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 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
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 中华人民共和国国家标准 Specification for Installation of Hydraulic Turbine Generator Units
水轮发电机组安装技术规范 GB 8564-2003
Chief Development Department: China Gezhouba (Group) Corporation, Sinohydro Corporation, China Three Gorges Project Corporation and Harbin Electric Machinery Co., Ltd. Implementation date: March 1, 2004
Standards Press of China 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 to JB/T8660. The following documents shall be taken as important evidence for acceptance of both unit and it auxiliary equipment as well as quality acceptance. a) Equipment installation, operation, instruction on operation and maintenance and technical documentation; b) All random drawing materials (including equipment installation drawing and structure drawing of spare parts); 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 ±30mm; b) Range deviation from the nose steel liner side to Y-axis of assembling unit±15mm; c) Discrepancy in elevation from the top of the nose steel liner (or bottom) ±10mm; 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.
Serial No.
1
2
3
4
5
Item Dimension of section of elbow tube Lower tube mouth of elbow Elbow pipe, top tube mouth of conical tube and/or azimuth Elevation of the top tube mouth of shaft tube and conical tube Diameter of the pipe orifice of conical
Table 1 Permissible deviation for Installation of Draft Tube Liner Unit: in millimeter Runner diameter D 8000≤D<10, D<3000 3000≤D<6000 6000≤D<8000 D≥10,000 000 ±0.0015H (B, r)
Description H – Section height; B –section length; r – arc radius of section
±0.001H (B, r)
Smooth transition of the down tube mouth of elbow pipe and concrete pipe mouth
4
0~+8
6
0~+12
8
0~+15
±0.0015D
10
0~+18
12
Distance from X, Y marks of the measured tube mouth to X, Y reference line of unit
0~+20
Evenly divided into 8~24 points for the measurement D – Design value of tube diameter; equally divided into 8~24 points
6
7
tube Perimeter difference of the neighboring pipe orifice inwalls of conical tube Center of the down tube mouth of conical tube without elbow pipe liner
0.0015 L
10
15
20
0.001 L
Perimeter of pipe orifice
25
Measurement or examination with plumbing bobs; smooth transition with the concrete pipe mouth
30
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. Runner diameter D No .
300 0 ≤D < 600 0
Item D < 3000
1
Center and azimuth
2
Elevation
3
4
Flatne ss of flange face to install coping and base ring
Radial survey
2
3
Notes 600 0≤D < 800 0
4
8000≤ D< 10000
5
D≥10 000
6
Measure the distance between X and Y marks on the built-in fitting and X, Y datum line of unit
±3 No machinework at the site
0.05 mm/m, maximal no greater than 0.60
Site 0.25 machinework No 0. 0. 0.6 machinework 3 Circumferential 40 0 at the site 0 survey Site 0.35 machinework Difference between each radius and the average radius shall not Roundness of runner exceed ±10% of the design chamber average clearance of the paddle and runner chamber
Elevation difference of the highest point and the lowest point
Measure the three upper, middle and lower sections with axial flow; measure upper spigot and lower spigot with mixed flow
5
Foundation ring, socket ring roundness and/or its right alignment with runner chamber
1.0
1.5
2.0
2.5
3.0
variable pitch turbine; evenly divide it into 8 ~ 64 measuring points Evenly divides it into 8 ~ 32 measuring points. For mixed flow unit, the lower fixed sealing ring hub is taken as the reference, and for axial flow unit, runner chamber hub is taken as the reference
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.
1 2 3 4
5
Table 3 Permissible deviation of spiral casing erecting, unit as millimeter Permissible No. Item Notes deviation G +2~+6 K1~ K2 ± 10 e1 ~ e2 ± 0.002 e L ± 0.001 L, the maximum value is ±9 D
± 0.002 D
6
Pipe flatness
orifice 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.
1
2 3
4
5 6
Table 4 Permissible deviation of spiral casing installation, unit as millimeter Permissible No. Item Notes deviation Center Distance to 0.003 D D - Inlet diameter of of the Y axle of spiral case. If the straight the unit steel pipe is well pipe assembled, then the Elevation ±5 steel pipe is taken as the reference and the deviation shall not be greater than 15% of the spiral case thickness Elevation of the ±15 furthest point Inclination of the 5 orientation pipe joint mouth Deviation of ±5 orientation pipe joint mouth and data line Ultima thule radius ±0.004 R R - Design value of ultima thule radius Pipe orifice knot ±0.002 H H - Pipe orifice knot height 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 No.
Item
1 2 3
Crack Surface slag Undercut
4 5 6
Not fully welded Surface porosity Weld Bead Manual welding Remaining-height ∆h
Submerged arc welding 7
Width of the Manual welding butt-joint welding Submerged arc welding
8 9
Splash Welding beading
Unit: in millimeter Allowable defects dimension Not allowable Not allowable 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
Not allowable Not allowable 12<δ≤25; ∆h=0~2.5; 25<δ<80; ∆h=0~5; δ-thickness of the steel plate
0~4 Cover 2~4 of the width of the groove of each side and the transition is smooth Cover 2~7 of the width of the groove of each side and the transition is smooth Clear up 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
Runner Diameter No.
1
Item
Center
D 3000
5
< 3000 ≤D 6000 < 6 000 D 8000
10
15
≤ 8000≤D < < 10 000
D ≥10,000
20
Notes
Measure the distance between undercoat flange and flange bore mouth at the upper
part of holder; evenly divide it into 8~16 points 2
3
4
Diameter of upper port Elevation of upper port Level upper port
±5
±8
±10
±12 Evenly divide it into 8~16 points Evenly divide it into 8~16 points
±3
of 6
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 Runner Diameter (mm) No.
1 2
3
Item
D<3000
Squareness 0.30 mm/m Center and ±1.0 elevation (mm)
Degree of 1.0 parallelization to the co-ordinate data line of unit
3000≤D <6000
6000≤ 8000≤D D≥10,000 D < < 10 8000 000 0.25
±1.5
±2.0
±2.5
±3.0
1.5
2.0
2.5
3.0
Notes
Measure from the flange face of the stay ring
4
Distance to the ±3.0 co-ordinate data line of unit (mm)
5.2 Runner installation 5.2.1Split runner of radial-axial flow turbine shall be assembled, welded and thermally treated according to special group welding process and shall be in accordance with the following requirements: 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 (Kg) t<5000 5000≤t<10000 10000≤t<50000 50000≤t<100000 100000≤t<200000 t≥200000
Maximal distance (mm)
Minimal distance (mm)
40 50 60 80 100 120
20 30 40 50 70 90
c) .During the adoption of surveying rod strain method or static pressure ball-bearing method, proceed according to the requirements and process as required by manufacturer. d) Residual unbalanced moment shall be in compliance with the design requirements. If no requirements are raised, requirements of Table 9 shall be met: Table 9 Allowable imbalance value of the unit mass of runner eper Maximal running rotation speed r/min Allowable imbalance value of the unit mass of runner eper (g·mm/kg)
125
150
200
250
300
400
550
450
330
270
220
170
5.2.6 Operational test of runner blade of Kaplan turbine and tightness compression test shall meet the following requirements: a) Oiliness of test purpose oil shall be qualified and the oil temperature shall not be lower than 5 °C; 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
Oil leakage limit of the each single paddle package per hour mL/h
5
7
10
12
15
e) Runner servomotor shall move steadily. Generally, minimal oil pressure to turn on and turn off shall not be greater than 15% of the nominal operating pressure; 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 Permissible No. Item Notes deviation 1) Seal ring ±10% design Tip of blade is 2) Fitting clearance measured only surface of seal when it is ring necessary, and 3) Tip of blade when the quantity flow is 0 Nominal head < 1 4) Wearing ring ±15% design 200 m of diversion clearance board 5) Flange protection cover also serves as sealing cover during overhaul Nominal 1) Exterior ±5% design Corresponding 2 head≥200 m margin of upper clearance fixed parts are
canopy 2) Exterior margin of lower ring 3) Seal ring of ±0.10 mm upper claw tooth 4) Runner band seal
coping and/or base ring
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 Runner D<300 3000≤D<600 6000≤D<800 8000≤D<1000 D Notes 0 0 0 ≥1000 diameter D 0 0 Permissibl 0.25 0.50 0.75 1.00 Evenly e variation distribut e 8~24 points c) Upper spigot centre of deriaz turbine and runner chamber shall be taken as the unit fiducial center;
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
3000≤D 6000≤D 8000≤D <6000 <8000 <10000 Roundness of 5% design clearance of runner sealing ring the wearing ring Concentricity of seal ring
D<3000
0.15
Check the 0.35 surface level of base ring
0.20
0.45
0.60
D ≥10000
Notes Evenly distribute 8~24 measuring points Evenly distribute 8~24 measuring points 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 In compliance with the design requirements alignment of wicket gate housing 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 D<30 3000 6000 8000≤ D Notes Item ≤D ≤D D ≥10 00 <600 <800 <1000 000 0 0 0 Elevation Mixe ±1.5 ±2 ±2.5 ±3 Measure the high and low d undercuts of fixed and rotation flow seal ring type Axia 0~+2 0~+3 0~ 0~+5 Measure the distance from base l +4 ring to the top surface of runner flow hub Mixe 0~+0. 0~+1. Measure the inside clearance 8 0 between paddle and runner d flow chamber varia ble pitch turbi ne Clearance Nom Difference between each clearance Measure the three parts at the
inal head <200 m Nom inal head ≥200 m
and actual clearance shall not exceed± influent, water outlet and middle 20% of the average clearance 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 b1 Difference between each b2 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 Height of the guide blade h Notes Item h<600 600 1200 2000 h≥4000 ≤h<1200 ≤h<2000 ≤h<4000 Guide 0.05 0.10 0.13 0.15 0.20 After the blade filling in of stamping without stamping steel steel ribbon, ribbon check the vertical Guide 0.15 0.20 plane of blade with guide stamping blade, zero steel clearance ribbon 5.5.4 Installation of servomotor shall meet the following requirements: 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 Runner diameter D Notes Item D<30 3000≤D<6 6000≤h<8 8000≤h<10 D≥100 00 000 000 000 00 Direct-cyli Guide 4~7 6~8 7~10 8~13 10~15 After the nder blade filling in with of stampi stamping ng steel steel ribbon, ribbon check the
Guide blade withou t stampi ng steel ribbon Wobble servomotor
3~6
5~7
6~9
7~12
9~14
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.
vertical plane of guide blade, zero clearance
If the caging device adjustmen t is convenien t, it can also be determine d according to the requireme nts 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 No. Item Notes D< 3000 3000≤D<6000 6000≤D<8000 Difference Structure between the with maximal and foundation 1 the minimal 3.0 4.0 5.0 ring refers to diameters at the flange on the pipe foundation orifice ring Left-right deviation of elevation at Centre and 2 ±1.5 ±1.5 ±2.5 the pipe elevation orifice level and its vertical label Distance (1) If stay between the ring is 3 ±2.0 ±2.5 ±3.0 flange face installed and runner first, then its
centerline
4
Vertical plane of flange face
0.8
1.0
1.2
downstream side flange is taken as reference; (2) Measure four points: up and down, right and left 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 Unit: in millimeter Runner diameter D Notes No. Item D< 3000 3000≤D<6000 6000≤D<8000 (1) Marked elevation of the upper lower stream flange level Azimuth and 1 ±2.0 ±3.0 ±4.0 (2) Distance elevation between X and Y marks on the installation and corresponding datalines (1) If the draught tube is installed first, Distance flange shall be from flange taken as 2 face to ±2.0 ±2.5 ±3.0 reference; (2) runner Measure the centerline four points up and down, right and left Maximum Plumbness and 3 0.8 1.0 1.2 size for plane of other
vertical plane of flange face
4
5
Roundness Distance between the inner and outward flange faces at the downstream side
flange faces shall be converted based on this deviation 1.0
1.5
2.0
0.6
1.0
1.2
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 Runner diameter D No. Item Notes D< 3000 3000≤D<6000 6000≤D<8000
1
2
3
4
Centre and position of flow channel cover board shaft hole Elevation of the foundation frame Height difference of the four corners of foundation frame Level degree of the flange of flow
±2
±3
±4
±5
4.0
5.0
0.8
6.0
Deviation of frame center line and design center line
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. 7.2 Installation of case 7.2.1 Distinguished built-up case shall conform to the requirements of Article 4.7. For plane of composition without sealing or without padding, sealant shall be spread. 7.2.2 During the installation of case, deviation of it from unit X, Y datum line shall not be greater than 1mm; discrepancy in elevation shall not exceed ±2mm; horizontal deviation of flange face on the case shall not be greater than 0.04mm/m. 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 Permissible No. Item Notes deviation Distance from the marks on measuring 1 Center (mm) 5 equipment to X and Y fiducial point 2 Elevation (mm) ±5 Measure the elevations of four 3 Planeness (mm/m) 1 corners of scavenge box (speed governor oil tank) Plumbness of Drainage thread 4 overhead tank 1 measurement in X (mm/m) 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 Emergency bearing Nominal Safety valve Working oil bump oil pump oil Initial oil Full Full Starting Reverter Starting Reverter pressure drainage opening shutoff pressure pressure pressure pressure pressure pressure 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 No. Item Permissible Notes
deviation
1
Center (mm)
5
2
Elevation (mm)
±5
3
Cabinet level (mm/m)
0.15
4
Plumbness or level of accident regulation valve
0.15
5
Plumbness of electronic cabinet
1
Measure the distance from the marks on the equipment to X and Y datum line of unit Measure the base of electrohydraulic conversion device Measure the sub-frame of accident regulation valve 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.
8.2.9 Record relation curve of input and output signals (electric current and electric pressure) of speed detector. Within the scope of ±10% nominal speed, static characteristic curve shall be rounded as straight line and its speed dead band shall meet the design set value. Within the scope of ±2% of nominal speed, deviation of the measured amplification coefficient shall not be greater than ±5% of design value. 8.3 Oil filling adjustment test of speed regulating system 8.3.1 Switch on oscillating current. Examine the oscillating quantity of electrohydraulic conversion device, which shall meet the design requirements. 8.3.2 Examine the zero deflection and null shift of pressure of electrohydraulic conversion device. Generally, its zero deflection shall not be greater than 5% of nominal value of output quantity (electric current, electric pressure); within the working oil pressure scope, the pressure null shift shall not create overt shift of servomotor. 8.3.3 Record the relationship transfer curve of incoming frequency and the electricity-liquid or electricity- machine conversion device output. Dead volume and amplification coefficient shall meet the design requirements. 8.3.4 Determine the relation curve between the output voltage (electric current) of feedback transducer and servomotor stroke. Within the total excursion range of servomotor, it shall be linear and its characteristics shall meet the design requirements. 8.3.5 The first oil charge of speed regulating system shall proceed slowly. Generally, oil charge pressure shall not exceed 50% of the nominal pressure. Servomotor actuates several times the entire stroke. No abnormal phenomena shall exist. Operation switching of speed governor between manually, automatically or different kinds of control modes shall be tested. The actuating mechanism shall be normal. Servomotor has no evident swing. Oil pipeline and bearing components shall take proof test as required by 4.11. 8.3.6 Manually operate the opening restriction of wicket gate servomotor; check the indicated value on the indicator of mechanic cabinet. The indicated value shall be in compliance with the stroke of wicket gate servomotor and servomotor of runner blade. Deviation shall not be greater than 1% of the entire stroke of plunger for the former and for the latter the deviation shall not be greater than 0.5°. 8.3.7 Time for emergency shutdown and opening of guide blade and runner blade as well as step closure stroke, time and design value of guide blade shall not exceed±5% of the design value, but ultimately it shall satisfy the requirements of calculation of guaranteed regulation. Generally, time of shutdown and starting shall adopt twice the needed time for 75% ~ 25% opening. 8.3.8 Deviation of time and design value of the shutdown of guide blade by accident regulation valve shall not exceed ±5% of the design value, but ultimately it shall satisfy the requirements of calculation of guaranteed regulation. 8.3.9 Examine the dead-stroke of reversion mechanism. Generally, the value shall not be greater than 0.2% of the entire stroke of servomotor. 8.3.10 Plot the relation curve of wicket gate servomotor stroke and guide vane opening from starting and closing directions. Measure 4~8 guide vane openings for each point. Adopt the average value. When the guide blade is wide open, measure the opening of all the guide blades. Generally, the deviation shall not exceed ±2% of the design value.
8.3.11 Plot the relation curve and switch rule of wicket gate servomotor stroke and runner blade servomotor stroke under different water head on-cam relationship from the starting and closing directions. It shall meet the design requirements. The inaccuracy of its runner blade servosystem shall be smaller than 1.5% of the entire stroke. 8.3.12 Setting of the practical open-loop gain of servosystem: time for the switch-on and closure of servomotor has been adjusted and meet the design requirements. Set amplification coefficient and lever ratio as the maximum design value. Input step-function signal into servosystem equivalent to 10% of the entire stroke of servomotor. Observe the movement of servomotor; the maximal amplification coefficient and lever ratio that can keep the servosystem stable and not over control are the practical open-loop gain. 8.3.13 Record the static characteristic curve of speed regulating system when permanent speed droop bp = 6%, static characteristic curve shall be approximated as straight line. Speed dead band is no greater than 0.04%. For speed regulating system of Kaplan turbine, inaccuracy of its runner blade servosystem shall not be greater than 1.5%. 8.3.14 When the spiral case is anhydrous, record the pressure of overhead tank of low oil pressure closedown and drop-out value of oil level. 8.3.15 When the spiral case is anhydrous, measure the minimal operation oil pressure of guide blade and runner blade operating mechanism. Generally, it shall not be greater than 16% of the nominal oil pressure. 8.3.16 Speed regulating system of impulse turbine shall take oil charge adjusting test according to related test items and standards in Article 8.3. 8.4 Simulation test of speed regulating system 8.4.1 Simulate all kinds of malfunctions of speed regulating system. Protective devices shall be secure. The actuating mechanism and alarm signals are correct. 8.4.2 Carry out the starting, shutting down, and emergency stop simulation test by manually operation and in automatic mode. The actuating mechanism of speed regulating system shall be normal. Alarm signal shall be correct.
9 Installation of vertical type hydrogenerator 9.1 Combination of framework 9.1.1After the combination of bracket arms of combined type framework, check the joint close clearance, which shall meet the requirements of Article 4.7. Top of bearing framework and combination slots of bracket arms shall be checked with 0.05mm clearance gage. Partial discontiguous length shall not exceed 10% of the total length of the top. 9.1.2 Combination of welded type framework shall meet the following requirements: a) After the fastness of the bearing of central body, adjust the level, measure the planeness on plane of composition, which shall not be greater than 0.04mm/m. b) After bracket arm is coupled with the central body, check if the following items, which shall all meet the design requirements. 1) Undercut of the joint face of each bracket arm and central body 2) Skew of each bracket arm (namely squareness); 3) Height difference between interface of each bracket arm sub-frame and plane of composition of central body.
4) Middle ordinate of the exterior margin of each bracket arm; c) Weld as required by the manufacturer. If no definite requirements are raised out by manufacturer, regulations of 4.14 shall be met. d) Carry out the appearance examination and non-destructive inspection over the butt-welded seam as required by drawing or technological documents provided by manufacturer. If no definite requirements are raised by the manufacturer, examine over weld appearance according to Table 5 and assess the non-destructive test according to the following standards: 1) When radiographic inspection is adopted, assess according to GB3323 standard. If the weighted butt weld is no lower than Grade II, ratio of radiographic inspection welding seam is 50%; generally butt weld shall not be lower than Grade III. Ratio of radiographic inspection welding seam is 25%; 2) When supersonic flaw detecting is adopted, assess according to GB11345 standard. If the weighted butt weld is no lower than Grade II, ratio of supersonic flaw detecting is 100%; generally butt weld shall not be lower than Grade BI. Ratio of supersonic flaw detecting is 50%; e) After the weld of bracket arm, the central body maintains level condition of below 0.04mm/m. Examine the height difference of middle ordinate of exterior margin key groove of each bracket arm as well as sub-frame interface of each bracket arm and the upper plane of central body, which shall meet the requirements of design drawing. 9.1.3 After the combination of support abutment of leaf typethrust bearing, check the planeness of bearing installation plane, and the deviation shall not be greater than 0.2mm. Clearance of the joint close surfaces shall conform to the requirements of Article 4.7. 9.1.4 As for leaf type bearing framework, group welding of its central body and bracket arm may proceed according to requirements of Article 9.1.2 and 9.1.3. 9.2 Grounding and scraping of bearing shell 9.2.1 Thrust bearing pad shall be free of flaws including cracks, slag inclusion and concentrated porosity. The total area of partial peel-back area of tiling materials of bearing shell and metal base billet shall not be greater than 5% of the tiling surface. If necessary, ultrasonic or other methods may be used in the examination. Try the bearing shell thermometer, high-pressure oil jacking conduit with bearing shell and examine. 9.2.2 Working face of rotating plate shall be free of scars and rustiness. Its roughness and rigidity shall meet the requirements. If necessary, examine the parallelism of two planes and planeness of working face according to the drawing. 9.2.3 Thrust bearing pad grounded and scraped on site as required by manufacturer shall meet the following requirements after the grounding and scraping: a) On the tiling surface, within each 1cm2, 1~3 contact points shall exist: b) Partial non-contact area on the surface, each part shall not be greater than 2% area of bearing shell, but the maximal shall not be greater than 16cm2. The total shall not be greater than 5% of the bearing shell area; c) Fuel inlet side shall be scraped as required by manufacturer; d) As for bearing shell of strut bolt thrust bearing without filler plate shall, after reaching the requirements of a) and b), scrape the middle part of tiling lower. Around the strut bolt, on
the round parts with 2/3 the tile length as diameter, clear away the contact points (feather contact points may be sustained). Scrape for one round, and then minimize the scope. Around the strut bolt, on the round part with 1/3 length of tile as diameter, scrap for the second time in 90° direction with the previous scraping; e) After the unit jigger, draw out thrust pad to examine osculation conditions, which shall meet the requirements of a) and b); f) Jacking oil container by high-pressure oil shall be examined or grounded and scraped according to design requirements. g) As for the thrust bearing with double tile structure, contact surface between thin tile and pillow shall meet the design requirements. If no definite requirements are raised on design, contact surface of thin tile and pillow shall be over 70% and the contact surface shall distribute evenly. When thrust pad is under strained condition, examine the gaps between thin tile and pillow with 0.02mm clearance gage, there shall be zero clearance. 9.2.4 guide-blocks need to be grounded and scraped on site shall be in compliance with related requirements of Article 5.6.1. 9.3 Stator installation 9.3.1 After the combination of split stator of laminations inside the manufacturer, the following requirements shall be met: a) Check the clearance of combination seam of sub-frame with 0.05mm clearance gage, and the gage shall not pass through at around the screw bolt and/or assembling pin; b) Pad the iron core commissures as required. After padding, iron core commissure shall have no clearance at the commissure of iron core; c) Radial undercuts at the slot bottom of iron core commissure shall not be greater than 0.3mm; d) Trunking width of commissure shall meet the design requirements; e) Combination of magnet yoke and sub-frame shall meet the requirements of Article 4.7. 9.3.2 The roundness of stator of lamination built-up by leaf inside the manufacturer, difference between each actually measured radius and average radius shall not be greater than ± 4% of the design air interstice value. Generally, along the stacking height direction, select one surveyed cross-section every 1m and each section shall have at least measuring points. Each section of each flap shall have least 3 points. Commissure shall have measuring points. Roundness of the iron core of one-piece stator shall also meet the aforesaid requirements. 9.3.3 Combination of magnet yoke of lamination on site shall proceed according to the regulations of manufacturer. If no definite regulations are raised, the following requirements shall be met. a) Arrange, adjust and pack the buttress and wedge plate according to the indexing azimuth and radius of extent. Packing buttress shall be fastened temporarily, and height difference of top surface of wedge plate shall be within 2mm. b) Installation of central cyclometer shall be secure. When measuring the circle, various exogenous influences shall be avoided. The squareness of central axis of cyclometer shall not be greater than 0.02mm/m. The maximal inclination within the measuring range shall not be greater than 0.05mm.
Actual diameter and the static balance of the feeler arm of the cyclometer central axis shall be examined. c) In the process joint close of the sub-frame combination, fill in the filler pieces as required by the manufacturer. Generally, thickness of the filler piece is 2mm ~ 3mm when the circumferential lamellae are butt welded. When the circumferential lamellae are lap welded, the thickness of filler piece is 1mm. As for sub-frames with the localization ribs welded in the manufacturer, calculate the shrinkage of welding seam according to the structure of sub-frame. If necessary, carry out the synthetic welding test and make process assessments to determine the padding thickness at the commissure. It is generally recommended: 2.5mm for butt weld, 1mm for lap weld. d) After the combination and adjustment of stator frame, before the welding, the following requirements shall be met: 1) The difference between the radius of screw centre (for sub-frame with core hole for screw, it refers to the core through screw center) to secure the lower tooth press plate on the lower ring plate circle of sub-frame and the design radius shall not be greater than±1.5mm; 2) Deviation for the average value of the absolute radius of the inner circle of each circumferential lamellae and the design value shall conform to the requirement of manufacturer. Generally it is recommended: See Table 23 for the butt weld structure; See Table 24 for the lap weld structure; Table 23 Deviation for the average value of absolute radius of inner circle of each circumferential lamellae of butt welded structure sub-frame and the design value Unit: in millimeter Number of the paddles of 3 4 5 6 8 sub-frame Deviation for the absolute radius of each +1.0~+2.0 +1.5~+2.5 +2.0~+3.0 +2.5~+3.5 +3.0~+4.0 circumferential lamellae Table 24 Deviation for the average value of absolute radius of each circumferential lamellae inner circle on butt welded structure sub-frame and the design value Unit: in millimeter Number of the paddles of ≤5 ≥6 sub-frame Deviation for the absolute radius of each +0.5~+1.5 +1.0~+2.0 circumferential lamellae 3) Welding of the sub-frame of localization rib inside manufacturer, difference between the inner circle radius of localization rib and the design radius shall not be greater than±1% of the air interstice.
9.3.4 After the welding, examine and adjust the sub-frame, requirements of 9.3.3d (1) (2) shall be met. The absolute size dimension of each radius shall not be greater than ±2mm. After the sub-frame of the localization rib welded in the manufacturer is group welded on site, deviation of the radius of localization rib measured at each circumferential lamellae and the design value shall be within ±2% of the air interstice. But the maximum allowable offset shall not go beyond ±0.5mm of the design value. 9.3.5 Installation of the localization rib shall conform to the following requirements; a) Align the localization rib before installation. Examine with leveling rule at least 1.5m long. Linearity of the localization rib in both radial and peripheral direction shall not be greater than 0.1mm. If the localization rib is smaller than 1.5m, examine with leveling rule no shorter than the length of the localization rib; b) After localization (or lap welding) of the reference rib of localization rib, the deviation of its radius and design value shall be within±0.8% of the design air interstice. Peripheral and radial inclination maximum deviation shall not exceed ±0.5mm of the design value no greater than 0.15mm; c) After the entire welding of the localization ribs, deviation of the localization rib radius and the design value shall be within ±2% of the design air interstice. Maximum deviation shall not exceed ± 0.5mm of the design value. Deviation of radius of the two neighboring localization ribs at the same height shall not be greater than 0.6% of the design air interstice. For the same localization rib at the same height, difference of radius resulted by surface skew shall not be greater than 0.10mm; d) Deviation for the middle ordinate of localization rib at the same height and the average value shall not be greater than±0.25mm, but the cumulative departure shall not be greater than 0.4mm; e) Vergence direction of the installed localization rib in peripheral direction and inclination value shall meet the design requirements. f) Generally, zero clearance shall exist between cradle and field ring plate of the localization rib; g) Even the localization rib has been welded in the manufacturer; it shall still take an examination on site according to the above requirements. Those that go beyond the standards shall be disposed.; 9.3.6 The installation of lower tooth press plate shall meet the following requirements: a) Height difference of each finger plate shall not be greater than 2mm. Height difference between the pressure fingers of each two neighboring finger plates shall not be greater than 1mm. For the structure of denticle press plate, pressure finger of each finger plate and the inner circle of cross section are 1mm ~ 3.5mm. higher than the ex-circle, which depends on the piling height of iron core, structure and articulation of lower tooth press plate. Generally, the higher the stator core is, the higher the inside of lower tooth press plate is compared with its outer side. When the stacking height is over 2.5m, upper value shall be adopted. b) Take the shallow tooth punching as the template. Adjust the deviation of pressure finger centre and the punching tooth centre. The deviation shall not be greater than 2mm. Radial distance of finger plate teeth end and punching teeth end shall meet the drawing requirements.
9.3.7 Stator-core lamination shall meet the following requirements: a) Core stamping shall be clean, nondestructive, leveling off, and with perfect lacquer film; b) Stack up stator core punching according to the procedure required by the manufacturer. Control different punching segments and stack-up height of each subsection. Paint bonding agent between the punchings of upper and lower ends of lamination according to the manufacturer; c) As required by the manufacturer, lamination shall abut against the localization rib or radial clearance is left. If clearance is left, then the left clearance shall be even. d) During the lamination of iron core, each punching shall be fitted with at 2 slot rods and slot-wedge slot rods to locate as required by the manufacturer and shall be reshaped with dressing stick; e) According to the deviation of stacking height and waveness measured after the compaction of lamination by section. In each lamination, amount of deviation shall not be greater than 0mm ~ +1mm. Make altitude compensation as specified by the manufacturer; f) Stacking height of iron core shall consider the amount of reduction of entire impaction and thermal pressure. Generally, the amount of reduction of thermal pressure should be considered according to 0.2%~0.3% of the stacking height, and shall be evenly distributed into each lamination segment; g) During the stacking of iron core, check frequently and adjust the roundness. 9.3.8 Impaction of stator core shall meet the following requirements: a) Pressure bolt outside the iron core shall be installed according to the design requirements. Over 2mm spacing shall be maintained between it and iron core. Core-through pressure bolt shall maintain insulated and nondestructive, secure, and the belleville spring gasket shall be in good condition. b) The iron core shall be segmented and impacted entirely. The subsectional crush height and times shall meet the requirements of manufacturer. If not specified by the manufacturer, subsectional crush height shall be determined by the structure of iron core. Generally, each segment should not exceed 600mm; c) Packing force of the segmentional impaction of iron core and entire compaction should meet the requirements of manufacturer; d) Packing force over iron core shall be built up in sequence by times until it reaches the specified numerical value of the manufacturer. Check the impacted average pressure with the method of measuring the elongation of evenly distributed impacted impaction screw. The number of screws measured on the entire circle shall not be fewer than 10; e) For stator core required to be thermally impacted, the thermal impaction shall proceed after the entire impaction of iron core and before the core flux test. Heat up according to the requirements of the manufacturer. Cool down to ambient temperature naturally. Impact according to the requirements of c) and d); f) impact and examine according to requirements of d) of this article after the core flux test; g) Before and after the core test, examine the grounding insulation of core through screw and the insulating value shall meet the requirements of manufacturer. 9.3.9 After the completion of lamination and subsectional impaction, proceeds the installation of upper press plate. After the complete installation and emplacement of
impaction screws, adjust the deviation of pressure finger centre of upper press plate and punching teeth centre, which shall not be greater than 2mm. Radial distance of pressure finger teeth end and punching teeth end shall meet the requirements of drawing. 9.3.10 After the installation of stator iron core, the following requirements shall be met: a) Roundness measuring of iron core: measure along the stacking height direction around every other 1m and in many sections. Each section shall have at least 16 measuring points. When the diameter of stator core is large, measuring points of each cross section shall be increased accordingly. The difference between each radius and the design radius shall not be greater than±4% of the design air interstice of generator; b) Measure stacking height on at the bottom of iron core slot and at least 16 measuring points evenly distributed on the back. Deviation of the measured value of each point and design value shall not exceed regulations in Table 25. Generally positive deviation shall be adopted; Table 25 Permissible deviation for the height of each measuring point of the stator core Unit: in millimeter Height of the 1000 < h < 1500 ≤h< h < 1000 h≥2500 2000≤A<2500 iron core h 1500 2000 Deviation -2~+4 -2~+5 -2 ~ |6 -2~+7 -2~+8 c) Waveness of the rabbet tooth tip at the upper end of iron core shall not be greater than the value regulated in Table 26; Table 26 Allowable value for the waveness of the upper end of iron core Unit: in millimeter Length of the 1000 < l < 1500 ≤ l < l < 1000 2000≤ l <2500 l≥2500 iron core l 1500 2000 Deviation 6 7 9 10 11 d) Examination over the iron-cored flute profiles with continuous manger rod shall all pass through. Groove depth and slot width match the design value. 9.3.11 Installation of supporting ring shall proceed. Joint weld of metal supporting ring shall adopt non-magnetic material. Connection of insulated supporting ring shall meet the requirements of manufacturer. The insulation wrapping shall be tight. The lap joints between the original insulation and new insulation shall be machined into slope. Generally, the lap length shall not be smaller than that specified in Table 27. Table 27 Insulation wrapping lap length of the supporting ring Nominal voltage of generator Lap length mm
6.3
10.5
13.8
15.75
18.0
25
30
40
45
50
9.3.12 Before the setting-in of loop, the following examination shall be made: a) Check the width of straight line portion of each single stator coil in cold state, which shall meet the design regulations; b) Carry out the electrical test on coil according to requirements of 14.1; 9.3.13 setting-in of stator coil shall meet the following requirements: a) Coil and iron core as well as supporting ring shall be secured. The elevation of upper and lower end coils shall be identical. The hypotenuse gap is in compliance with the design requirements. The coils shall be fixed and secured; b) Deviation of longitudinal separation shall be within the length scope of joint sleeve. c) After the straight line portion of coil is embedded into the winding slot, if the unilateral clearance is over 0.3mm and the continuous length is greater than 100mm, semiconductor packing strip may be used in filling. The filling-in depth shall be identical to the insert depth of coil as much as possible. Adopt stator coil of semiconductor slot liner structure. The unilateral clearance shall meet the requirements of manufacturer. d) After the setting-in of upper coil and inner coil, carry out the voltage withstand test according to the regulations of Article 14.1; e) Grounding insulation of coil adopts epoxy-based mica. For unit with voltage grade at 10.5kV or higher, generally, surface gutter potential or cell resistance shall be determined after the setting-in of coil, under the nominal phase-to-phase voltage and the gutter potential shall be lower than 10V or the cell resistance shall meet the requirements of manufacturer. 9.3.14 Slot wedge, coil and iron core gullet shall couple tightly. Examine the slot wedge tightness according to the specified method of manufacturer after the hammering-in of slot wedge. Allowable interstitial length of each slot wedge shall not exceed 1/3 of the slot wedge length. Slot wedge shall not project iron core, ventilation opening of slot wedge shall align with the center of core ventilation channel. The deviation shall not be greater than 3mm. The length protruding out the iron core slot opening and its fixing form shall meet the design requirements. 9.3.15 Weld of coil joint shall meet the following requirements: a) Operating personnel of braze welding must accept professional training and take their job after they pass the examination. b) Before braze welding, the coil bar joints and the brazed parts shall be cleaned up as required by manufacturer and metallic luster shall come out. c) Use the soldered fitting of tin soldering size bridge casing structure, joint copper wire, size bridges sheath, copper wedge and so on to meet the tin dipping. Size bridges sheath, copper wedge and current-carrying part of copper wire shall be tightly bonded and shall not be clamped by force; the clearance between copper wire and size bridges sheath is no greater than 0.3mm generally. Allowable partial clearance is 0.5mm; d) Use brazed joint of bonded construction phosphorus copper brazing filler metal braided wire, the lap length of divided conductor shall not be smaller than 5 times the thickness of divided conductor. e) Use brazed joint of phosphorus silver-bearing copper brazing filler metal buttstrap. Generally padding clearance after joint fit-up is smaller than 0.25mm. f) Joint brazing shall proceed according to the heating method and processes specified by manufacturer.
9.3.16 Requirements on the coil splices insulation: a) For insulation wrapped with mica ribbon, before the wrapping, scrape the original insulation into slope. Generally, its lap length shall meet the requirements of Table 27. The wrapped insulation layers shall be coated with glue. The wrapping shall be dense and the number of wrapping layers shall meet the design requirements; b) For insulation adopting epoxy to cast, the mixture ratio of epoxy shall meet the design requirements. Clearance around the joints and insulation case shall be even. The lap length of coil terminal insulation and case shall meet the design requirements. The casting shall be saturated without penetrability pore and crackle. 9.3.17 Installation of bus rod shall conform to the following requirements: a) Bolting joint shall be tin dipped or silver plated. The contact surface of joint shall level off. Straightness of the contact surface of joint shall not exceed 0.03mm or contact surface of joint shall meet the requirements when checking with 0.05mm clearance gage. Use moment spanner to screw down the connecting bolt with the designed pretightening force of screw bolt. b) Soldered joint shall be free of pores, slag inclusion and the surface shall be polished. The solder shall be replete. 9.3.18 Measurement of insulation over the ground and that between windings of stator winding a) When insulation value of each phase of stator winding is converted into 100°C, it shall not be lower than the value calculated according to the following equation.
R=
UN ( MΩ) 1000 + S N / 100
Where: UN - Nominal line voltage of hydraulic generator, unit in V; SN - Nominal capacity of hydraulic generator, unit in kVA For dry and clean hydraulic generator, insulation resistance Rt (MW) of stator winding at room temperature t (°C) may be amended according to the following equation. Rt = R × 1.6(100-t)/1G Where R - Calculated value of hot insulation resistance when of winding the corresponding temperature is 100°C, MW. b) When the temperature is under 40°C, absorption ratio of insulation of epoxy reconstituted mica R60/R15 is no smaller than 1.6 or its polarization index R10min/1min is no smaller than 2.0. 9.4 Rotor installation 9.4.1 Hot jacket of wheel hub shall meet the following requirements: a) Except for the shrink range, swelling capacity of wheel hub shall also add the gap width of ensembling technological requirements, as well as the systolic value generated by the cooling of wheel hub during the process of sheating. Shrink range takes the value measured and examined before the shrinkage fit and refers to the value provided by manufacturer. Generally, gap width for technological requirements of emboitement adopts
1/1000 of the axial diameter. The systolic value generated by the cooling of wheel hub is adopted between 0.5mm ~ 1.0mm. b) Before heating up of the wheel hub, squareness of the principal axes and levelness of wheel hub in lift and strained condition shall be adjusted and controlled within 0.05mm/m. During the warming up, monitor and control the temperature to make it evenly inflate. After the heating up, check the swelling capacity of wheel hub carefully. The value must satisfy the calculation requirements of a) in this article; c) After the shrinkage fit of wheel hub, lug boss of principal axes shall be cooled first. During the cooling procedure, generally temperature difference of the upper and lower side of the wheel hub is not higher than 40°C. 9.4.2 Before the assembling of wheel arm, examination and adjustment over the central body shall be carried out as follows: a) Examine the dimension of each part as required by drawing; b) Rotor central body shall support firmly. Adjust the level of central body and its levelness shall not be greater than 0.03mm/m. 9.4.3 Examine after the combination of wheel arm, which shall meet the following requirements: a) The clearance of combination seam shall meet the requirements of Article 4.7. b) Difference of elevation of each hookup at the lower end of wheel arm shall not be greater than 1mm when the overall diameter of wheel arm is smaller than 8m; when the overall diameter of wheel arm is 8m or longer, the difference of elevation shall not be greater than 1.5mm; c) Roundness and squareness of the exterior margin of wheel arm, chord length of the upper and lower ends of each key groove, as well as depth and width of key groove shall all meet the design requirements: d) Tangential and radial inclination pitch of the wheel arm key groove shall not be greater than 0.25mm/m and the maximal value shall not be greater than 0.5mm. 9.4.4 Assembling of the rotor field spider of disc type structure shall meet the following requirements: a) Rotor central body shall support firmly; adjust the level of central body. Levelness measured of the top of the flange face shall not be greater than 0.03mm/m; b) After the combination of the symmetric scallop lobes of the rotor field spider, rotor field spider and central body, the following requirements shall be met: 1) Elevation difference of the upper plane of the wheel arm is 1.5mm. Planar height difference between two neighboring hookups shall not be greater than 1mm; 2) Radius of vertical supporting plates shall be decided by the shrinkage of welding seam. Generally it is 2mm ~ 5mm larger than the design value. If the external surface of vertical supporting plate needs planing and milling, after considering the shrinkage of welding seam, then add proper planing and milling allowance; 3) Squareness of vertical supporting plate shall not be greater than 0.15mm/m; 4) Dimension of the flexible chord length of wheel arm before welding shall consider the welding shrinkage. 9.4.5 During the welding process of rotor disc bracket, the dimensional variance of bracket shall be monitored. Measures to correct deviations shall be adopted. On the
completion of welding, examination shall be made over the appearance and non-destructive test according to the requirements of drawing and technological documents provided by the manufacturer. If the manufacturer does not put forward definite requirements, the qualitative assessment of butt weld welding seam shall meet the requirements of Article 9.1.2d). On the completion of the welding, when the central body level meets the requirements of Article 9.4.4a), Examine the dimension of disc bracket, which shall meet the following requirements. a) Deviation between the outerplanar radius of vertical supporting plate that influence the rotor roundness and design value shall not exceed ±1.5% of the air interstice. For rotor field spider used to form vertical supporting plate or sub-vertical supporting plate, radius of its vertical supporting plate shall meet this requirement after it is welded, thinned, and disposed. After the welding, during the process of refacing and milling after the welding, the deviation of radius after the processing and the design value shall not exceed ±1% of the air interstice; b) Vertical degree of vertical supporting plate shall not exceed 0.2mm/m; c) Chord length at the top and bottom of wheel arm exterior margin shall meet the design requirements; d) Discrepancy in elevation of the vertical supporting plate hookup shall not be greater than 2mm, but the elevation difference of two neighboring hookups shall not be greater than 1mm; e) Planeness of the brake hoop plate joint face shall not be greater than 2.5mm. 9.4.6 Examination over the yoke punching and vent spacer shall meet the following requirements: a) Surface of yoke punching and vent spacer shall level off, be free of oil sludge, rustiness and burrs. b) Yoke punching shall be weighed and grouped in the manufacturer. If yoke punching is not grouped according to quality in the manufacturer, it shall be weighed and grouped according to Table 28. Draw out 3~5 pieces from each group and measure the thickness. The positive side and the opposite side of each sheet shall be in accordance with each other when they are piled up. c) According to the weighing, grouping, thickness record and yoke installation drawing of the punching, count and list for the counterweight of yoke stack. Vent spacer also participate in the counterweight; d) Height and position of wind deflecting belt and line seam ring of vent spacer shall meet the design requirements. Table 28 Quality grouping of yoke punching Unit: in kilogram Rotation speed n t/min Mass of each yoke punching t Kg t < 20
n < 100
100≤n<300
n≥300
0.3
0.2
0.1
20 ≤t < 40 t ≥ 40
0.4 0.5
0.3 0.4
0.2 0.3
9.4.7 Installation of brake hoop plate shall conform to the following requirements: a) Brake hoop plate shall be assembled according to serial number. Assemble according to symmetric mass principle. b) For brake hoop plate with welded structure, planeness of brake surface of brake hoop plate shall be smaller than 2.5mm. No downbulge is permitted for longitudinal ream and the allowable fovea superior value shall not be greater than 0.5mm; c) Brake hoop plate of fabricated structure: 1) Radial direction of the circumferential lamellae shall be horizontal and the deviation shall be within 0.5mm. Waveness around the entire circumference shall not be greater than 2mm; 2) Seam crossing shall have clearances above 2mm. Examine the flashboard juncture along the rotation direction of unit. The piece after shall not bulge out of the previous piece. 3) Screw bolt at the circumferential lamellae part shall yield to the friction surface by over 2mm. 9.4.8 Stack-up of yoke punching shall meet the following requirements: a) Try stacking 100mm of yoke punching first. Examine and make sure dimension of each part meets the requirements, and then formally stack up; b) Generally, punching shall be located by yoke key and dowel. Yoke without localization structure can be evenly penetrated by over 20% permanent screws in the localization, and each punching shall have at least 3 yokes; Yoke without localization structure can be evenly penetrated by over 20% permanent screw stems in the localization, and each punching shall have at least 3 screw stems; c) Temporary guidance key will serve as a structure for tangential grinder and radial location. Proceed the installation of guidance key as regulated by the manufacturer; d) During the lamination procedure, clearance between the punching and stud excircle of rotor field spider shall be even. Front and back side of punching shall be identical. Lamination mode and stacking height shall meet the design requirements; e) Impaction of the yoke shall be made by moment spanner symmetrically and orderly. Increase the packing force bit by bit until it reaches the required pretightening force. At least 10 screw stems should be spot tested in the peripheral direction for the prolongation value to check the pretightening force. Stress and prolongation value of permanent screw stem shall meet the regulations of manufacturer; f) After the compaction of yoke, stacking factor of yoke calculated according to weight method shall not be less than 0.99. Subsectional crush height shall meet the requirements of manufacturer. If there are no definite requirements raised by manufacturer, generally, the subsectional crush height shall not be greater than 800mm. But for punching of inferior quality or yoke subsection with greater stacking pressure, the crush height shall be lowered. g) During the procedure of yoke stack-up, check and adjust the roundness frequently. h) As for brake plate laying at the lower part of yoke, adjustment of its radial level and waveness shall proceed at the same time of impaction, and shall meet the requirements of 9.4.7c);
i) After the yoke is fully impacted, the average height of yoke shall not be lower than the design height. Deviation in height at the same longitudinal section shall not be greater than 5mm. Deviation of the height along circumferential direction and the design height shall not go beyond the limit regulated in Table 29. Table 25 Permissible deviation for the height of each measuring point along the peripheral direction of the yoke Unit: in millimeter 1500 ≤A < 2000 ≤A < 1000 ≤A < Yoke height h≥2500 h < 1000 1500 2000 2500 Permissible -1~+5 -1 ~ +7 -1~+8 0~+10 0~+11 deviation j) Generally, zero clearance between yoke and the hookup of wheel arm. Very few that have clearance shall not be greater than 0.5mm; k) Dimension of air chute, dovetail slot, spring gutter and so on shall meet the design requirements; l) Press plate of yoke shall be weighed and shall be disposed with symmetric mass; m) Contact surface of yoke and polar shall be examined with leveling rule no shorter than 1m, which shall be straight; very few higher spots shall be planished; n) Stack-up of subsectional yoke shall also meet the aforesaid regulations and the requirements of drawing. 9.4.9 Installation of radial yoke key shall meet the following requirements: a) Compact the yoke key under cold state. Relative displacement incurred in the radial direction between the rotor spider and yoke during the cold key stroke shall meet the commendatory value of manufacturer. If no definite provisions are given by the manufacturer, generally, average value of relative displacement in the radial direction may be controlled at 0.08mm ~ 0.25mm according to the dimension of residual distortion of the rotor yoke; b) For yoke with key stroke heating requirements, the length uncased on the top of the yoke key must satisfy the requirements of hot key stroke; c) During the warming up of the key stroke (or hot tray) of the yoke, yoke shall have good insulation. Measures shall be taken to sustain a temperature difference between yoke and bracket arm. d) Pressing magnitude of the hot key stroke of (or hot tray) shall meet the design requirements. e) Cool the hot key stroke of yoke down to room temperature. Check the yoke roundness to make sure it is eligible. The lower part of yoke key shall be cut flat and evenly according to hookup of wheel arm. 150mm ~ 200mm shall be kept on the upper end, but an adequate distance shall be maintained between it and upper framework or breastplate. f) For rotor of non-shaft construction, after the heating of key stroke (or tray heating), distortion at the upper and lower spigots of rotor center part shall be checked. g) Installation of manifold key combination with yoke cross key, peripheral positioning key, secondary positioning key and lamination key shall proceed according to the requirements of manufacturer.
9.4.10 measure the yoke roundness. The difference between each radius and the design radius shall not be greater than±3.5% of the design air interstice. 9.4.11 Before the installation of magnetic poles, the following examination shall be taken: a) When the pole coil is impacted, the height difference of press plate and iron core shall meet the design requirements. When no regulation is given, the difference shall not go beyond the range of -1mm ~ 0mm; b) Before and after the suspension and installation of magnetic pole, check and test according to regulations of Article 14.4; c) Examine the polarity and installation mass according to magnetic pole number. Fit the magnetic poles in order according to the manufacturer’s serial number. When no regulation is given by manufacturer, It shall meet the requirement that the imbalance mass in the symmetric direction shall not go beyond the requirements of Table 30 after the magnetic pole is fitted within the scope of 22.5°~45° angles. Generally mass balance takes into account the mass of leading wires and attachments. Table 30 Permissible deviation for the mass imbalance of magnetic pole installation Unit: in kilogram Permissible deviation for the mass imbalance in the installation Total mass of yoke of magnetic poles under different rotation speed (r/min) and magnetic poles t ≥200~< 500 ≥500 < 200 t<200 6 3 2 200≤t<400 8 4 2 400≤t<600 10 5 3 600≤t<800 12 6 4 t ≥800 14 7 4 9.4.12 Installation of magnetic pole shall meet the following requirements: a) The elevation deviation in the installation of pole center shall meet the requirements of Table 31; Table 31 Elevation deviation of the installation of magnetic poles center Length of the magnetic pole iron core m Permissible deviation of elevation mm ≤ 1.5 ±1 1.5~2.0 ±1.5 >2.0 ±2.0 b) For rotor with nominal speed at 300r/min or above, the elevation difference of magnetic pole installation at symmetric directions shall not be greater than 1.5mm; c) Before the hammering in of the magnetic pole key, apply lubricant on the inclined plane. After the hammering in, the osculation shall be tightly closed. For magnetic pole key that has passed examination, lower part shall be cut flat and even referring to the dovetail slot bottom. About 200mm is given over on the upper end. But still, it shall maintain adequate distance from the upper framework or breastplate; d) Bearing plate of magnetic pole shall abut against the dovetail bottom of magnetic pole and shall be anchor-held by welding.
e) Interelectrode support block shall be installed in the right way, with fastening support and shall be locked reliably. 9.4.10 Check the rotor roundness after the installation of magnetic pole. The difference between each radius and the design radius shall not be greater than±4% of the design air interstice. Integrate offset value of rotor shall satisfy requirements of Table 32, but the maximal shall not be greater than 1.5% of the design air interstice. Table 32 Entire allowable eccentricity of the rotor Rotation rate of n<100 100 ≤n<200 200 ≤n<300 unit (n) r/min Allowable 0.50 0.40 0.30 decentralization
300 ≤n<500 0.15
9.4.14 Connection of magnetic pole joint and installation of excitation leading wire shall meet the following requirements: a) Joint dislocation shall not exceed 10% of the joint width. Current density of contact surface shall meet the design requirements: b) Welding of soldered joint shall be replete, with luminescent and clean appearance and shall possess certain elasticity. Osculation and joints of bolting shall be rigorous and the connection shall be in compliance with requirements of 9.3.17 a); c) Wrapping of splice insulation shall meet the design requirements. A safety distance no smaller than 8 mm shall be kept between the joints and grounding conductor. After the tightening of the insulation clamping plate, 1mm~2mm clearance at both ends of the two clamping plates; d) Ranging of the Excitation Leading Wire of rotor shall be tight and the fastening shall be secure. The joints at the terminals shall be connected according to design requirements. The joints of the bolt connection shall be tin-coated or silver coated. The coated layer shall be neat and clean and shall be made as required by 9.3.17a). The bolts shall be locked and reliable. 9.4.15 The blower fan shall be free of flaws like cracks/ The installation shall be solid, locked and reliable. It is strictly forbidden to adopt gas cutting or electric welding over the blower fan. Generally, distance between its metal parts and magnetic poles as well as coils is no smaller than 10mm. 9.4.16 Check the counterface of the damping ring joints with 0.05mm clearance gauge. The inserting depth shall not be greater than 5mm. Connecting bolts of damping ring shall be tightened according to the moment regulated by the manufacturer, locked and reliable. 9.4.17 Before the rotor is suspended into the unit pit, test according to Article 14.5 item by item. 9.5 Overall installation 9.5.1 Installation of framework shall meet the following requirements: a) Central deviation of the machine frame shall not be greater than 1mm. For units with rotation speed higher than 200r/min, the excircle of oil deflector should be centered. The
central deviation value shall meet the manufacturer’s requirements. Roundness of the oil deflector shall be in compliance with the design requirements; b) Central deviation of thrust bearing base of the machine frame shall not be greater than 1.5mm and its horizontal deviation shall not be greater than 0.04mm/m. For elastic oil tank thrust bearing without support bolts and multi-spring support structure thrust bearing, horizontal deviation of the machine frame shall not be greater than 0.02mm/m; c) Elevation deviation of the machine frame installation shall not exceed ±1.5mm generally; d) Jack of the machine frame in radial direction should be flat and stress it bears shall be even. Generally, its installation elevation deviation shall not be beyond the range of ±5mm. 9.5.2 Installation of the actuator shall meet the following requirements: a) Tightness compression test on the actuator shall be carried out strictly according to the design requirements. Sustain for 30min, and during the 30 minutes, the pressure drop shall be within 3%. Piston of the spring-return actuator shall be able to reset automatically after the pressure is removed; b) Deviation for the installation elevation of the actuator top surface shall be within ±1mm. Gap deviation between actuator and rotor braking ring plate shall be within ±20% of the design value; c) Pipeline of the braking system shall take tightness compression test strictly according to the design requirements; d) Actuator shall take lowering and lifting test by having compressed in to check the flexibility of the actuator’s mechanism and if the stroke of the actuator meet the requirements. 9.5.3 Stator installation shall meet the following requirements: a) Stator installation azimuth shall be in compliance with the position of the lead-out of generator and ensure the normal connection of the generator lead-out. b) During the alignment of stator according to the actual central line of water turbine, for measurement at the same section during installation, difference of each radius and the average radius shall not be greater than ±4% of the design air clearance. The alignment of stator according to rotor shall meet the requirements of d) of this article. c) Check the installation elevation of stator according to the elevation of main axle flange of the water turbine and actually measured dimension of each part. Average central elevation of the stator iron core and average central elevation of the rotor magnetic pole shall be made identical and the deviation shall not exceed ±0.15% of the effective length of the stator iron core, and the maximum shall not exceed ±4mm; d) when the rotor is in the center of the unit, check the air clearance between the upper and lower ends of rotor. Difference between each clearance and the average clearance shall not be greater than ±8% of the average clearance. 9.5.4 Rotor installation shall meet the following requirements: a) Adjust the elevation of the top surface of the actuator before the installation of stator in suspension-type unit and sustain 4mm~8mm clearance between the stator and the carrier plate during the coupling of thrust collar after the rotor is suspended. b) For axleless umbrella type or half umbrella type hydraulic generator, adjustment of surface elevation of its actuator only needs to consider the shaft coupling clearance between
water turbine and generator. During the suspension of rotor, drop the rotor directly onto the thrust bearing through guide part; c) During the suspension of rotor, clear the lower part of the rotor completely. Measure the deflection of the rotor at the lower part of yoke; d) When the stator of generator is aligned according to rotor, then the rotor shall be aligned according to qualified water turbine shaft. Central deviation between the two flange surfaces shall be smaller than 0.04mm and the parallelism between the flange surfaces shall be smaller than 0.02mm. Check the uprightness of generator shaft or the flange surface level on the central body of rotor; e) If the stator center of generator has been aligned according to the fixed part of water turbine, then adjust the center according to the air clearance after the rotor is suspended and check and measure the air clearance between stator and the upper and lower ends of the rotor, the difference between each clearance and the average clearance shall not exceed ±8% of the average clearance value. 9.5.5 Installation of thrust collar shall meet the following requirements: a) Before the coupling of thrust collar, adjust the elevation and level of the carrier plate. Measuring with no lubricant applied on the surface of thrust bearing pads, its horizontal deviation shall be within 0.02mm/m. Its elevation shall consider the deflection value of bearing generator frame and compression value of the elastic thrust bearing; b) Before the hot coupling of thrust collar, adjust its level under lifting and lowering state. During the hot coupling of transitional fitting thrust collar, the heating temperature of thrust collar should be better within 100°C; c) After the heating up of thrust collar, the installation of clasp shall only proceed after its temperature falls to ambient temperature. After clasp is stressed, check the clearance between the upper and lower stressed surface of the clasp with 0.02mm gage, which shall not be able to pass through. Otherwise, it shall be drawn out and disposed and shall not be padded; d) During the coupling of thrust collar and axial bolts, pretightening load to connect the bolts shall meet the requirements of 4.9. No clearance shall exist between the coupling interfaces. Check with 0.03mm gage, which shall not pass through. Central deviation of thrust collar with guide spindle journal neck shall not exceed 0.03mm. 9.5.6 Adjustment of thrust bearing pad shall meet the following requirements: a) Adjust the stress of thrust bearing pads when the shaft is upright, and the elevation and level of carrier plate meet the requirements, and the rotor and runners are in the central position; b) Generally, adjust the stress of rigid support thrust bearing with the method of measuring the distortion of bearing bush. Lifting and lowering the rotor, the difference between the distortion value of each block plate and the average distortion value shall not exceed ±10% of the average distortion value; c) When the method of hammering load bearing bolt is adopted to adjust the stress on rigid support thrust bearing, monitor the main shaft with a percentage meter at the water turbine bearing. The hammering impact shall make the main shaft to have an 0.05mm~0.10mm inclination on average. Under equal hammering impact, the variance in the
inclination of main shaft and the average inclination value shall not exceed ±10% of the average inclination value; d) For hydraulic support thrust bearing, when the upper and lower parts of guide bearing pads are cling to each other near the thrust bearing, lift and lower the rotor. When lowering rotor and releasing the guide bearing pad, the deviation for the quantity of compression of each elastic oil tank shall not be greater than 0.2mm; e) For hydraulic thrust bearing without support bolt, the quantity of compression of each elastic oil tank shall meet the design requirements. f) For balance weight thrust bearing, under the condition that the balance weight is fixed, lift and lower the rotor, measure the distortion of pillow or upper balance weight. The distortion value shall meet the design requirements. When there is no design requirement, the distortion value of each pillow or upper balance weight and the average distortion value shall not exceed ±10% of the average distortion value; g) For thrust bearing of elastic-girder double support-point structure, after carrier plate is suspended onto thrust bearing pads, adjust the level of carrier plate, which shall not be greater than 0.02mm/m. Check each side of oil outlet of thrust bearing pads and carrier plate, between which there shall be no clearance. Difference between two angles of oil inlet sides of each tile and the average clearance of carrier plate shall not be greater than ±20%; h) Installation of multi-spring support structure thrust bearing shall proceed according to the requirements of manufacturer; i) After the final adjustment and location of thrust bearing pad, axial clearance, tangential clearance of the press plate as well as the deflector of the thrust bearing pads and the tiles, and radial relative position of thrust bearing pads and carrier plate, and axial clearance between steel casing of hydraulic bearing and oil tank chassis shall all meet the design requirements: j) To facilitate the checking that if the elastic oil tank has leakage or not, when the thrust bearing has been adjusted to be qualified and rotating part of the unit falls on the thrust bearing, it is required to measure the distance from the upper surface of thrust bearing base to carrier plate according to the crossing line direction and then record it; 9.5.7Check and adjust the axial line of the machine frame, which shall meet the following requirements: a) Generally, jiggering method is used to check and adjust the axle line. Before the jiggering, the rotating part of generator unit is in central position and the main shaft is in natural state and upright; b) If pressurized oil jack is adopted in jiggering, thrust bearing pads and pressurized oil jack system shall be cleaned up. When pressurized oil jack jigger is not adopted in jiggering, surface of thrust bearing pads shall be coated with uncontaminated cleaned lubricating granules. c) For rigid jiggering of thrust bearing, stress over each tile shall be adjusted to be even. Level of carrier plate shall meet the requirements of 9.5.5a). Adjust the single side clearance of the guide bearing pad near thrust collar or temporary guide bearing pad, which is generally 0.03mm~0.05mm. On the completion of adjustment of axle line, the swing value of each part of the generator unit shall not exceed requirements of Table 33.
If permitted by conditions, for elastic thrust bearing, swing in every squater of the unit axial line shall also be checked according to rigid method jiggering. At the same time, carry out elastic jiggering as required by Clause d of this article. Check the axial swing of the carrier plate’s exterior margin; Table 33 Allowable swing for the axle line of generator Unit: in double-amplitude Name of measuring swing Rotation speed of the axle nr/min the axle point classification n<150 150≤n<300 300≤n<500 500≤n<750 n≥750 shaft neck between the upper Generator and lower Relative 0.03 0.03 0.02 0.02 0.02 shaft bearing of swing mm/m generator shaft and flange Shaft neck at the Turbine Relative 0.05 0.05 0.04 0.03 0.02 guide shaft swing mm/m bearing point Generator Absolute slip ring 0.50 0.40 0.30 0.20 0.10 shaft swing mm Notes: 1. Absolute swing refers to the actual swing value measured at the measuring point. 2. Relative swing: ratio of the distances from the absolute swing (mm) and measuring point to carrier plate space (M). 3. In no case shall absolute swing at the turbine guide bearing point exceed the following values: For unit with the rotation rate lower than 250r / min, it is 0.35mm. For unit with the rotation rate lower than 250 ~ 600 r / min., it is 0.25mm. For unit with rotation rate at 600r / min or above, it is 0.20 mm. 4. The aforesaid all refers to the jiggering swing of the unit, not the operation swing. d) Elastic jiggering of hydraulic prop thrust bearing shall proceed after the stress over the toroidal membrane is adjusted to be qualified. Air clearance between the upper and lower part of the guide bearing pad close to the thrust bearing shall be adjusted to 0.03mm~0.05mm. During the jiggering, axial swing at the margin of carrier plate shall not go beyond the requirements of Table 34. After the axial line is checked and adjusted to be qualified, stress over the toroidal membrane shall be counterchecked, which shall meet the requirements of 9.5.6 d); Table 34 Allowable axle swing for carrier plate (End face run-out) Diameter of the carrier plate (m) Axial Swing (mm)
<2.0 2.0~3.5 >3.5
≤0.10 ≤0.15 ≤0.20
e) For multi-sectional axle construction unit, checking shall be made over the bending conditions of each segment during the jiggering. Generally, the deviation shall not be greater than 0.04mm / m. Check the in-plant operation record of axial line and the clearance variations between the upper and lower shafts and the rotor after the thermal keying (thermal padding) to check the axial changes during jiggering; f) When the rotor is in central position, check the air interstice for every 90° rotation with jiggering method and the value shall meet requirements of 9.5.3 d); g) When the rotor is central position, air interstice monitoring plant should be used to adapt to the jiggering method and check the stator roundness, rotor roundness, which shall meet the requirements of 9.3.10 a) and 9.4.13 respectively; h) Suspending steel wire at the cross direction or suspending steel wire in the center if axle hole or other methods should be used in checking the folding and verticality of the axials. 9.5.8 Installation of the high pressure oil lift device and external cycle cooling unit of thrust bearing shall meet the following requirements: a) Oil pipeline of the system shall be cleared clean. Pump oil into the oil system continuously with oil pump until the oil quality reaches the standard. Carry out the oil pressure test according to the design requirements; b) Cracking pressure of overflow cock shall meet the design requirements. Each non-return valve shall take tightness & oil-pressure resistance test when bearing reversed compression. Sustain for 10min under 0.5, 0.75, 1.0 and 1.25 times of the working pressure. No leakage shall happen under the aforesaid pressure conditions. c) Adjust the oil mass of flow regulating valve of each tile under the working pressure to make the grading tolerance of each tile's oil film thickness no greater than 0.02mm; d) External cycle cooling unit and pipeline of thrust bearing shall be cleared clean and water-pressure resistance test shall be carried out according to the design requirements. 9.5.9 Insulation resistance of each part of thrust bearing of the suspensory unit shall not be smaller than the values regulated in Table 35. Table 35 Insulation resistance of each part of thrust bearing of the suspensory unit Electric voltage Parts of the Insulation of megohm Notes No. thrust bearing resistance MΩ meter (V) Measure after Base and the installation 1 bracket of thrust 5 500 of base and bearing bracket
2
High pressure oil injecting oil pipeline
10
500
3
Entire body of the thrust bearing
1
500
4
Entire body of the thrust bearing
0.5
500
5
Entire body of the thrust bearing
0.02
500
6
Embedded temperature detector
50
250
Before connecting with the joint of thrust bearing pads, test each single one On the completion of the bearing installation, jack up the rotor. Before infusing lubricating oil, the temperature shall be 10 ~ 30°C. On the completion of the bearing installation, jack up the rotor. After infusing lubricating oil, the temperature shall be 10 ~ 30°C. The rotor falls on the thrust bearing. The rotation part and all connectors on the fixed parts shall be dismantled temporarily. Before infusing in lubricant oil, measure the insulation resistance of each thermometer core wire to thrust bearing
pad Note: 3, 4 and 5, one item of which may be adopted to measure. 9.5.10 Installation of guide bearing shall meet the following requirements: a) Axial line of the generator unit and stress over thrust bearing pads shall be adjusted to be qualified; b) Wearing ring clearance of water turbine and generator air interstice shall be qualified; c) During the final installation of sectional type guide bearing pad that have a insulation requirement, the insulation resistance shall be generally above 50MW; d) Bearing bush shall be installed according to the position of spindle center, at the same time, adjust the gap according to the swing direction and the size of the jigger. The total clearance shall meet the design requirements: e) Permissible deviation for the clearance of sectional type guide bearing pad shall not be greater than ±0.02mm, and the clearance deviation of two neighboring tiles and the required value shall not be greater than 0.02mm. After the adjustment of the clearance, the tiles shall be secured and locked; f) When the main shaft is in central position, measure the distance from shaft neck and machined surface of tile base in the crossing direction of X and Y and then make records. 9.5.11 Installation of oil slot shall meet the following requirements: a) Oil slot shall take koresene tightness leakage test according to requirements of 4.12; b) Water-pressure resistance test shall be carried out before the installation of oil tank cooler according to the design requirement . After the installation, carry out the proof test according to the requirement of 4.11; c) Axial clearance between the rotation part and fixed parts inside the oil groove shall meet the requirements of crest rotor. Its diametral clearance shall meet the requirements of design drawing. Groove-style pressurized blanket is put into the gutter and the amount of compression shall be about 1mm. The pressurized blanket and the rotor shaft shall not closely contact; d) Oil groove shall be clean inside and the oil circulation line shall be ensured to be smooth according to the design requirements. e) Excircle of oil baffle shall be concentric with the unit. The centricity deviation shall not be greater than 1.0mm, and the deviation of the radial distance and average distance between the oil baffle excircle and the shaft neck inner circle shall not exceed ±10%. f) Fuel head of oil groove shall meet the design requirements, generally, the deviation shall not exceed ±5mm; Trademark of the lubricant oil shall meet the design requirements. Check the oil quality before infusing oil, which shall be in compliance with regulations of GB/T11120; g) When the electric welding operation proceeds on the rotatable parts, ground wire of welding machine shall be connected to the parts that need to be welded directly. And security protection measures shall be adopted to ensure that electric welding slag will not splash into oil groove and bearing. 9.5.12 Installation of cover board, air damper and fire pipe
a) Distance from the air damper and fire pipeline to the stator coil or rotatable parts shall not be shorter than the design size. Generally, it shall not be greater than 20% of the design value; b) Direction of spray hole (used to spray water or CO2 gasses) of the fire pipeline shall be correct. Check according to different structural shape as required by the manufacturer. If necessary, air ventilation method may be adopted to check; c) Both upper, lower cover plate and upper, lower air damper shall be assembled strictly according to the design requirement. The welding shall be reliable. bolt shall be secure and the latchdown shall be solid. Tightness of upper and lower cover plates shall be kept ensured. 9.5.13 Installation of air cooler shall meet the following requirements: a)Before the installation of each single cooler, water-pressure resistance test shall be carried out as required by 4.11; b) For set swinging of the air cooler, permissible variation in the direction of height is ±10mm and permissible variation in the circumferential direction is ±6mm. Weld or connect U according to design requirement; c) Dewing proof measures shall be taken for pipelines inside the units that are likely to generate condensed water. 9.5.14 Installation of temperature measuring equipment of generator shall meet the following requirements: a) Generally, the insulation resistance of temperature measuring equipment shall not be lower than 0.5MW. For bearing that has insulation requirements, after the installation of each thermometer, insulation resistance over the bush shall meet the requirements of No.6 of Table 35; b) For terminal board of the temperature measuring equipment of stator coil, if discharge gap exists, the gap generally ranges at 0.3mm ~ 0.5mm; c) Before the pressurizing of bearing oil groove, the temperature measuring equipment shall be checked. Ohmic value grading tolerance of each resistance thermometer shall not be greater than 1.5% and the grounding insulation shall fit. Signal thermometer indication shall be close to the bearing bush temperature in the mean time. Temperature measuring leading wire shall be fixed and reliable; d) Labeling of the thermometer and temperature measuring on-off shall be in accordance with the tile number, cooler number and coil slot number. 9.5.15 Installation of slip ring shall meet the following requirements: a) Horizontal deviation of the installation of slip ring is generally no greater than 2mm; b) Related electrical test of slip ring shall meet regulations of 14.4; c) Sliding of the slip ring brush inside the brush carrier shall be flexible and free of blockings. A 2mm ~ 3mm clearance between the brush carrier and the surface of the slip ring shall be kept. Counterface between brush and slip ring shall not be smaller than 75% of the brush section. Spring pressure shall be homogenous. 9.6 Installation of excitation system and devices 9.6.1Installation of excitation system and device shall be in compliance with the regulations of GB/T7409.3. Moreover, it shall only proceed after the indoor building operation is completely finished and the indoor humidity reaches the requirements. 9.6.2 Special requirements on the installation of tray and cabinet of excitation system
a) Use one time ventilation or enclosed recycle air cooling rectified power cabinet. Dust filter shall not be choked. Pathway of cooling water of the heat exchanger shall be smooth. b)Patching contact terminal of butt connected drawer shall be checked according to design requirement. 9.6.3 Installation of magnetic blow-out switch a) Examination shall be carried out respectively over the dividing and closing coil of the on-off gearing as well as lock catch mechanism. and actuation test shall be implemented to make sure the reliability and actuation time meet the product standard; b) Check the arc extinguishing contact terminal and main contact terminal, the sequence of movement shall be correct. Movement of normally closed interlock shall be prior to the normally open interlock. After the normally closed interlock disconnects, the spacing shall meet the design requirements: c) When DM type magnetic blow-out switch is adopted, the following items shall be checked: The number, shape, and installation site of arc chute pieces, joint and ohmic value of shunt resistance, opening distance of the arc extinguishing contact terminal shall all meet product requirements and stipulated requirements. 9.6.4 Laying and wiring of excitation system cables Length of power cables connecting the excitation transformers and power cabinet shall be identical. Cable laying and wiring inside the tray shall meet the requirements of GB50168 and GB50171.
10 Installation of horizontal hydraulic generator 10.1 Grounding and scraping of bearing bush 10.1.1 Examinations over bearing bush and carrier plate shall proceed in compliance with the requirements of Article 9.2.1 and Article 9.2.2. For bearing bush that required to be grounded and scraped on site by the manufacturer, scrapings are made in two parts: initial scraping and refined scraping. Initial scraping shall take place before the rotor penetrate the stator and refined scraping shall proceed after the alignment of rotor center. 10.1.2 Grounding and scraping of the pedestal bearing shall meet the following requirements: a) The clearance between bearing bush and shaft neck shall meet the design requirements. Clearances on both sides are half as large as the crest clearance. The difference of the clearance on both sides shall not exceed 10% of the gap width; b) Angle of contact between the lower part of bearing bush and shaft neck shall meet the design requirements, but it shall not be larger than 60°. Complete uniform contact is required along the bearing bush length. Within the scope of angle of contact, per square centimeter shall have 1~3 contact points; c) For bearing adopting pressure oil circulating oil system, the oil groove size shall meet the design requirements. Length of the shell cover at both ends of longitudinal oil groove at the commissure shall not be shorter than 15mm. 10.1.3 Grounding and scraping of thrust bearing pads shall meet the following requirements:
a) Counterface of thrust bearing pads and thrust disc shall reaches 75%. Per square centimeter shall have 1~3 contact points; b) For thrust bearing pads without adjustment structure, the thickness shall be homogenous. Thickness difference for all the tiles in the same unit shall not be greater than 0.02mm. 10.2 Installation of bearing pedestal 10.2.1 Oil container of the bearing pedestal shall be clean. oil conduit shall be fluent. Kerosene leakage test shall be carried out according to the requirements of Article 4.12. 10.2.2 According to the actual center of fixed part of water turbine, make initial adjustment over the center of the holes of the two bearing. Their concentricity deviation shall not be greater than 0.1mm. Horizontal deviation of bearing pedestal in the transverse direction generally shall not exceed 0.2mm/m, and in the axial direction it shall not exceed 0.1mm/m. 10.2.3 Other than the adjustment of center of bearing hole according to the actual center of water turbine’s fixed parts, also , the installation of bearing pedestal shall consider the flexural deflection value of the principal axes and the compression value of bearing pedestal after the rotor is positioned. a) Raise and drop the rotor onto the bearing pedestal. Measure the compression value of bearing pedestal. Pad with fillers of identical thickness under the bottom of bearing pedestal; b) According to the flexural deflection value of principal axes of rotor, adjust the rising value of rear bearing pedestal of generator to enable the water turbine flange to connect with the generator flange in parallel aligned. 10.2.4 When padding is needed to adjust the bearing pedestal, the number of fillers shall not exceed 3. The filler shall be able to pass through foundation bolt. 10.2.5 For bearing with insulation requirements, after the installation and connection of all pipelines, check the grounding insulation ohmic value of bearing pedestal with 1000V megohm meter, which shall not be smaller than 0.5MW.Partition insulator shall be clean and shall be used by full sheet. The peripheric width shall be 10mm ~ 15mm greater than that of bearing pedestal. Pin bolt and foundation bolt shall be both insulated wrapped. 10.2.6 During the preassembling of bearing cover, check the horizontal countersurface of bearing pedestal and bearing cover. Tighten the bolt and then check the counterface with 0.05mm feeler gauge. No clearance shall exist. Binding face of the bearing cover, connection between the oil catch and bearing bush shall install sealing element or be coated with sealing paint as required by manufacturer. 10.2.7 Clearance of each built up edge between the bearing pedestal and foundation plate as well as the installation of wedge plate shall meet the requirements of Article 4.7 and Article 4.5. 10.3 Installation of stator, rotor and/or fitment 10.3.1 Stator and rotor that need to be installed on site shall be in compliance with requirements of relevant clauses in 9.3 and 9.4. 10.3.2 Coaxial water turbine and principal axes of generator shall be aligned at one time. For assembling units with turbine and generator set an axle separately, principal axes flange of generator rotor shall be aligned according to the turbine main shaft. The concentricity deviation shall not be greater than 0.04mm. Inclination of the two flange faces shall not be greater than 0.02mm.
10.3.3 Air interstice between the stator and rotor shall be homogenous. The gap width of each polar shall take the arithmetic mean value of four measured values (each time rotate the rotor by 90°). The difference of gap width of each polar and the gap width shall not exceed ±8% of the average gap width. 10.3.4 Adjustment of the axial center of stator and rotor shall enable the stator to deviate to the rear bearing with reference to rotor. The off-set value shall meet the regulations of manufacturer. Generally, the offset value may adopt 1.0mm ~ 1.5mm or is accounted according to half of the thermal expansion extending quantity of the generator shaft. 10.3.5 After the connection of principal axes, the jiggering to examine the swing of each part shall meet the following requirements : a) Swing at each shaft neck shall not be greater than 0.03mm; b) End face run-out of the thrust disc shall not be greater than 0.02mm; c) Swing of coupling flange shall not be larger than 0.1mm; d) Swing at the slip ring section shall not be greater than 0.2mm. 10.3.6 Air fan installation a) Surface of the airfan shall be smooth and clean, free of cracks and other mechanic deflection; b) Air fan assembled on site shall be locked and secured and the bolt shall be tightened as required by the manufacturer. It is forbidden to use spring ring. Gas cutting and electric welding are forbidden too; c) The clearance of air leaves and air ducting devices shall be homogenous. The deviation shall not exceed ±20% of the actual average gap width; d) Distance from the air fan to the end face of air ducting shall meet the design requirements. When there is no design requirement, generally, the distance shall not be smaller than 5mm. 10.3.7After the interior of the generator is cleaned and free from impurities, fitting of all parts of the end cover is completed, and each fitting clearance meets the requirements, then installation of generator end cover shall proceed. Sealing of the binding face between the end cover and the casings shall meet the design requirements. 10.4 Checking of each part of the bearing and clearance adjustment 10.4.1 After the adjustment of the axial line, jigger and check the contact situation, which shall meet the following requirements: a) Counterface of principal axes and lower bearing shell shall meet the requirements of 10.1.2 b); b) Counterface of thrust bearing pads and thrust disc shall meet the requirements of 10.1.3 a). 10.4.2 Clearance of bearing shall meet the following requirements: a) Crest clearance and side clearance of shaft neck and bearing bush shall meet the requirements of 10.1.2 a); b) Axial clearance at both ends of bearing shells and shaft shoulder shall keep adequate clearance when the rotor runs with the highest temperature rise and the principal axes bulges by 0.011mm for per meter length and per Celsius degree rise to ensure the rotor can expand freely.
10.4.3 Generally, axial clearance (hob shift axial) of thrust bearing pad is 0.3mm ~ 0.6mm (greater value is adequate for larger axial diameter). 10.4.4 Coupling of bearing shell and casing of bearing shall meet the following requirements: a) For cylindrical bearing bush, there shall be no clearance between the upper bearing shells and the bearing cover and there shall be 0.05mm tightening; the lower bearing bush and the bearing pedestal shall contact closely and the carrying surface shall be over 60%; b) For spherical surface bearing bush, the counterface area of spherical surface and spheric seating shall be 75% of the entire spherical surface and the distribution shall be even. After the tightening of bearing cover, the clearance between the shells and the spheric seating shall meet the requirements of manufacturer. 10.4.5 Clearance of sealing ring and axis of rotation shall be in compliance with the regulation of design drawing. Generally it is around 0.2mm. During the installation, the contra-aperture clearance of two half shall not be greater than 0.1mm, and there shall be no staggering.
11 Installation of bulb-type hydraulic generator 11.1 Installation of stator 11.1.1 An entire stator shall meet the following requirements: a) Measure the roundness of stator. It shall meet the requirements of Article 9.3. b) Measure the concentricity screw-in hole distribution circle of the pipe shaped holder at the downstream side of stator. For stators that have no inclination and eccentric structure, deviation of two centers shall not be greater than 1mm; for stators that have inclination and eccentric structure, Eccentricity of the screw-in hole distribution circle of the pipe shaped holder at the downstream side of stator and inclination angle shall meet the drawing requirements. 11.1.2 For stator of complete circle laminar on site, stator cage combination, stator core stacking and stator winding installation shall proceed as required by 9.3. For stator with inclination and eccentric structure, installation of stator core shall proceed according to technical document of the manufacturer. 11.2 Installation of rotor 11.2.1 After the rotor racket is established, adjust the central body level, which shall not be greater than 0.03mm/m. 11.2.2 Install magnetic poles according to the requirements of 9.4.11 and 9.4.12. After the installation of magnetic pole, check the polar distance of two terminals of magnetic pole, which shall meet the requirements of design drawing and technical documents. 11.2.3 Install brake hoop according to requirements of 9.4.7. 11.2.4 Measure roundness of rotor. Difference between each radius of rotor and the average radius shall not be greater ±4% of the air interstice. The overall eccentricity of rotor shall be in compliance with the regulations of 9.4.13. 11.2.5 Installations of lead-out wire of rotor, interpolar connecting wire and damping ring connecting wire shall proceed according to related requirements of 9.4. 11.3 Installation of principal axes and composition bearing
11.3.1 After the principal axes are positioned in the erecting yard, adjust the level of principal axes, which shall not be greater than 0.05mm/m. 11.3.2 Examination of thrust bearing pads in both positive and reverse direction as well as the grounding and scraping shall meet the requirements of related clauses in 9.2. 11.3.3 After valving carrier plate or thrust ring is fitted into principal axes, check and measure the built up edge of carrier plate or thrust ring and two sides of the spigot of principal axes and carrier plate or thrust ring built up edge, no clearance shall exist. Check with 0.05mm feeler gage, which shall not be able to pass through. Stagger at the commissure of valving carrier plate working face shall be smaller than 0.02mm. The piece behind shall not protrude over the previous one along the rotation direction. 11.3.4 Adjust clearance between positive-going thrust bearing pads and carrier plate. The clearance between positive-going thrust bearing pads and carrier plate shall be within ±0.03mm of the average interstice. 11.3.5 Adjust clearance between the reverse thrust bearing pads and carrier plate, clearance between each reverse thrust bearing pads and carrier plate shall be within ±0.05mm of the average clearance. 11.3.6 After the installation of positive and reverse thrust bearing pads and principal axes, generally, the total clearance between positive and reverse thrust bearing pads and carrier plate is 0.3mm ~ 0.6mm; if the manufacturer has regulations, adjustment shall be made as required by the manufacturer, and the total clearance deviation shall not exceed 0.1mm. 11.3.7 Installation of radial bearing shall meet the following requirements: a) Check the radial bearing bush according to requirements of 5.6.1 a). If grounding and scraping are required, requirements of Article 10.1.2 shall be met. b) Clearance between bearing bush and shaft neck shall meet design requirements of manufacturer; c) Spherical surface supported radial bearing, clearance between spherical surface and shell bearing, shell bearing spherical surface and spheric seating shall meet the design requirements of manufacturer. 11.3.8 Clearance of end face sealing of composite bearing shall be adjusted according to design requirement. 11.4 Generator installation 11.4.1 Installation of principal axes and composite bearing shall meet the following requirements: a) After the position of axial line is determined, adjust the bracket centre of bearing. The clearance between the bearing support and radial bearing spheric seating shall meet the design requirements: b) Total clearance between the positive carrier plate and reverse thrust bearing pads shall meet requirements of Article 11.3.6. Radial bearing clearance shall meet the design requirements; c) Insulation for oil receiver or bearing shall meet the requirements of Article 10.2.5. 11.4.2 Installation and adjustment of the high pressure oil lift device of radial bearing shall proceed as required by Article 9.5.8.
11.4.3 After the connection of principal axes and rotor, jigger to check the swing of each part, which shall meet the following requirements: a) Swing of each shaft neck shall be smaller than 0.03mm; b) Ending beat of carrier plate shall not be greater than 0.05mm; c) Swing of coupling flange shall not be greater than 0.10mm; d) Swing of the slip ring shall not be greater than 0.20mm. 11.4.4 During the stator installation, clear the built up edge of stator and tubiform seating. settle sealing pad base according to the design requirements. Adjust the air interstice between the stator and rotor and the difference between each clearance and average clearance shall not exceed ±8% of the average interstice. 11.4.5 Take longitudinal center line between the turbine runner and runner chamber as the reference. Adjust the axial magnetic centre between the stator and rotor. When the stator core length is shorter than 1.5m, the magnetic centre deviation of stator and rotor shall be smaller than ±1mm; when the stator core length is longer than 1.5m, the magnetic centre deviation of stator and rotor shall be smaller than ±2mm. 11.4.6 During the installation of socket pin and cooling cone, clean the built up edge between socket pin, cooling cone and stator carefully. Install sealing packing in strict compliance with the design requirements. If the socket pin needs to be welded, rigid process measures shall be adopted to ensure the weld quality. 11.4.7 Installation of supporting structure shall proceed according to manufacturer's requirements on different structural shapes. Measure and record the subsidence value of upstream side of the stator due to the weight of bulb. 11.4.8 Setup, installation and test of high-pressure oil, lubricating oil system, cooling water system, ventilation system and brake line shall proceed according to related technical requirements of Chapter 9. 11.4.9 Radial and axial clearance of windshield and the rotating part shall meet the design requirements. The deviation shall not be greater than 20% of the design value. 11.4.10 All sealing elements shall be installed according to the requirements of manufacturer. After the completion of the installation, all the built up edges shall take tightness compression test as required by the manufacturer.
12 Installation of pipeline and fitments 12.1 Fabrication of pipe fittings and fitments of pipeline 12.1.1 Bending radius of pipe shall not be shorter than 3.5 times of the pipe diameter during hot bending and no shorter than 4 times of the pipe diameter during cold bending of the pipe. When the hot bending is carried out by pipe bender, it shall not be shorter than 1.5 times of the pipe diameter. 12.1.2 During the heating of bending pipeline, the heating shall be homogeneous and the temperature shall rise slowly. Generally, the heating-up frequency shall not exceed 3 times. In general, temperature for the hot bending of pipe and heat treatment condition shall proceed according to the regulations of Table 36. Table 36 Temperature and heat treatment conditions for hot bending of pipe in common use
Materials
Steel grade
Carbon steel
10, 20
Stainless steel
1Cr18Ni9Ti
Non-ferrous metal copper
Copper Metallic copper alloy
Hot bending Heat treatment conditions temperature Heat treatment Constant span ℃ temperature temperature hour 750~1050 Without Without treatment treatment 900~1200 (1050~1100)℃ 0.8min per quenching millimeter wall 500~600 Without treatment 600~700
Cooling method Without treatment Water quenching
12.1.3 During the bending of slit tube, position of its longitudinal seam shall be located at 45° point from the horizontal and perpendicular direction. 12.1.4 After the bending of the tube, the quality shall meet the following requirements: a) Flawless, free from lamination and being overburnt, etc.. b) Diameter difference between the maximal pipe cross-section and the minimum cross-section shall not exceed 8% of the pipe diameter. c) Bending angle shall be in compliance with shaping plate. d) Generally, height of fold of rippling inside the elbow shall not be greater than 3% of the pipe diameter. Wave spacing shall not be shorter than four times the height of ripplings. e) After the plying of annular tube, preassembling shall proceed. Generally, the radius deviation shall not be greater than 2% of the design value. The pipe shall be at the same level and the deviation shall not be greater than 40mm. 12.1.5 Incision quality of the pipe shall meet the following requirements: a) Cut surface shall level off. Generally, partial convexo-concave shall not be greater than 3mm. b) Generally, vertical misalignment for the pipe end incision plane and the center line shall not be greater than 2% of the external diameter of the pipe and shall not be greater than 3mm. 12.1.6 Generally, W-shape expansion joint is annealed with a pipe and shall be kept on the same plane. 12.1.7 Generally, curvature radius of welded elbow shall not be shorter than 1.5 times of the pipe diameter; the number of 90° elbow bend segments shall be at least 4. After the welding, the axis angle of elbow bend shall be in compliance with the shaping plate. 12.1.8 Vertical misalignment of the branch pipe to weld T-joint generally shall not be greater than 2% of its height. 12.1.9 For the fabrication of the conical tube, generally, the length shall not be shorter than 3 times the difference of the exterior diameters of two tubes. The diameter and roundness shall meet the design requirements. The deviation shall not exceed ±1% of the design diameter and shall not exceed ±2mm.
12.1.10 The fabrication form, material quality, size and precision shall meet the regulations of design drawing. Holes on the branch, supporting structure and hanger shall be drilled by machine. 12.1.11 During the fabrication of flange gasket, the gasket material shall be adopted according to the media and pressure of the pipe-line transportation. The gasket shall be chopped into an entire circle to avoid interfacing. When concatenation is needed for large caliber gasket, beveled edge lapping or labyrinth halving joint shall be adopted. It must not be flush-jointed welded. Gasket size shall match the packing strip. The inner diameter is permitted to be 2mm ~ 3mm larger and outer diameter is permitted to be 1.5mm ~ 2.5mm shorter. 12.2 Pipeline welding 12.2.1 Proper groove type and size shall be adopted for pipe coupling according to the pipe wall thickness. Generally, when the wall thickness shall not be larger than 4mm, I type groove shall be adopted and the contra-aperture clearance is 1mm ~ 2mm; when wall thickness is greater than 4mm, adopt 70° angle V-groove. contra-aperture clearance and truncated edge shall both be 0mm ~ 2mm. Contra-aperture misalignment of pipe shall not exceed 20% of the wall thickness, but at the most it shall not exceed 2mm. 12.2.2 For contra-aperture welding of steel tube of oil and gas system as well as water system that has special purpose, welding technology of argon arc welding bottom closing and arc welding capping shall be adopted. For butt welding of the pipe with outer diameter D≤50mm , full argon arc welding should be adopted. 12.2.3Contra-aperture welding of copper pipe and welding of copper pipe and carbon steel pipe joints shall adopt faucet insertion welding. 12.2.4 Technological requirements of pipeline welding a) Adoption of welding rod shall be determined according to the chemical composition and mechanical property of parent metal, crack resistance of soldered joint, working conditions and execution conditions, and its welding process shall have a high performance. b) During the tack weld, welding material and welding process shall be identical with that adopted in root layer. Tack weld length, thickness and spacing shall ensure that welded joint will not crack in the welding process; c) Generating the arc and testing current on the parent metal surface other than the groove, and parent metal damage from arcking shall be prevented. d) When contra-aperture welding of stainless steel tube is precoated with argon arc welding, the inside of welded joint shall be filled with argon gas or other protective gases or other measures shall be adopted to prevent the inner side weld metal from being oxidized; e) The welding shall adopt proper welding methods and welding order. During the welding process, quality of arc starting and arc ending shall be guaranteed. During the arc ending, the arc crater shall be filled in. Interlayer joint of multi-layer welding shall be staggered; f) Within the specified scope of welding operation guide book, with the guarantee that through welding and fusion are in good conditions, adopt undercurrent, short arcking, fast welding and multilayer multi-pass welding process and the temperature between layers shall be controlled. 12.2.5 Weld quality examination
a) Reinforcement height of weld surface is 1mm ~ 2mm; cover surface width for I type groove is 5mm ~ 6mm and for V-groove it shall be 2mm broader than each groove. b) Weld surface shall be free of crack, slag inclusion and air cavity, etc.. undercut depth shall be shorter than 0.5mm; length shall not exceed 10% of the welded joint length and shall be shorter than 100mm; c) Other than the conduit for natural flow discharge agent, the welded joint of pipe shall all be checked in the intensity pressure test with water as the medium and no leakage and/or seaminess shall happen. Intensity pressure test shall proceed according to Article 4.11. d) For conduit butt weld with nominal operating pressure greater than 8MPa, except that intensity pressure test with water as media, sampling inspection of radiographic inspection shall also proceed. Casual inspection proportion and quality grade meet the design requirements. When there is no requirement, the casual inspection proportion shall not be lower than 5% and the quality shall not be lower than Grade III. 12.3 Installation of pipeline 12.3.1 During the pipe laying, position of weld shall meet the following regulations: a) Spacing between two circumferential seams of the ascending pipe shall not be shorter than 100mm, and shall be twice longer than the outer diameter of pipe; b) Distance from the butt weld to the bend starting point shall not be shorter than 100mm and shall not be shorter than the outer diameter of pipe; c) Clear distance from circumferential weld to the support and hanger shall not be shorter than 50mm. Pipeline drilling through partition wall and floor slab shall have no weld junction in the partition wall and floor slab; d) No pore shall be opened on the pipeline welded joint. If the pore must be drilled, the welded joint shall be examined to be qualified in the non-destructive test. 12.3.2 Check the flatness of contra-aperture of pipe, if measuring at the point 200mm from interfacing centre, the Permissible deviation is 1mm; the permissible variation of the overall length shall not exceed 10mm. 12.3.3 Entombment of pipeline shall meet the following regulations: a) Deviation of the exit position of pipeline shall not be greater than 10mm. Protrusion of nozzle out of concrete surface shall not be shorter than 300mm in general. Distance from the pipe to the concrete wall shall not be shorter than the installation dimension of flange in general, and the nozzle shall be credibly blocked off. b) Screw thread and flange are not suitable to be adopted in the connection of pipeline; c) Pressure sensing tube shall have as few turns as possible. The curvature radius shall be large. Evacuation shall also be taken into account. Pressure tapping hole shall meet the design requirements: d) Drainage pipeline and oil exit pipeline have corresponding gradient with the flow direction. The gradient shall meet the design requirements. IF there is no design requirement, generally, the construction shall proceed according to 2%~3% gradient; e) Generally, the oil-piping adopts the method of burning tube casing; f) When the pipeline passes through expansion joint of concrete, the passing measures shall meet the design requirements.
12.3.4 Installation site of exposed pipe shall meet the following regulations: a) Generally, deviation of pipe installation position (co-ordinate and height mark) shall not be greater than 15mm outdoor and no greater than 10mm indoor; b) Generally, the flection and horizontal deviation of horizontal pipe shall be within 0.15% and shall not be longer than 20mm. Squareness deviation of the riser shall not exceed 0.2% and shall not exceed 15mm; c) Installation of racking pipe shall be at the same level. Deviation shall be within 5mm. Pipe spacing deviation between pipes shall be within 0mm ~ +5mm; d) Gradient of gravity drain pipe and oil exit pipe shall be identical with the direction of liquid stream. Generally, the gradient shall range at 0.2%~ 0.3%. 12.3.5 Flanged connection shall meet the following regulations: a) Packing strip and/or packing plate shall not have flaws that affect the sealing property. As for gasket thickness, except that rubber plate for low-pressure water pipe is allowed to be as thick as 4mm, generally, the thickness is 1mm ~ 2mm and the gasket shall not exceed two layers. b) After the screw-in of flanges, they shall parallel. The deviation shall be within 1.5 / 1000 of the outer diameter of flange and no greater than 2mm. Specification, dimension, and installation direction of binding bolts shall be identical. The packing force of bolt shall be homogeneous. The bolt shall be higher than the screw cap by 2~3 screw-pitches. c) During the welding of pipe and flat flange, inside and outside welding shall be adopted. The inside weld shall not tower above flange working face. After the welding, all flange and pipe shall be perpendicular. Generally, the deviation shall be within 1%. d) No flange shall be set up at the elbow bend of pressure piping; e) Branch pipe welded on the main pipe shall have reinforcement flange or other reinforcement measures over the part running through the main pipe. 12.3.6 Oil system pipeline shall not adopt welded elbow. When hot pressing elbow bend is adopted, the wall thickness of elbow bend shall not be thinner than wall thickness of ascending pipe. 12.3.7 Distance from the installation site of clamped-in style and cutting sleeve pipe heads to the supporter and hanger shall meet the design requirements. 12.3.8 For pipeline with cutting sleeve pipe head, material quality, roundness, deviation of outer diameter of the pipe as well as the length of the protruded cutting sleeve shall meet the design requirements. After the fastening of compression nut, the top of the pipe shall not touch the union body. Central deviation of the interlocking nozzle of double jointer shall not be bigger than 2% of the pipe diameter. 12.3.9 Sealing materials of gas thread joints should adopt teflin tape or sealant. When the screw thread is screwed down, sealing materials cannot be squeezed into the pipe. 12.3.10Before the installation of pipe, pipe fittings and valve, the interior of the pipe shall be cleaned up. During the installation, impurities shall be ensured not to fall in. 12.3.11 During the installation of pipeline, fixing and adjustment of supporting structure and hanger shall timely proceed. Position of supporting structure and hanger shall be correct. The installation shall be neat and solid, and contact with the pipe shall be in good condition.
12.3.12 As for materials used for the heat insulation of pipeline, the intensity, unit weight, coefficient of heat conductivity, resistance to heat, water content and specification of species shall all meet the design requirements. 12.4 Treatment of the inner wall of pipeline 12.4.1 Before the installation of oil system conduit and speed regulating system conduit, the inwalls may be pickled, neutralized and immunized. When there is no design requirement, Annex D shall be referred to. 12.4.2 Before the use of oil system, water system, gas system and speed regulating system, the inwalls shall be rinsed and checked according to the design requirements and standard. When there is no design requirement, Annex D shall be referred to. 12.5 Test of the conduit and pipe fittings 12.5.1 Bearing vessels machined at the construction site and pipe fittings with working pressure as 1MPa or above, intensity compression test shall be carried out according to requirements of Article 4.11 Atmospheric vessel machined at the construction site by themselves shall take leakage test as required by Article 4.12. 12.5.2 For valve with working pressure as 1MPa or higher, or valves of important parts under 1MPa shall take tightness compression test as required by Article 4.11. 12.5.3 Before concrete placement, the built-in pressure piping and pipe fittings shall take tightness compression test as required by Article 4.11. 12.5.4 After the installation of conduits of oil, water and gas system, generally, oil charge test, water passage or ventilation test shall be carried out. During the test, the pressure is gradually raised to nominal operating pressure, no leakage phenomena shall happen.
13 Installation of butterfly valve and ball valve 13.1 Installation of butterfly valve 13.1.1 Before the installation, the tightness of butterfly valve shall be checked. For inflatable type rubber sealing, leakage test shall be carried out in water with the pressed-in compressed air pressure as 0.05Mpa, there shall be no leakage. solid core rubber sealing and metallic sealing shall be checked according to design requirement. 13.1.2 Butterfly valves that need to be decompounded, cleared and packaged on site, after the installation, they shall meet the following requirements : a) Bearing clearance shall meet the design requirements and no leakage is permitted at the bearing sealing section. b) Clearance between each built up edge shall meet the requirements of Article 4.7; double ends of the rubber packing of the valve body’s valving built up edge shall protrude the packing groove undersurface of upper and lower flange of the valve body by 1mm ~ 2mm. 13.1.3 After the installation of valve body and faucet, the following requirements shall be met: a) Before the sealing, check the clearance between faucet and the valve body is homogeneous at the closing position. The deviation shall not exceed 20% of the actual average gap width;
b) At the closing position of faucet, when the inflatable type rubber seal is under the unaerated state, seal clearance shall meet the design requirements. The deviation shall not exceed ±20% of the design gap width. Under working pressure, the rubber seal shall have zero clearance. c) At the faucet closing position , solid core rubber seal and metallic seal shall have no clearance with the valve body. Adjust the tightness to make it meet the design requirement. 13.1.4 Deviation for the installation site of butterfly valve shall meet the following requirements: a) The length of steel penstock on the upper or downstream side of butterfly valve or spiral casing nozzle protruded out of the concrete wall surface shall guarantee adequate operating space for the installation and welding of fittings. b) During the installation of butterfly valve, central line along the direction of flow shall be determined according to the actual center of spiral casing and steel tube. Generally, its deviation from the design position shall not be longer than 3mm; Generally, deviation of the horizontal central line (at the upper and downstream position) to the design center) and the design central line shall not be longer than 10mm; measuring after the flange welding, deviation for the level and squareness of butterfly valve shall not be greater than 1mm / m. For butterfly valve with diameter longer than 4m, the deviation shall not be greater than 0.5mm / m; c) To facilitate the butterfly valve to move towards the telescopic joint direction during the overhauling, enough space shall be kept between the foundation bolt and screw. The value shall not be shorter than the diameter of rubber packing between flanges. 13.1.5 After the installation of butterfly, the following examinations shall be carried out: a) Deviation for the opening of the valve ring of butterfly valve shall not be greater than ±1° when it is in fully open position; b) Carry out proof test over the butterfly valve under the maximal hydrostatic pressure, sustain for 30min, and the water leakage shall not exceed the designed allowable value. When there is no means to carry out the test under maximal hydrostatic pressure, the test may be carried out under actual hydraulic pressure and the water leakage which is converted into that under maximal hydrostatic pressure shall meet the design requirements; c) Check up the mechanical caging, hydraulic locking as well as validity of position switch. 13.2 Installation of ball valve 13.2.1 For ball valve that needs to be disassembled, cleaned and packaged on site, after the assembling, other than the regulations of 13.1.2, it shall also meet the following requirements: a) Sealing surface of the working closure and overhauling closure shall be rigorous. Check with 0.05mm feeler gauge, and it shall not pass through. Otherwise, the surface shall be grounded and scraped. b) Stroke and conjugation size of sealing ring shall meet the design requirements. Generally, its actual stroke shall not be smaller than 80% of the design value and its action shall be flexible.
13.2.2 Rotary motion of the ball valve faucet shall be flexible. Enough clearance shall be kept between the faucet with the fixed part. Generally the clearance shall not be smaller than 2mm. Maximal clearance between the sealing ring and lock ring shall not be smaller than the actual stroke of sealing cover. 13.2.3 Permissible deviation for the installation site of ball valve shall meet relevant regulations of Article 13.1.4. 13.2.4 Carry out proof test on ball valve, which shall meet the requirements of 13.1.5 b). 13.3 Installation of flexible connector 13.3.1 clearance between the internal and external casings of padding type flexible connector shall be adjusted homogeneous. No choking or blocking shall take place. The Permissible deviation for the width of packing groove shall not be greater than the gap width of sealing cover and external casing. 13.3.2 Stretching space for padding type flexible connector shall meet the design requirements. During the welding of adjuster of steel pipe, shrinkage of welding seam shall be taken into account. After the welding, check the stretching space of flexible connector. Generally the deviation shall not exceed30% of the design stretching value. 13.3.3 Before the installation of bellows-type flexible connector, check the bellows piece according to the design requirement. After the welding of adjuster of steel pipe, check the distance of installing and welding bellows pieces, the roundness of nozzle at both sides and staggering, which shall all meet the design requirements. 13.3.4 After the welding of adjuster of steel pipe and bellows, carry out the non-destructive test on welding seam according to design requirement. When there is no regulation, check according to the requirements of 5.1.8 a) and b). 13.4 The installation of hydraulic control valve and air valve 13.4.1 Action of hydraulic control valve shall be flexible. The closure shall be in good condition and the stroke shall meet the design requirements and no oil leakage shall happen. 13.4.2 By-pass pipe shall have a semi-isolated section designed. when hydraulic control valve, hand brake and by-pass elbow are connected together, tightness compression test shall be carried out according to requirements of 4.11. 13.4.3 The action of the air valve shall be exact. When spiral casing is free of water inside, in a fully open position, after the water is filled, it shall be able to close automatically and shall have no water leakage. Sealing surface of the air valve shall take kerosene leakage test according to Article 4.12. 13.5 Installation of operating mechanism 13.5.1 Installation of the oil pumping plant of operating system shall meet the related requirements in 8.1.1 ~ 8.1.8. 13.5.2 Other than related requirements of 5.5.4, installation of the servomotor of valve shall also meet the following requirements: a) Installation of the foundation plate and pedestal of wobble servomotor shall be determined according to the actual position of joint pin hole of oscillating arm when the faucet is in complete shutdown position. position deviation of the foundation plate shall not be greater than 3mm. After the servomotor installation, its level or squareness deviation shall
not be greater than 1mm / m. The discrepancy in elevation for the pedestal shall not exceed ±1.5mm and the axis pin joint shall be flexible; b) Circular arc type servomotor shall adjust its caging device to ensure the deviation is smaller than 1.5mm when the valve is in fully open or complete shutdown position. 13.5.3 Under the condition that steel penstock is anhydrous, operate faucet and by-pass valve with oil pressure unit. The operation shall be stable. Record the oil pressure value and switching time, which shall meet the design requirements. 13.5.4 For valve gate with closedown heavy punch, heavy punch closedown test shall be carried out when the steel penstock is under anhydrous or still water conditions. Record the closing time.
14 Electrical test of water-turbine generator set 14.1 Before the setting-in of stator coil onsite, carry out sampling test over single coil bar. The spot test rate shall be 5% of the entire quantity of coil bars in each case. If unqualified coil bar is discovered during spot test, then raise the odd test rate of the box of coil bars correspondingly. Test contents are as follows: a. Carry out the Insulation resistance test with 2500V megohmmeter, which shall not be lower than 5000MW; b. In the discharge inception test of a single coil bar, the corona starting voltage shall not be lower than 1.5UN. When the value is lower than this, corona prevention measures shall be taken again. When the elevation is over 1000. the trial value of corona starting voltage shall be amended according to JB / T8439: c. Alternate current voltage withstand test shall proceed according to test standards required in Table 37. 14.2 During the installation process of stator coil, carry out the alternate current voltage withstand test according to the standard of Table 37 . Table 37 Standards for alternate current withstand voltage in the technical process of stator coil (kV) Nominal voltage, kV Winding type Test stages 2≤UN≤6.3 6.3≤UN≤24 Test standard 1. Before the setting-in; 2.75UN+1.0 2.75UN+2.5 Circle type 2. After 2.5UN+0.5 2.5UN+2.5 setting-in(after slot wedge is drilled) 1. Before the setting-in; 2.75UN+1.0 2.75UN+2.5 2. After setting-in of Strip type 2.5UN+1.0 2.5UN+2.0 lower coil 2.5UN+0.5 2.5UN+1.0 3. After the setting-in of upper coil (after
slot wedge is drilled) Note: UN is the nominal line voltage of electric generator. The duration after the kV is raised to the nominal testing voltage, if not specified specially, it shall all be 1min. 14.3 Test item and standard of stator shall meet the requirements of Table 38. Table 38 Test items and standards of stator No. Item Standard Note Alternate current withstand voltage In compliance with the 1 of each single requirements of Table 37 stator coil (1) Insulation value, Measure the absorption ratio or insulation polarization index shall be in resistance and compliance with regulations Use 2500V megohmmeter or 2 absorption ratio or of 9.3.18 (2) Unbalance above polarization index factor of insulation of the stator resistance in each phase winding shall not be greater than 2 (1) Measure in cold state, difference of the temperature After the alignment caused between the winding surface and Measure the by the deviation due to the the ambient air temperature shall ohmic resistance length difference of leading not be greater than 3K (2) When for each phase and 3 wire and the odds between decompression is adopted, let each branch of the each other shall not be electric current in, which shall not ohmic resistance greater than 2% of the be greater than 20% of the of stator winding minimal value. nominal current (3) Find out the reason if the standard specification is not met. (1) Testing voltage is 3.0 (1)Generally, it is carried out times nominal voltage value under cold state (2)The testing Direct current (2) leakage current shall not voltage increases by grade, voltage withstand increase with the extension increasing each grade is 0.5 times test of stator of time (3) Under the nominal voltage and sustain 1min 4 winding and regulated testing voltage, at each phase, read the leakage measurement of difference of each phase of current value (3) If (2) and (3) are leakage current leakage current shall not be not met, try to find out the reason greater than 50% of the and fix it. minimum value Alternate current (1) For stator that is Before the suspension of nominal 5 voltage withstand delivered integrated, the line voltage, carry out voltage test of stator alternate current voltage withstand test according to this
winding
withstand test voltage of the standard. Before the voltage stator winding shall be 0.8 increases, alternate current voltage times of the factory routine withstand test shall not be carried test voltage. out any more. (1) Alternate current (2) For stator assembled voltage withstand test shall onsite, when the nominal proceed by phase. During the voltage is 20kV or lower, the voltage increase, the starting testing voltage shall be twice voltage shall not exceed 1/3 of the the nominal line voltage plus testing voltage generally, and then 3kV gradually raise it to the testing (3) Corona starting voltage voltage value. Appropriate time of the complete machine for the process is about 10s ~ 15s shall not be lower than 10 times the nominal line (2) Before test, ground connect all voltage. the temperature measurement resistance inside the stator winding with short-circuit (3) Before the voltage endurance, must measure insulation resistance and polarization index. Direct current voltage withstand test shall be carried out first. (4) During the voltage withstand, under nominal line voltage, the head end shall have no overt golden yellow light spots and continuous corona belt. When the elevation exceeds 1000m, the corona inception test voltage shall be modified according to JB8439.
6
Magnetic examination of stator iron core
Magnetic flux density shall be converted according to 1T. The time duration is 90min. (1) Maximum temperature rise of iron core shall not exceed 25°C. Maximal temperature difference between each other shall not exceed 15k. (2) Temperature difference between iron core and sub-frame shall be in
(1) Stator stacked on the construction site shall take this test. Stator stacked in the manufacturer may not take this test (2) When test is carried out on hydraulic generator stator with a greater diameter, attention shall be paid on the alignment of deviation generated by the maldistribution of flux density.
compliance with the regulations of manufacturer. (3) Iron-loss per unit weight shall be in compliance with the regulations of manufacturer (4) Stator core has no abnormal conditions. 14.4 For rotor assembled on site, its single pole and slip ring, leading wire and brush carrier shall all take voltage withstand test and insulation resistance test according to regulations in Table 39. Table 39 Voltage standard and insulation resistance of each single pole, slip ring, leading wire and brush carrier Name of components Voltage withstand Insulation standard(V) resistance; MΩ Each single magnetic Before the 10Uf+1500, but shall ≥5 polar suspension and not be lower than installation, 3000 After the suspension 10Uf+1000, but shall and installation not be lower than 2500 Slip ring, leading wire and brush carrier 10Uf+1000, but shall ≥5 not be lower than 3000 Note: Uf refers to the nominal excitation voltage of generator rotor, V 14.5 Test item and standard of rotor winding shall meet the requirements of Table 40.
No.
1
2 3
Table 40 Test item and standard of rotor winding Item Standard Notes (1) When nominal voltage of rotor winding is greater than Generally, it is not lower than 200V, 2500v megohmmeter Measure the insulation 0.5MΩ . shall be adopted. resistance of rotor (2) When nominal voltage of winding rotor winding is below 200V, 1000V megohmmeter shall be adopted. Measure the ohmic Compare with each other and The inlet electric current resistance of each the odds shall not be greater shall not be greater than 20% single polar than 2%. of the nominal current. Measure the ohmic Compare the measured value The measurement shall
resistance of rotor winding
4
5
with the value converted from the ex-factory evaluation under the same temperature.
proceed under cold state. Difference between the surface temperature of winding and ambient temperature shall not be greater than 3K. Measure the Before and after the Compare with each other, alternating-current suspension and assembling, there shall be no overt impedance of each the measurements shall be difference. single pole coil. carried out respectively. (1)For rotor arrived with a (1) Field-installed rotor shall solid body, the test voltage be tested shall proceed after shall be 8.0 times the nominal all the packages are finished excitation voltage and shall before it is suspended into not be lower than 1200V. unit pit Alternate current (2) For field-installed rotor, (2) After the rotor is voltage withstand test when nominal excitation suspended into the unit pit or of rotor winding voltage ≤500, it shall be 10Uf, before the voltage increase of but it shall not be lower than assembling unit, generally, 1500V; when the nominal no alternate current voltage excitation voltage >500, it withstand test will be carried shall be 2Uf+4000V out again. Note: Uf refers to the nominal excitation voltage of generator rotor, V.
15 Trial run of water-turbine generator set 15.1 General specifications 15.1.1Before the trial, establish trial run program or outline of the assembling unit and test check items and safety precautions according to the regulations of DL / T507, DL/ T827, GB/ T18482 and normative provisions of this standard and by combining the physical circumstances of power station. For assembling unit that needs to take type approval test, the test contents and items shall be regulated in a particular technical agreement. 15.1.2 For assembling unit and related auxiliary equipment, an overall liquidating and checking shall be carried out. The installation quality shall be eligible and accepted. Water turbine, electric generator, speed regulating system, excitation system and the related appurtenance system, must be in a state that can be triggered at any moment. 15.1.3 Water transfer and anchor gate as well as valve of water sewage system (including sewage regulating room) shall be tested to be qualified and in a state of closing position. Manhole and choke plug shall all be blocked off reliably. 15.1.4 Relay protection, autocontrol, measuring instrument of water-turbine generator set and related electric installation of assembling units shall all be tested and qualified according to corresponding regulations and norm.
Safety measures for related assembling units shall all be set to ensure the safe operation of assembling units. 15.2 Water filling test of assembling unit 15.2.1 Fill water into tail water surge-chamber, draft pipe and spiral casing to equalize the pressure. Check each part and no abnormal phenomena shall emerge. 15.2.2 Fill water into the water diversion system and water carriage system in stages according to design requirements. Monitor and check the variation conditions of each part, and no abnormal phenomena shall happen. 15.2.3After equalizing the pressure, proceed the manual and automatic actuation tests of water inlet bulkhead gate or work gate or butterfly valve, ball valve and cylindrical valve. The start-stop time shall meet the design requirements. 15.2.4 Examine and debug units spiral casing water catchment system and draft pipe water catchment system, which shall work in good condition. Hydraulic pressure and flow rate of each part of the technical water supply system of the unit shall be normal. 15.3 Zero load trial run of unit 15.3.1 Operational check of unit mechanism: a) During the start-up process of unit, monitor each part and there shall be no abnormal phenomena; b) Measure and record the water level of upper and lower stream as well as the no-load opening of unit under this water head; c) Observe bearing oil surface, which shall be in normal position. Oil groove shall have no splashing of oil. Monitor the bearing temperature of each part and there shall be no rapid increase. Operate till the temperature is stabilized and the steady temperature shall not exceed design set value; d) Measure the operation swing (double amplitude) of unit and the value shall not be bigger than 75% of the total clearance of bearing; e) Measure the vibration of unit and measured value shall not exceed the regulations of Table 41. If the vibration of unit exceeds the set value in Table 41, dynamic balancing test shall be carried out; f) Measure the residual pressure and phase sequence of electric generator and the phase sequence shall be correct; g) Clean slip ring surface. Table 41 Allowable vibration value of water-turbine generator set for each part Unit as millimeter Nominal speed n (r/min)
Unit type Vertical type unit
Item
Water turbine
n<100
100 ≤n<250
250≤n<375
375≤n<750
Horizontal vibration of top cover
0.09
0.07
0.05
0.03
Vertical vibration
0.11
0.09
0.06
0.03
of top cover Vertical vibration of bracket with 0.08 0.07 0.05 0.04 thrust bearing Horizontal vibration of 0.11 0.09 0.07 0.05 bracket with guide bearing Hydraulic Horizontal generator vibration of 0.04 0.03 0.02 0.02 sub-frame in stator core position Vibration of stator core (100HZ 0.03 0.03 0.03 0.03 double-amplitude value) Horizon Vertical vibration of the bearing 0.11 0.09 0.07 0.05 tal unit in each part Axial vibration of thrust bracket 0.10 0.08 Bulb Radial vibration of each guide turbine 0.12 0.10 bearing unit Radial vibration of bulb holder 0.12 0.10 Note: Vibration value refers to the double-amplitude value under all kinds of stable operation behaviors except for overspeed operation 15.3.2 Adjustment and test of speed regulator: a) Check vibration of plunger of electro-hydraulic converter or electro-hydraulic servo valve, which shall be normal; b) When the unit is operated manually, check the rotational oscillating value within 3min. Adopt the average of three measured values, which shall not exceed ±0.2% of the nominal value; c) speed regulator shall take manual and automatic switchover test. The actuation shall be normal. Servomotor shall have no overt swing; d) Zero load disturbance test of speed regulator: During the automatic run of unit under no load condition, exert normal speed ±8% phase step disturbing signal. Record transition process of rotation rate and servomotor stroke of unit. The maximal overshooting of rotation rate shall not exceed 30% of the disturbance quantity of rotation rate; and the overshooting frequency shall not exceed twice. Time of regulation from the disturbance to the specified rotation speed shall meet the design value. Select a group of controlling parameter for the unit's application of no-load operation; e) With the selected parameter, during the automatic run of unit under no load condition, the relative oscillating quantity of rotation rate shall not exceed ±0.15% of the nominal rotation value. 15.3.3The following items shall be checked during the closedown process and after
closedown: a) Record the closedown rotation rate and time relation curve; b) Check the actuation of tachometric relay; c) Monitor the bearing temperature of each part. Each part of the unit shall have no abnormal phenomena; d) Check each part of unit after closedown, no abnormal phenomena shall exist. 15.3.4 Overspeed test of the unit shall proceed according to the designed setting value of overspeed protective device and the following items shall be checked: a) Measure the swing and vibration value of each part. b) Monitor and record bearing temperature of each part; c) Oil groove shall have no splashing of oil; d) Pull-on value of setting overspeed protective device; e) Check the inside of unit after overspeed test. 15.3.5 For automatic starting of unit, the following items shall be checked; a) Record the relation curve of rotation rate and time from sending out starting up impulse to normal speed; b) Check the actuation and oil pressure of high pressure oil lift device of thrust bearing, which shall be normal; c) Starting up procedure of unit and the actuation of automation component shall be normal. 15.3.6 In case of automatic shutdown of unit, the following items shall be checked: a) Record the relation curve of rotation rate and time from sending out closedown impulse the time the unit rotation speed drops to zero. b) When the unit rotation speed drops to the specified rotation speed, the high pressure oil lift device of bearing shall be able to plunge automatically; c) When the rotation speed of unit drops to the specified actuation rotation speed, the actuation of tachometric relay shall be normal. Check the actuation conditions of unit. d) During the closedown process, actuation of the speed regulator and each automatic component shall be normal. 15.3.7 In case of steady-state short-circuit current rise of electric generator, the following items shall be checked: a) Electric current of the electric generator shall rise step by step. The secondary circuit of each electric current shall not open circuit. The connection, service condition and electrical measurements meter display of each protective relay device shall be correct; b) Record the short-circuit characteristic curve of electric generator; c) Under nominal current of generator, trip off field breaking switch and the demagnetization shall be normal. Record the demagnetization oscillogram of electric generator and calculate the time constant; d) Carry out the difference adjustment polar examination of excitation device CT and manual tune-up test of rotor current. 15.3.8 Voltage build-up test of electric generator shall meet the following requirements: a) Rise the voltage to nominal voltage in stages and the electrification of electric generator and generator voltage equipment shall all be normal: b) voltage, phase sequence and meter display of voltage transformer shall all be correct.
b) Voltage, phase sequence and meter display of secondary circuit of voltage transformer shall be correct. protective relay device shall work in normal condition. c) Under 50% or 100% nominal voltage, pop out field breaking switch and the demagnetization conditions shall be normal. Matriculate the demagnetization oscillogram of electric generator under nominal voltage. Work out the time constant: d) Measure voltage of generator shaft in nominal voltage; e) Swing and vibration value of operation of the unit shall meet the regulations in Table 15.3.1. 15.3.9 Under nominal speed, record the no-load characteristic of electric generator. When the exciting current of electric generator rises to nominal value, measure the maximum voltage of generator stator. For electric machine with interturn insulation, the time duration under maximum voltage shall be 5min. When this test is carried out, the stator voltage shall be limited within 1.3 times of nominal voltage. 15.3.10 Tune-up test of excitation device of electric generator under no load condition shall meet the following requirements : a) Field flashing test of excitation device shall be normal; b) Check the voltage regulation scope of excitation device system, which shall meet the design requirements: c) Check the excitation regulator plunge. Regulate upper and lower limit, interconversion of manual drive and automatism, passage switch, 10% phase step quantity disturbance, and the stability and overshooting of excitation regulator under switching on and closedown conditions. Generally the swing frequency shall not exceed twice. The voltage overshooting shall not exceed 10% and the time of regulation shall not exceed 5s. d) Change the rotation rate of unit and measure the terminal voltage variance of electric generator. For each 1% change of the frequency, the regulating system of automatic excitation shall guarantee that the generator voltage variation is within ±0.25% of the nominal voltage; e) Thyristor excitation adjuster shall have protective adjustment including disconnection, overvoltage and simulation actuation test. The actuation shall be correct; f) Under the condition that electric generator has load on or under nominal rotor current, thyristor excitation shall check the flow equalization coefficient and voltage-sharing coefficient of bridge rectifier and the value shall meet the design requirements. When there is no regulations on design, generally the flow equalization coefficient shall not be smaller than 0.85; generally the voltage-sharing coefficient shall not be smaller than 0.9. Proceed the adjustment and inspection of low excitation, overexcitation and flow equalization, and the actuations shall be correct. 15.3.11 According to different neutral point grounding methods, electric generator shall have single-phase earth test for extinction coil compensation or protective action validity verification. 15.3.12 If the unit design has electric braking, then electric brake test shall be carried out. Rotation rate of the plunged electric braking and rotation rate of the plunged composite braking and overall braking time shall meet the design requirements. 15.4 Test over paralleling in of unit and under load
15.4.1 Unit parallel test shall meet the following requirements: a) Current rise test of main transformer over high side through steady state short circuit shall be normal; b) The test of generator on the ascending loading of main transformer and impulse switch-on test of the main transformer by the system shall be normal. Check synchronized return circuit connection, which shall be correct. c)Once and secondary electric units related to unit plunge are all tested to be qualified. 15.4.2 In load test of unit, active load shall step up gradually. The meter display shall be correct. Temperature, vibration, and swing of each part of the unit shall meet requirements and the operation shall be normal. Observe the work condition of draft pipe aeration device under all kinds of working conditions, unit vibration section under current water head and the peak load value 15.4.3 Excitation device test with unit under load shall meet the following requirements: a) Adjustment process shall be stable under different kinds of loads; b) When conditions permit, measure and calculate the voltage adjustment ratio of generator voltage, which shall meet the design requirements; measure and calculate the static voltage error of generator voltage, and the value shall meet the design requirements: c) Thyristor excitation adjuster shall have tests and calibrations on all kinds of limitators and protections; d) Proceed power system stabilizer device (pss) test under small load. 15.4.4 Governor test with unit under load shall meet the following requirements: a) Carry out all kinds of control mode switches during automatic run. Load and servomotor stroke swing of unit shall meet the design requirement; b) Under small load, check the nominal load under a combination of different controlling parameters, raise or lower the speed sharply by 10% of the nominal load. Record the transition process of parameters including rotation rate, hydraulic pressure, horsepower and servomotor stroke. Select controlling load-carry duty parameters, which shall meet the design requirement. When this test is carried out, vibration section of unit shall be sheered off. 15.4.5 Load rejection test of unit shall proceed under 25%, 50%, 75% and 100% of the nominal load and related parameter values shall be recorded. Observe the stability of automatic excitation adjuster. When 100% load is rejected, the overshooting of generator voltage shall not be greater than 15% of the nominal value. The time of regulation shall not be greater than 5s and the voltage swing frequency shall not exceed 3 times. Regulating performance of speed regulator shall meet the following requirements: a) When 25% of nominal load is rejected, record the self-regulating transition process. Measure the servomotor response time, which shall not be greater than 0.2s; b) When 100% nominal load is rejected, check the closing rules and time of wicket gate servomotor, record the hydraulic pressure rise rate of spiral casing and the rotation speed rise rate of unit, both of which shall not exceed the design value; c) When 100% nominal load is rejected, record the self-regulating transition process and check the step closure of guide blades. During the changing process of rotation speed, wave peak exceeding the steady-state speed by 3% does shall not happen more than twice; d) After the rejection of 100% of the nominal load, record the time from the
servomotor's first move to the turnon direction to the time the oscillation value of unit does not exceed ±0.5%, which shall not be bigger than 40s; e) Examine the camrelationship of feather turn or impulse turbine during the process of load rejection, which shall meet the design requirements. 15.4.6 At nominal load, the following test shall be carried out: a) Closedown test of guide blade under low oil pressure; b) Closedown test of guide blade by accident proportioning valve; c) Proceed the closedown test of main gate or master valve (cylinder valve) test under hydrodynamic conditions according to the physical circumstances of design requirement and power station; d) Power station without accident regulation valve shall take forced shutdown test; e) Counter-weight close-down test of bulb tubular generating unit. both electric power receiving station delivery head and electric system conditionality, set be Restricted by the conditions of water head and electric system of power station and the unit cannot have nominal load, the test can be carried out at the current conditions under as large load as possible. 15.4.7 At nominal load down, the unit shall proceed 72h continuous service. Restricted by the water head and electric system conditions of power station, the unit cannot have nominal load, proceed 72h continuous service at as large load as possible. 15.4.8 According to the contract requirement, for unit with 30d test run requirements, after the 72h continuous trial run and closedown of the unit to deal with the discovered flaws, proceed the 30d trial run immediately. During the 30d trial run period, intermittence due to the malfunction of unit or its auxiliary facilities or the installation and manufacturing quality of equipment shall be timely dealt with. After they equipments are qualified, proceed the 30d operation, if the intermittence is shorter than 24h and the frequency does not exceed three times then the operation time before and after the intermittence may be accumulated. Otherwise, the time before and after the intermittence shall not be accumulated. Restart 30d trial run test. 15.4.9 Proceed the leading phase operation in compliance with the design requirement, leading phase depth and related protection setting shall meet the requirements. 15.4.10 For condenser operation test of the unit, record the following items: a) Record the consumed wattful power of unit after the closedown of guide blade when the runner operates under water; b) Check the water pressure and aeration conditions as well as the actuation of aeration device, which shall be normal. Record the wattful power consumed by unit after the water level inside the draft pipe is pressed down under the runner; c) During the switchover between electricity generation and condenser operation, the actuation of automatic control program and automation component shall be exact. d) Within the scope of design, regulation of generator reactive power shall be stable. Record the maximal reactance capacity output when the rotor current is nominal value. 15.4.11 As for hydrostorage reversible type unit, except for the aforesaid requirements, generally, the following requirements shall also be met: a) Check the actuation of air inflation and water pressing as well as automatic aeration.
Record the process time of charge and water pressing as well as the difference value of pressure drawdown of air-hammer pot. The value shall meet the design requirements. b) Check the actuation of coping air evacuation valve. Observe the degassing and drainage of the vent-pipe vibration and the outflow of exhaust pipe, which shall be normal. Record the time of the entire exhaust process, and the value shall meet the design requirements. c) Record the start-up procedure curve of unit under frequency conversion and back-to-back modes. In frequency varying staring mode, in the start-up procedure of unit, the telephone harmonic form factor of high voltage side of main transformer shall not exceed the set value. As for asynchronous starting mode, during the start of unit, record the parameters of system voltage, electricity generation / motor stator voltage and stator current, which shall meet the design requirements. d) Proceed working condition zero flow test of water pump. Observe the pressure generating process of runner chamber. Record the pressure between the runner and guide blade during the pressure generating process and the pressure of spiral casing and draft pipe, determine the vibration of each part of the unit, and determine the optimal time to turn on guide blade. Transition process of working condition from zero flow to water pumpage working condition shall be normal. e) Within the specified delivery lift, the unit shall take trial pumping tests under different delivery lifts. The actually measured delivery lift, flow, input power and guide vane opening shall comply with the complex characteristic curve of the water pump / water turbine provided by the manufacturer. The swing and vibration value during operation of the unit shall be in compliance with regulations in 15.3.1 d) and e). f) Transcribe the normal shutdown curve and emergency shutdown curve of unit under the working condition of water pump, which shall be exact. g) Proceed the switch tests between all kinds of service conditions such as from electricity generation to water pumpage and from water pumpage to electricity generation. The transition process parameter shall meet the design requirements and the conversion program shall be exact and reliable. h) Carry out 30d trial run test of the unit, the electricity generation and water pumpage shall proceed in compliance with the requirements of electric system. For power station that needs to have initial water filling, within 30d trial run period, all requirements on the initial water filling of reservoir shall be met.
Annex A (Informative) Handover of Informative Annex A.1 Final drawing and materials a) Final drawing for the installation within the installation scope of this standard b) Ex-factory record, certificate, and technical specification, etc. arrived with equipments c) Design and modification documents d) Summary list of defects mappings in all major equipments and technical materials on defects dealing of related equipments A.2 Installation and test data sheet a) Water turbine 1) Installation record of the draft pipe (elbow bend and conical tube) undercoat 2) Installation record of stay ring; 3) Installation record of spiral casing; 4) Record on defect detecting test for welding seam of spiral casing; 5) Record of hydraulic test of spiral casing on site; 6) Installation record of servomotor; 7) Record on thermal treatment and detection of split runner welding seam; 8) Combination record of split runner (after the thermal treatment); 9) Static balancing test record of runner; 10) Roundness record of the upper and lower seal ring of runner; 11) Record on the welding, thermal treatment and acceptance of work of one-piece runner installation on site 12) Combination and installation record of base ring; 13) Top cover combination and installation record; 14) Record on the upper and lower terminals of guide blade and vertical plane clearance; 15) Record of the distance between two axial holes of the wicket gate actuating rod; 16) Impaction stroke record of wicket gate servomotor; 17) Maximal gate opening record; record on rotation angle scope of paddle corner; 18) Record of wearing ring clearance on each part of water turbine; 19) Assemble clearance record of main guide bearing; 20) Installation record of cylindrical valve; 21) Installation record of aeration device in the spindle center hole 22) Installation record of the runner chamber of Kaplan turbine 23) Record on the runner actuation of Kaplan turbine and withstand voltage test; 24) Relation curve of leaf blade rotation angle of Kaplan turbine and servomotor stroke; 25) Clearance record between Kaplan turbine leaf blade and runner chamber; 26) Installation record of oil receiver; 27) Installation record of impulse turbine chassis;
28) Installation record of impulse turbine muzzle; 29) relation record on the needle stroke of impulse turbine and refractor opening; 30) Withstand voltage and actuation test record of feathering francis runner 31) Clearance record of feathering francis runner leaf blade and runner chamber; 32) Relation curve on rotation angle of diagonal flow turbine leaf blade and servomotor stroke b) Speed regulating system 1) Tightness withstands voltage test record of overhead tank, oil pipeline and bearing components; 2) Commissioning record of oil pressure installation; 3) Emergency shut-down and opening time record of guide blade; 4) Sectional closure stroke and opening time record of guide blade; 5) Sectional closure stroke and opening time record of blade; 6) Time record for guide blade closedown of accident regulating valve; 7) Comprehensive wander test record; 8) Relation curve of guide vane opening and servomotor stroke; relation curve of blade angle and servomotor stroke; 9) Relation curve for wicket gate servomotor of design head and blade servomotor stroke 10) Relation curve on the input rotation speed, output electric voltage and electric current of speed detector 11) Transfer curve on the switch conversion device of electrohydraulic or electric machine 12) Transfer curve of speed regulating system c) Electricity generator part 1) Chassis installation record 2) Chassis welding inspection record 3) Chassis installation record 4) Clearance record of the joint close of magnet yoke and iron core 5) Stator installation record 6) Record of onsite laminations installation of the stator 7) Installation record of rotor field spider 8) Welding inspection record of rotor field spider 9) Installation record of rotor yoke 10) Installation record of braking ring plate 11) Installation record of magnetic pole 12) Counterweight record of rotor 13) Fit-up gap record of thrust bearing pad 14) Adjustment record on the stress over thrust bearing 15) Distance record between the elastic bearing base and carrier plate 16) Distance record from shaft neck to the base ring 17) Air interstice record of stator and rotor 18) Adjustment records on the axial line of unit 19) Clearance record of guide bearing pad
20) Withstand voltage test record of brake 21) Record on the installation elevation of brake 22) Resistance measurement record of bearing insulation 23) Withstand voltage test record of cooler 24) Withstanding pressure and test record of high pressure oil lift device 25) Record on the bearing installation of horizontal type sub-frame 26) Installation record on the pipe shaped base of bulb unit 27) Installation record with vertical or horizontal bracing of bulb unit d) Excitation system part 1) Installation of the disc & cabinet of excitation system and test record; 2) Installation of exciting transformer and the test record; 3) Installation of magnetic field breaker & field breaking switch and test record; 4) Installation of heavy-duty rectifier and test record; 5) Installation of pulse transformer and test record; 6) Nonlinear resistor test record; 7) Installation of silicon control junctor and test record; 8) Records on cable running and wiring of each disc, cabinet and component of excitation system; 9) Inspection record on the return circuit components such as interfacing, operation, protection, surveillance, and signal etc. of excitation system; 10) Record on the return circuit components such as interfacing, operation, protection, surveillance, and signal etc. of excitation system; 11) Insulation record on each component of excitation system and one-time or secondary circuit; 12) Dielectric strength test record of each component of excitation system; 13) Test record of each basic unit of automatic excitation adjuster 14) Test record of each supplementary unit of automatic excitation adjuster 15) Overall static characteristics test record of automatic excitation adjuster 16) Trial run record of excitation system. See A.2.h.). e) Butterfly valve and ball valve 1) Valve body installation record 2) Withstand voltage test record of rubber waterstop 3) Sealing device clearance record 4) Through valve hydraulic test record 5) Servomotor stroke record 6) Servomotor installation record 7) Operation record in anhydrous conditions or still water conditions 8) Welding inspection record of telescopic joint f) Others 1) Record of the extension value of bolt required to be tightened 2) Oiliness test record 3) Test record of wind system, water system and oil system g) Electric equipment of unit
Record on the electrical test carried out in compliance with the requirement of this standard. h) Trial run Record on tests carried out as required by this standard
Annex B (Normative) Installation Requirements of Mechanism Hydraulic Pressure Governor B.1.1 Installation deviation of governor cabinet shall meet the requirements of Table B1. Table B1 Permissible deviation for the installation of governor cabinet No. Item Permissible deviation Notes 1 Center (mm) 5 Measure the distance from the mark on the equipment to X and Y datumline of unit 2 Elevation (mm) ±5 3 Level of the 0.15 Measure pedestal mechanic cabinet (upper spacer) of (mm/m) governor driving motor Notes: Installation of compounded speed regulator shall take the actuating mechanism bracket regulating shaft as the bench mark. The deviation shall meet the design requirements B.1.2 Rinsing, installation, and adjustment of the governor component shall meet the following requirements: a) Connection of governor driving motor and centrifugal flyweight shall be concentrical. The rotation shall be flexible. Radial and axial swing of rhombohedral centrifugal pendulum spring pedestal relative to the bearing at the upper end of steel band shall not be greater than 0.04mm. b) When the buffering piston moves up and down and returns to the last 1mm middle position, the time it takes shall meet the design requirements: Time difference for the two rounds up and down shall not exceed 10% of the set time. Measure the return interval of buffering bearing plate of speed regulator in the three positions of middle and two terminals. There shall be no clearance between the support bolt of buffer and bearing plate. Actuation of buffer relay piston shall be stable. The deviation it returned to the middle position shall not be greater than 1mm. c) Each indicator and leverage in mechanism cabinet of speed regulator shall be adjusted according to the drawing. Generally, the position deviation of mechanism shall not be greater than 1mm. d) When indication of steady state speed droop (residual degree of irregularity) is zero, total stroke of return mechanism actuation and slippage mechanism shall be zero. The maximum deviation shall not be greater than 0.05mm. B.1.3 Others refer to related contents in Chapter 8.
Annex C (Normative) Requirement on the Dryness of Hydraulic Generator Stator C.1.1 Dryness of stator coil may be neglected when it satisfies the following conditions: a) Per phase insulation resistance of winding is in compliance with the regulations of Article 9.3.18 a); b) Below 40°C, for asphalt mica insulation, the measured absorption ratio of insulation R60/R15 shall not be smaller than 1.3; for epoxy reconstituted mica insulation, it shall not be smaller than 1.6; the measured insulated polarization index R10min/R1min shall not be smaller than 2. C.1.2 For stator needs to be dried, during the drying, attention shall be paid to the following items: a) Generally, the assembled stator is dried with surface baking method by external heating; b) In the drying process of stator winding, the temperature shall rise gradually. The temperature rise shall be 5°C ~ 8°C per hour. c) The maximum temperature of coil shall not exceed 70°C when measured with alcohol thermometer and shall not exceed 80°C when measured with flush type resistance thermometer; d) Generally, insulation resistance shall be stabilized for 4h ~ 8h.
Annex D (Informative) Acid Washing, Passivation and Rinsing of Pipeline D.1.1 Acid washing and passivation of pipeline a) Before the installation of pipeline, the inner walls may be acid washed and passivated by the adoption of vat leaching method or systemic circulation method. b) Acid washing of the inner walls of pipeline shall remove the rustiness and make sure that the un-rusted surface is not spoiled (namely overpickling). c) When there are overt oil spots on the inner wall of pipeline, no matter which acid washing method is adopted, before the acid washing, the pipeline shall be degreased. The pipeline may adopt organic solvent (Dichloroethane, trichloroethane, carbon tetrachloride, industrial alcohol, etc.), aqua fortis or alkali liquor to degrease. d) Before the acid washing with systemic circulation method, the piping system shall take air leak-off-test or hydraulic pressure leak-off-test. e) When systemic circulation acid washing is adopted, generally, the process shall follow such order: leak-off-test, degreasing (if necessary), rinsing, acid washing, neutralizing, passivation, rinsing, drying, greasing, resetting, etc.. f) Sustain the consistency and temperature of acid liquor during the acid washing. g) If there is no definite regulations, formulation of the acid washing liquid, neutralizing liquid and passivation liquid of the steel tube may adopt products that have been appraised and is proved to be effective and reliable in the actual application. h) After the acid washing, visual inspect the pipeline. It is deemed as qualified if the inner walls shows metallic luster. i) During the acid washing, neutralizing and passivating operation, the operators shall wear special protective clothing, goggles, acid resistant gloves and so on. j) Pipeline after qualified acid washing, neutralizing and passivating shall be protected by sealing if it cannot be re-assembled and placed in service timely. k) Waste water and used liquid after the acid washing shall be disposed before discharge, which shall be in compliance with related environmental protection regulation to avoid environmental pollution. D.1.2 Pipeline rinsing D.1.2.1 Rinsing of water system pipeline a) Before rinsing, orifice plate sieve, thermometer, valve plug of check valves shall be dismantled from the piping system and shall only be reassembled after they are rinsed and qualified. b) The rinsing shall proceed with the maximal pressure and flow that can be reached within the system until the water color and transparency at the outlet are the same as water at the inlet by visual inspection. D.1.2.2 Rinsing of the air system pipeline a) Generally, air system pipeline shall be purged with compressed air. Flow velocity of compressed air is 5m / s ~ 10m / s. Place a piece of board pasted with plain paper or white
cloth at the air discharge outlet for 3min ~ 5min, if no dirt and moisture content are discovered, then the air is qualified. b) Air system pipeline may also adopt clear water at a speed of 0.8m / s to rinse until the water at the discharge outlet is clean, it is deemed qualified. After the pipeline is rinsed with water and is blown dry, it may be put in application. D.1.2.3 Rinsing of oil system pipeline. a) After the oil-piping is pickled and qualified before the oil filling into the system, oil-piping may be rinsed with oil that has been filtered with pressure type filter press and has been pressed by oil pump. b) Oil rinsing shall be carried out in the oil circulation method. During the circulating process, raise and lower oil temperature two or three times within the temperature scope of 40°C~70°C every 8 hours. c) After the rinsing of the pipeline oil, check with 200 mesh sieve. It is deemed as qualified when the number of remaining impurities per square centimeter is limited within 3. d) The brand of oil use in rinsing shall be the same as that used by the system. After the rinsing is qualified and the rinsing is discharged, then new oil may be infused into the system. D.1.2.4 Rinsing of the speed regulating system pipeline shall proceed according to design requirement.
Annex E (Informative) Non-destructive Test Examination Standard over Related Welding E.1 GB3323-87 Abstract of the standard Methods for radiographic inspection and classification of radiographs for fusion welded butt joints in steel E.1.1 According to the property of weld quality and quantity, it falls into four grades: a) Grade 1 welding seam shall be free of flaw, faulty fusion, incomplete penetration and streak liquid b) Grade II welding seam shall be free of flaw, faulty fusion and incomplete penetration c) Grade III welding seam shall be free of flaw, faulty fusion and incomplete penetration in both sides welding and one side welding with backing board. Allowable incomplete penetration length of one side welding without backing board shall be evaluated according to Table E - 6 Evaluation on the Grade according to the Length of streak slag inclusion. d) Welding defects over the limit of Grade III are rated as Grade IV. E.1.2 Welding defects may be round defects or streak slag inclusion. E.1.3 Defects with length-width ratio smaller or equal to 3 are round defects. It may be round, oval, cone or of irregular shapes, such as with tails (when measuring the size, the tails shall be included). It includes gas cavity, slag inclusion and tungsten inclusion. E.1.3.1 Round defects are evaluated by choosing evaluated area and evaluated area shall be selected at the most seriously defected part. See Table E1 for the sizes of evaluated area. Table E1 Round defects evaluation area Unit as millimeter Thickness of the parental materials (T) T<25 25≤T<100 Dimension of the evaluated area 10 X 10 10 X 20
T>100 10 X 30
E.1.3.2 During the evaluation of round defects, the flaw size shall be converted into number of imperfection points according to Table E2. Table E.2 Conversion table for the number of points of imperfection Unit as point Diameter of defects mm <1 > 1~2 > 2~3 > 3~4 > 4~6 >4~8 >8 Number of points 1 2 3 6 10 15 25 E.1.3.3 See Table E3 for size of the defects with points discounted Table E3 Size of the defects with points discounted Unit as millimeter Thickness of the parental materials T Long diameter of the flaw T≤25 < 0.5 50≥T>25 < 0.7 T>50 <1.4%T
E.1.3.4 When a round defect is connected with the sideline of the area of interests, it shall be counted into the number of points within the assessment area. E.1.3.5 Where are few defects near the assessment area and it is considered it is not suitable to assess the grades by size, the assessment area may be expanded by three times along the welding seam direction after discussion and work out the total number of defects. Assess with 1/3 of this value. E.1.3.6Grading of the round defects see Table E4.
Table E4. Grading of round defects (according to the upper limit of the number of imperfections) Unit: in points Evaluation area mm 10 X 10 10 X 20 10 X 30 Thickness of the 15 25 50 100 parental thickness T T < 10 T>100 ≥T>10 ≥T>15 ≥T>25 ≥T>50 mm I 1 2 3 4 5 6 Quality II 3 6 9 12 15 18 Grade III 6 12 18 24 30 36 IV Defect points grade greater than Grade III E.1.4 Slag inclusion with length-width ratio of defect greater than 3 is streak slag inclusion . See Table E5 for the grading of streak slag inclusion. Table E5. Grading of streak slag inclusion Quality grade
Length of each single streak slag inclusion
II
T≤12, the value is 4; 12
III
T≤9, the value is 4; 9
Unit: in millimeter Total length of streak slag inclusion On any line, for any group of slag inclusions with spacing between two neighboring slag inclusions not longer than 6L, the accumulative spacing length shall not exceed T within 12T weld length On any line, for any group of slag inclusions with spacing between two neighboring slag inclusions not longer than 3L, the accumulative spacing length shall not exceed T within 6T weld
length IV
Greater than Grade III
Note: 1. In the table, L refers to the maximal length of this group of slag inclusion. 2. Grading of the long gas cavity with length-width ratio greater than 3 is the same with the grading of streak slag inclusion. 3. When the IV Grade III upward 4: When the checked welding seam length is smaller than 12T (Grade II) or 6T (Grade III), it may be converted according to ratio. When the converted total length of the streak slag inclusion is smaller than the length of a single streak slag inclusion, the single streak slag inclusion shall be taken as the allowable value.
E.1.5 Within the round assessment area, if both round defects and streak slag inclusion (or incomplete penetration) exist, they shall be graded respectively and the total of the grade minus 1 will be taken as the final grade. E.2.GB11345-89 Abstract of Method for manual ultrasonic testing and classification of testing results for ferritic steel welds Classify the defects in compliance with the regulations of Table E6 according to the flaw indication length. Table E6 Grades classification of defects Grades Inspection A B C Plate thickness 8~15 8~300 8~300 2/3δ, minimal δ/2, minimal 10, δ /3, minimal I 12 maximal 30 10, maximal 20 3/4δ, minimal 2/3δ, minimal δ /2, minimal Grade II 12 12, maximal 50 10, maximal 30 evaluation 3/4δ, minimal 2/3δ , minimal III <δ, minimal 20 16, maximal 75 12, maximal 50 IV Over Grade III Notes: 1 δ refers to the plate thickness of the parental materials on the machined side of groove. When the plate thickness of parental materials is not even, the thinner point thickness will be adopted. 2 Fillet weld of tube holder (δ,) is the center line height of the welding seam section.
Annex F (Informative) GB11120-1989 L-TSA Requirements on Steam Turbine Oil Table F.1GB11120-1989 L-TSA Requirement on Steam Turbine Oil Quality index Item Viscosity grade Kinematic Viscosity (40°C), mm2/s Viscosity indexa, not lower than Flow pointb, °C, not higher than Flash point (opening), °C not lower than Density (20°C), kg/m3 Acid value, mgKOH/g, not greater than Neutralization value, mgKOH/g, not greater than Mechanical impurities Water contents Demulsificati on valuec (40-37-3) L
Top grade
First grade
Quality products
32
46
32
46
32
46
28.8~35. 2
41.4~50. 6
28.8~35. 2
41.4~50. 6
28.8~35. 2
41.4~50. 6
Test metho d GB 3141 GB 265
90
90
90
GB 1995
-7
-7
-7
GB 3535
180
180
180
GB 3536
Report
Report
Report
GB 1884 GB 1885
-
-
0.3
GB 264
Report
Report
-
GB 4945
No
No.
No.
No.
No.
No.
15
15
15
GB 511 GB 260 GB 7305
54 ℃, min, not greater than Air bubble testd, ml/ml, 24 ℃, not greater than; 93 ℃, not greater than; Later 24℃, not greater than; Oxidation stability e a. Overall oxidative product, %: Precipitate, %: b. Acid value after oxygenation 2.0 mgKOH/g, H is not smaller than: Rust test in liquid phase (synthetic sea water) Copper strip test (100°C,3h) Air release valuef (50°C)
5
450/0
450/0
600/0
100/0
100/0
100/0
450/0
450/0
600/0
Report Report 3000
Report Report 2000
Report Report 1500
GB 8119 SY 2680
Rustless
Rustless
Rustless
GB 11143
1
1
1
GB 5096
-
SY 2693
6
5
6
SY 2669
Notes: 1. For steam turbine oil produced from intermediate base crude, viscosity index of L - TSA quality products is permitted to be not lower than 70 and viscosity index of first grade products are allowed to be not lower than 80. According to the production and practical application, after consultation with the user, this standard may not be a limit. 2. Pour point index may not be limited by this standard according to the practice of production and application after consultation with the user. 3. When the products are for the purpose of military, the demulsification value shall be negotiated by the
manufacturer and the army. 4. During the air bubble test, if the oil surface is not covered by bubbles, the report result is “0”. 5. Oxidation stability is a item that shall be guaranteed. It is spot checked once a year. 6. Air release value in the first grade products may not be limited by this standard according to the practical production and application and after the negotiation with user.
Annex G (Normative) Wording Explanation: G.11. Words used for different degrees of strictness are explained as follows in order to mark the differences in executing the requirements in this code. G.1.1 Words denoting a strict requirement under normal conditions: “Shall” is used for affirmation; “shall not” for negation. G.1.2 Words denoting an indication of the most suitable choice when conditions permit: “Should” is used for affirmation; “should not” for negation. G.1.3 Words denoting the option available, sometimes with the conditional permit. “May” is used for affirmation; “may not” is used for negation; G.1.4 Words denoting a causal possibility and capability “Can” is used for affirmation; “can not” for negation.
