponding datalines

2

Distance from flange

face to runner centerline

±2.0 ±2.5 ±3.0

(1) If the draught tube is installed first, flange shall be taken as reference; (2) Measure the four points up and down, right and left

3 Maximum

size for 0.8 1.0 1.2

Plumbness and plane of other

vertical plane

of flange face

flange faces shall be converted based on this deviation

4 Roundness 1.0 1.5 2.0

5

Distance between the

inner and outward flange faces

at the downstream

side

6.1.3 For the installation of cover board of flow channel, permissible variation shall meet the requirements of Table 19

Table 19 Permissible variation for the installation of cover board of tubular turbine

flow channel Unit as millimeter

Deviation

of frame center line and design center line

2

Elevation of the foundation frame

±5

3

Height difference of the four corners of foundation frame

4

Level degree of the flange of flow

0.8

channel cover board shaft mm/m

6.1.4 For the installation of tubular turbine servomotor, the permissible variation shall meet the requirements of Table 7

6.1.5 After the installation and acceptance of stay ring, pour the concrete according to Article 5.1.11 and 5.1.12

6.2 Installation of principal axes

6.2.1 Generally, installation of principal axes shall be carried out in the clipping room Place the principal axes on the bracing frame used for installation Adjust the degree of level Generally, it shall not be greater than 0.5mm/m

6.2.2 Oil supply line shall be rinsed rigorously No oil leakage Make sure the exactitude sliding of inner oil supply line inside the outer oil supply line

6.2.3 The examination of water guide-block before its installation shall comply with the requirements of Article 5.6.1 When it is fitted into the principal axes, the bearing shell clearance shall comply with the design requirements Sealing on both ends of the bearing shell shall be in good condition Return oil shall go smoothly.6.2.4 Coupling of water guide-block and shell bearing shall comply with requirements of Article 10.4.4 Clearance of the plane of composition between the shell bearing, supporting ring and hub cap shall conform to the requirements of Article 4.7

6.2.5 Installation of main guide bearing shall consider the variance generated by the deflection of rotation parts

6.2.6 For bearing with grounding insulation requirements, before oil charge, check its insulation with 1000V megohm meter, and it shall not be lower than 1MW

6.3 Installation of guide apparatus

6.3.1 Split of outer and inner cone and control loop composition plane shall be spread with sealant or fitted with stamping steel ribbon according to the design requirements The combination seam shall conform to the requirements of Article 4.7 Fitting of stamping steel ribbon shall leave 1mm ~ 2mm space on both sides

6.3.2Installation of guide apparatus shall meet the following requirements:

a) Right alignment of outer and inner cone shall be adjusted The deviation shall not be greater than 0.5mm;

b) On the upper stream, distance between the inner and outer flange shall meet the design requirements The deviation shall not be greater than 0.4mm;

c) Adjustment of guide blade end clearance shall be measured in a closed position Clearance distribution of inside end surface and outer end surface shall meet the design requirements End clearance at both the head and end of guide blade shall be basically the same The rotation shall be flexible;

d) Maximal allowable partial vertical plane clearance of guide blade shall not be greater than 0.25mm and the length shall not exceed 25% of the gate height

6.4 Installation of guide apparatus

6.4.1 When inner cone, outer cone and gate vane are entirely suspended into unit pit, adjust the right alignment of inner cone and hub cap as well as stay ring to no greater than 0.5mm

6.4.2 After the control loop and outer cone are suspended into unit pit, measure or adjust the clearance between control loop and outer cone to make it meet the design requirements

6.5 Installation of the principal axes, runner and runner chamber

6.5.1 After the installation of runner, carry out the tightness compression test and actuation test, which shall meet the requirements of 5.2.6

6.5.2 During the axial line adjustment, axial variance generated by operation shall be taken into account, as well as the actual inclination value of stay ring flange face, which shall meet the design requirements

6.5.3 After the connection of runner and principal axes, check the plane of composition with 0.03mm clearance gage, which shall not pass through

6.5.4 Oil supply line of oil receiver shall take the jigger examination Its swing value shall not be greater than 0.10mm Right alignment of tilting fillet of oil receiver and the operational oil tube shall not be greater than 0.15mm for fixed tile; for floating tile, it shall not be greater than 0.20mm

6.5.5 Adjust and install runner chamber centering runner The runner chamber value and impeller clearance value shall meet the design requirements

6.5.6 Installation of main shaftseal shall meet the requirements of Article 5.6.4 and 5.6.5 6.5.7 After the installation of telescopic joint, clearance left in advance for collapsing shall meet the design requirements The deviation shall not be greater than± 3mm

6.6 Waterway surface and plane of composition shall be fitted with sealing element and spread

with sealant according to the design requirements Tightness examination shall be carried out, and no leakage is permitted

6.7 For guide apparatus with heavy punch, after completing the installation of water turbine

and formation of operating system of guide apparatus, carry out the heavy punch turnoff test under anhydrous or still water conditions Record the closing time

7 Installation of impulse turbine

7.1 Installation of diversion conduit

7.1.1 Range deviation of inlet center line of diversion conduit and the unit coordinate line shall not be greater than ±2 x 10 -3 of inlet diameter

7.1.2During the flange welding of spiral distributor, flange distortion shall be controlled and checked No injurious deformation shall be generated

7.1.3 After the welding of spiral distributor, check the elevation, horizontal distance relative to unit coordinate line of each flange and muzzle shank base, distance between each two flanges, squareness of flange, the angular position of holes, to make the deviation meet the design requirements

7.1.4 Carry out the water test on spiral distributor and breeches pipe Test pressure shall

be carried out according to the manufacturer's regulations Welding seam of spiral distributor and breeches pipe shall be free of leakage phenomena Injurious deformation shall not happen

to Y-pipe flange

7.1.5 IF spiral distributor and Y-pipe are used in pressure pouring concrete, the hydraulic pressure inside spiral distributor shall be controlled according to design requirement

For vertical type unit, the elevation of each nozzle flange on the case shall be in accordance with each other Their height difference shall not be greater than 1mm; squareness of each flange shall not be greater than 0.30mm/m Distance from the flange to co-ordinate data line

of unit shall meet the design requirements

7.2.3 For double wheels horizontal type unit laid on two terminals of generator, relative height difference of the two cases shall not be greater than 1mm; the center distance shall be based on the thrust disc position, the length of generator armature and actually measured length of the axial plus thermal expansion protraction of generator armature, the deviation shall not exceed 0mm ~ +1mm

7.3 Installation of the bearing of turbine shaft

7.3.1 Installation of the vertical turbine bearing shall meet the following requirements: a) Examine the elevation and level of bearing flange and the discrepancy in elevation shall not be greater than 2mm Generally, horizontal deviation shall not be greater than 0.04mm/m;

b) Preassemble the main guide bearing and its bracket Deviation of the bearing support centre and unit centre shall not be greater than 0.40mm After the preassembling and localization, drill locating hole on the case Fit up assembling pin;

c) Install main guide bearing after unit axial line is qualified by passing examination The following requirements shall be met:

1) No oil leakage is permitted for thin oil bearing tank Carry out the kerosene test according to requirements of Article 14.2

2) Compression test on bearing cooler shall be carried out as required by Article 4.11 3) Oil quality shall be eligible The oil level shall meet the design requirements Generally, the deviation shall not exceed±6mm

7.3.2 Installation of the horizontal water turbine bearing shall meet the following requirements

a) If horizontal type main guide bearing needs grounding and scraping on site, requirements in Articles 10.1.1 and 10.1.2 shall be met

b) Bearing clearance adjustment shall be in compliance with the requirements of Article 10.4

7.4 Installation of turbine shaft

7.4.1 Before installation of turbine shaft, check the planeness and fineness of combined

flange

7.4.2 For vertical type unit, installation of upper flange face on the turbine shaft shall be 20mm ~ 25mm lower than the design elevation For the turbine shaft structure directly connected with generator armature, align the right alignment and parallelism of generator rotor

flange and turbine shaft as well as elevation of generator armature flange relative to nozzle-axis

7.4.3 Principal axes level or vertical deviation shall not be greater than 0.02mm/m

7.4.4 Before the installation of guide bearing, the unit axial shall be examined and be in compliance with the design requirements

7.5 Installation of sprayer and servomotor

7.5.1 Before the installation, the sprayer and servomotor shall take tightness compression test as required by manufacturer

7.5.2 After the installation of sprayer and servomotor, under the action of 16% nominal pressure, actuating mechanism of nozzle needle and servomotor shall be flexible Let nominal pressure oil come into the turnoff chamber Zero clearance shall exist between the needle head and jet hole If the nozzle needle servomotor is built-in servomotor, check the blowdown chamber of mixed sewage of oil and water to make sure it is free from oil leakage and water leakage

7.5.3 Installation of sprayer shall conform to the following requirements:

a) Sprayer center line shall be tangential with the runner Radial deviation shall not be greater than ±0.2% d1 (which refers to the runner pitch circle diameter) Its axial direction deviation with bucket water diversion edge shall not be greater than±0.5% W (W refers to the maximum breadth of the inside of bucket);

b) Generally, deviation between flow deflector centre and sprayer centre shall not be greater than 4mm;

c) Deviation of compression length of buffer spring from the design value shall not be greater than ±1mm;

d) Synchronism deviation of the nozzle needle stroke of each sprayer shall not be greater than 2% of the design stroke

e) Axial and radial deviation of the center line of reverse braking sprayer shall not be greater than ±5mm

7.6 Installation of runner

7.6.1 Installation of runner shall conform to the following requirements

a) Plane of rotation of the water diversion edge of runner bucket shall pass through the flange centre fitted with nozzle on the case and the deviation shall not be greater than±0.5%W b) Ending beat magnitude of runner shall not be greater than 0.05mm/m

c) Clearance between the runner and dash plate shall meet the design requirements 7.6.2 Main shaft seal shall be in compliance with regulations of Article 5.6.5

7.7 Installation and adjustment of control mechanism

7.7.1 Deviation of the center of each component of control mechanism shall not be greater than 2mm Discrepancy in elevation shall not be greater than±1.5mm Level or vertical deviation shall not be greater than 0.10mm/m After installation, the actuation shall be agile 7.7.2 Flow deflector opening shall be 3mm greater than jet stream radius, but no greater than 6mm Actuating mechanism of each flow deflector shall be synchronized The deviation shall not be greater than 2% of the design value

8 Installation and debugging of speed regulating system

8.1 Installation and debugging of oil pressure devices

8.1.1 Permissible variation for the installation of scavenge box, basic parts of overhead tank, and equipment shall be in compliance with the requirements of Table 20

8.1.2 Brand and quality of the oil used in speed regulating system shall be in compliance with the regulations of Article 4.15 The oil temperature application scope is 10°C~ 50° C

Table 20 Permissible variation for the installation of scavenge box (oil tank of speed

governor) and overhead tank

Distance from the marks on measuring equipment to X and

Y fiducial point

2 Elevation (mm) ±5

3 Planeness (mm/m) 1

Measure the elevations of four corners of scavenge box (speed governor oil tank)

4

Plumbness of overhead tank (mm/m)

1

Drainage thread measurement in X and Y directions

8.1.3 Before the application of overhead tank, oil pipeline and bearing components, they shall take tightness compression test as required by Article 4.11 using qualified turbine oil 8.1.4 Decentralization and inclination for the installation and centering of horizontal type oil pump and electromotor elastic coupling shall not be greater than 0.08mm If axial movement of oil pump shaft towards motor side is zero, 1mm ~ 3mm clearance shall exist between coupling joints After all plugs are filled in, coupling joints may be allowed to rotate slightly The body of oil pump chamber shall be infused with qualified turbine oil

8.1.5 Each oil level of oil pressure installation shall meet the design requirements

8.1.6 Test run of oil pump and electromotor shall meet the following requirements: a) Examination and test of electromotor shall be in compliance with the related requirements of GB 50150;

b) Generally, oil pump operate with no load for 1h and operate for 15min respectively under 25%, 50%, 75% and 100% of the nominal pressures, no abnormal phenomena shall exist

c) During the operation, vibration of oil pump case shall not be greater than 0.05mm Temperature of bearing shell shall not be greater than 60°C;

d) Under nominal pressure, the measured oil delivery rate of oil pump shall not be smaller than design value

8.1.7 The adjustment of each component of oil pressure installation shall be in compliance with the following requirements:

a) Examine the relation curve of pressure, output voltage (electric current) of fuel level gauge and oil pressure, as well as oil level Within the variable scope, it shall be linear Its characteristics shall be in compliance with the design requirements

b) Adjustment of safety valve, signal indicator of working pressure of oil pump and annunciator of emergency bearing oil pump shall be in compliance with requirements in Table

21 if no design requirements are given The actuating mechanism deviation of pressure signal shall not go beyond ±1% of the setting value The return value shall not exceed the design requirements

c) For oil pump under continuous operation, if the actuating pressure of overflow cock has no design requirements, requirements on the setting value of working oil pump in Table 21 shall be met

Table 21 Setting value of the safety valve and signal indicator of oil pump

Unit: in megapascal Setting value

Safety valve Working oil bump Emergency bearing

Full shutoff pressure

Starting pressure

Reverter pressure

Starting pressure

Reverter pressure

2.50 ≥2.55 ≤2.90 ≥2.30 2.20~2.30 2.50 2.05~2.15 2.50 4.00 ≥4.08 ≤4.64 ≥3.80 3.70~3.80 4.00 3.55~3.65 4.00 6.30 ≥6.43 ≤7.30 ≥6.10 6.00~6.10 6.30 5.85~5.95 6.30

d) Actuating mechanism of safety valve shall yield no fierce vibration and noise;

e) Setting value of slip low oil pressure shall meet the design requirements The actuating mechanism deviation shall not be greater than ±2% of the setting value;

f) Self-acting air supply device of overhead tank and actuating mechanism of oil level dispatching device of scavenge box shall be accurate and secure

g) Start-up and closedown action of pressure oil pump and oil leakage pump shall be accurate and secure No reversal phenomenon shall exist

8.1.8 Under the work pressure of overhead tank, when the oil level is in normal position, shut down all communicating valve gate and sustain for 8h The drop-out value of oil pressure shall not be greater than 4% of the nominal operating pressure Record the drop-out value of oil level

8.2 Installation of speed governor

8.2.1 Installation of engine tank of speed governor, regulator cubicle, and accident regulation valve shall meet the following requirements:

a) Deviation for the installation of electro-hydraulic governor cabinet, regulator cubicle, accident regulation valve shall meet the requirements of Table 22:

Table 22 Permissible deviation for the installation of electro-hydraulic governor cabinet,

regulator cubicle and accident regulation valve

deviation

Measure the distance from the marks on the equipment to X and Y datum line of

4

Plumbness or level of accident regulation valve

0.15

Measure the sub-frame of accident regulation valve

5 Plumbness of

electronic cabinet 1

Drainage thread measurement in X and Y direction

b) Installation of combined type electro-hydraulic governor shall take the speed regulation axle mechanism bracket as reference and its deviation shall meet the design requirements c) See Annex C for the installation of mechanic hydraulic pressure speed governor

8.2.2 As for mechanic hydraulic pressure pieces that must be disorganized, the rinsing, packing and adjustment of the component shall meet the drawing requirement of manufacturer 8.2.3 Indicator and lever inside the cabinet of speed governor shall be adjusted according

to the drawing dimension Generally, the position deviation of each mechanism shall not be greater than 1mm

8.2.4 When guide blade and runner blade servomotor are in the middle position (equivalent to 50% opening), position of each oscillating arm and link rod of reversion mechanism shall meet the design requirements The plumbness or horizontal deviation shall not be greater than 1mm/m; joint of reversion mechanism shall be secure Carry out the load test according to the design requirements

8.2.5 Examine the return circuit connection of each system of electric part, and all shall meet the design requirements Determination of its insulation resistance and voltage withstand test shall proceed according to related requirements on commissioning test of electric installation in GB50150

8.2.6 Output voltage of the regulated power supply device in electric part shall meet the design requirements The output voltage variance shall not exceed ±1% of the design value 8.2.7 Examine the characteristic and adjustable parameter of each return circuit of electric part: regulating range including steady state speed droop bp (slip ratio ep), proportional gain

Kp, integral gain Ki, incremental gain Kd (or temporary droop bt, damping time constant Td, acceleration time constant Tn) etc shall meet the design requirements

8.2.8 Check the adjustment range of opening assignment, frequency setting, horsepower assignment, all of which shall meet the design requirements