Turbine

NEA Middle Marsyangdi HEP
Lot M: Mechanical Equipment Section B1: Particular Technical Specifications Chapter 1: Turbine
TABLE OF CONTENTS
TABLE OF CONTENTS................................................................................................................1 1 TURBINE......................................................................................................................................2 BOTTOM RING...........................................................................................................................19
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1 TURBINE
1.0 GENERAL
1.1.1 SCOPE AND LIMITS OF SUPPLY Two Francis type turbine of identical size and design shall be supplied as specified hereunder. The limits of supply are given mainly by: - The flange coupling face between turbine and generator shaft. - The flange face between turbine inlet valve and spiral casing. - The end of the draft tube elbow lining. The scope of supply of the turbines shall include: - Design, calculation, manufacture, workshop assembly and workshop testing of the equipment. - Priming and application of the finishing coating on all equipment to be painted. - Seaworthy packing of the equipment, including the protective varnishing or greasing of all surfaces which will be left bright during services. - Transportation (sea and land), including the necessary loadings and unloadings up to the powerhouse site, including the transport insurance. - Unloading at the powerhouse site, necessary storage, erection (including the necessary erection equipment), site tests and commissioning. All mechanical and electrical issues related to the joint design and operation of the turbine/generator units will be coordinated with the Lot E Electrical Equipment Contractor. The Lot M Contractor accepts that there will be a joint responsibility with the Lot E Contractor for the complete electro-mechanical design of the generator and turbine set and takes all necessary and required steps so that there will be no supply or functional gaps between Lot E and M. Any additional cost will not be borne by the Owner. 1.1.2 GENERAL ARRANGEMENT The direction of rotation of the turbines shall be clockwise when viewed from above. The arrangement of the generating sets will correspond to W 42 (DIN) and IM 8225 (IEC) respectively and is shown in the relevant drawings of the powerhouse. The spacing between the unit axis will be 15 m. The dimensions of the powerhouse layout shall be kept. Any changes required by the equipment offered by the Tenderer shall be clearly indicated in the Tender and its impact on the cost of civil works will be considered in the evaluation of the turbine Tender. The horizontal centreplane of the spiral casings shall in no case be set deeper than elevation 515.0 m a.s.l. Correspondingly the lowermost elevation of the draft tubes shall not be below el. 508.0 a.s.l. Setting of the turbine (horizontal centerplane of the spiral casing) has been fixed considering the stipulations given in the IEC Publications 193A and 693 and considering the rated speed of 333.3 rpm.
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Deeper turbine settings will not be accepted. If the Tenderer proposes a considerably less deep turbine setting and providing sufficient evidence that same will be complying with the above mentioned stipulations and directions its Tender will be evaluated accordingly. Cavitation performance of the turbine under the specified setting and consequences of cavitation damages are specified in the following sub-clauses 1.0.5.3 and 1.0.6.3. 1.1.3 OPERATING CONDITIONS 1.1.3.1 HEADRACE AND TAILRACE LEVELS Headrace Max. upsurge level in surge shaft Maximum flood level in desander Design flood level Normal operating levels (dayly pondage) Minimum operating level Tailrace Probable maximum flood level 530 m a.s.l. Normal operating level (both units under full load) 518 m a.s.l. (in rain season) Minimum operating level (one unit at half load) 516 m a.s.l. For river discharges up to 500 m/s the formula WL = 515.83 + 0.0109*Q 0.00002*Q applies. With: WL = water level in [m a.s.l.], Q = River discharge in [m/s]. 1.1.3.2 HEAD LOSSES The calculated total head losses of the waterways from intake to tailrace outlet are 11.6 m for both units running under full load (Q = 80 m/s) and 3.8 m for one unit running (Q = 40 m/s). 1.1.3.3 RANGE OF OPERATION The operating range for which each turbine shall be designed and the required or expected performance data are given on Page 5. Overloading up to approx. five (5) % shall be feasible under all heads without affecting smooth running and cavitation behaviour of the units. The extent of overloading capability shall be guaranteed. Except the design point (unit discharge of 40 m /s under a net head of 96.5 m) all other data (discharges and outputs) are to be considered as preliminary estimates. 1.1.3.4 SPEED Rated speed shall be 333.3 rpm. Proposals with other speeds are left to the Tenderer's discretion, but shall be understood as additional proposals relieving in no way the
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640.0 m a.s.l. 628.0 m a.s.l 626.0 m a.s.l. (in rain season) 621.0 - 626.0 m a.s.l. (in dry season) 621.0 m a.s.l.
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Tenderer from quoting primarily for 333.3-rpm turbines (refer also to clause "Alternative Proposals" in Section A). It shall also be understood that for being considered, such alternative proposals shall not affect substantially the civil structures, floor elevations, machine settings and other important project features. Furthermore, the potential generator suppliers shall be informed early enough on the rated speed of alternative turbines so as to enable them a timely corresponding proposal.
Range of operation
115
110
105
100 Design point for generator Pt = 35,9 MW
95
Hn by operation of one unit and max. water level Hn by operation of one unit and min. water level Hn by operation of both units and max. water level
90
Hn by operation of both units and min. water level max. opening of wicket gates Design point for turbine Pt = 32,7 MW 20 25 Discharge [ m3/s ] 30 35 40 45 50
85 0 5 10 15
The Tenderer shall guarantee in the annexed Data Sheets the maximum continuous runaway speed that can occur under the maximum static head and at full guide vane opening. Furthermore, the maximum temporary runaway speed (dynamic runaway speed) considering maximum upsurge in the surge shaft, shall be guaranteed. The first critical speed of the turbine/generator unit shall be at least 25% above the maximum continuous runaway speed and has to be guaranteed in the annexed Data Sheets. 1.1.3.5 CONTROL SYSTEM Control of the generating sets shall be either by: - Manual control from the turbine control board Manual or automatic control from the control room.
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Manual (local) control will be used only during commissioning of the units and after major maintenance and/ or repair work on the equipment. 1.1.4 PRESSURE RISE, SPEED RISE 1.1.4.1 PRESSURE RISE The minimum time for moving the wicket gates from any opening to speed/no load opening shall be set so that when suddenly rejecting any load up to the maximum combined full load of two (2) units, the maximum hydrodynamic pressure rise at the spiral casing inlet does not exceed 5 bar. This shall be guaranteed in the annexed Data Sheets. 1.1.4.2 SPEED RISE The maximum momentary speed rise due to instantaneous rejection of any load up to the maximum combined full load of two units shall be kept to a minimum and shall in no case exceed 45 %. It shall be calculated thoroughly by the Tenderer on the basis of the pressure tunnel characteristics and guaranteed in the annexed Data Sheets. The momentary speed rise is defined as follows:
Whereby:
n1 = Governed rated stable speed just prior to the load rejection. n2 = Maximum speed attained subsequent to the load rejection.
1.1.4.3 MOMENTUM OF INERTIA A momentum of inertia GD2 of approx. 700 tm2 is being assumed in the generator rotor. The exact determination of the pressure and speed rises, as well of the units stability behaviour shall, however be performed with the definite GD2 of the generator and turbine rotating parts. 1.1.5 GUARANTEES The Tenderer shall guarantee that each turbine is capable of operating continuously and without hunting and/or undue vibrations at any net head between 85 and 110 m and at any discharge between 16 and 40 m/s. 1.1.5.1 OUTPUT The Tenderer shall guarantee that under a net head of 98.0 m and with a turbine discharge of 40 m3/s each of the units will deliver when operating in parallel not less than 35.5 MW. Under the maximum permanent net head of approx. 105.0 m with one turbine working singly a continuous output of approx. 38.0 MW is expected.
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Under the minimum net head of approx. 93.0 m (with both turbines working in parallel) a unit output of about 34.0 MW is being expected. All guaranteed outputs shall be entered in the annexed Data Sheets. 1.1.5.2 EFFICIENCIES Best efficiencies are desired between net heads of 93 and 100 m. Efficiencies shall be indicated in the annexed Data Sheets (for 100, 85, 70, 50, and 40 % load inclusive) for the following net heads: 90 m, 93 m, 95 m, 98 m, 100 m and 105 m The following ponderation-mode shall apply for the determination of the weighted arithmetical average prototype efficiency which shall be guaranteed in the annexed Data Sheets.
T. discharge m/s 40 35 30 25 20 16 90 3% 1% 93 18% 2% Net head in m 95 98 19% 19% 4% 4% 1% 2% 1% 100 3% 4% 4% 1% 105 Total 4% 66% 2% 17% 5% 12% 1% 3% 1% 1% 1% 1% 100%
The overall weighted average efficiency reads, therefore, as follows and applies to each of both turbines.
whereby Ci represents the ponderation coefficients (or weights) as listed in the table and with which the different efficiencies are to be multiplied. shall be guaranteed as well in the annexed Data Sheets. Efficiency Evaluation Tender comparison will include comparison and evaluation of the overall weighted average prototype efficiency tendered and guaranteed. Based on the highest such efficiency quoted and guaranteed, lower overall weighted average prototype efficiencies will be charged with 100,000 per each 0.1% (absolute) minor overall weighted average prototype efficiency per unit. 1.1.5.3 CAVITATION Each runner shall be guaranteed against excessive deterioration due to cavitation for the first 8000 hours of operation after provisional acceptance of the turbine.
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Excluded from this guarantee is the removal of metal by erosion or damage due to the presence of injurious foreign elements in the water. This, however, is under the provision that no inappropriate material or grade of same has been used by the Contractor. Should within the first 8000 working hours after provisional acceptance of the turbines a runner show cavitation damage, the following consequences will apply: LOSS IN WEIGHT
- Cavitation attack of a runner resulting in a loss of metal not exceeding 0.12 . D2s .ta (in
weight grams) shall be considered as being tolerable. - Cavitation attack of a runner resulting in a loss of metal above 0.12 .D2s . ta but not exceeding 0.24 D2s t (both in weight grams) shall be subject to immediate full repair and reconditioning of the runner by and at the cost of the Contractor. - Cavitation attack of a runner resulting in a loss of metal exceeding 0.24 D2s . ta (in weight grams) shall entail an earliest rectification or redesign of the runner and model tests to replace the unsatisfactory runner by a more suitable one by and at the cost of the Contractor. This new runner shall be subject to the same cavitation guarantee period as the replaced one. Should cavitation attack continue to remain above 0.30 .D2s ta (in weight grams) then the turbine may be rejected. Definitions: Ds = D3 = runner discharge (outlet) diameter (in m) ta = actual operation period (working hours) AREA AFFECTED AND DEPTH OF PITTING. Cavitation shall be guaranteed also with respect to maximum depth of pitting and maximum runner surface affected whereby principally the corresponding recommendations of the "Cavitation Pitting Evaluation in Hydraulic Turbines, Storage Pumps and Pump-Turbines" (IEC - Publication 609) as adapted as follows shall apply for the first 8000 working hours after provisional acceptance of the turbines:
- For damage up to 0.75 times the values as per the charts' upper curve : tolerable.
- For damage between 0.75 and 1.25 times the values as per the charts upper curve : immediate and full repair and reconditioning of the runner by and at the cost of the Contractor. - For damage above 1.25 times the values as per the charts' upper curve: earliest replacement of the unsatisfactory runner by a suitably rectified or redesigned and model-tested one whereby all related cost shall be at the charge of the Contractor. Such new runner shall be subject to the same guarantee period as the replaced one. Should depth of pitting and/or runner area affected be again above 1.25 times the values as per the charts' upper curve then the turbine may be rejected.
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1.1.5.4 VIBRATIONS Vibrations of the turbine/generator units must be kept within half the limits as defined by VDI 2059, Part 5 (fig. 1) for the entire normal operating and speed range, i.e. non-excitedno load-guaranteed head and load range of the turbine (within 95 to 105 % of rated speed). Both the Contractors for turbine and generator equipment shall be held jointly responsible for meeting the above stipulated vibration limit of the turbine/generator unit. In cases of dispute between themselves the Engineer's decision will be binding to both Contractors. Vibration detection shall be at the elevation of the bearings and all necessary supervisory equipment which will be required during commissioning and for correct setting of the equipment shall be provided. Any excessive shaft displacement and objectionable resonant vibration on stationary parts of the turbine/generator unit shall be eliminated by the Contractor whose supply is concerned without delay and at no cost to the Employer. 1.1.5.5 PRESSURE PULSATIONS, NOISE LEVEL Utmost care shall be taken with regard to pressure pulsation generation within the entire operation and load range. Provisions shall be make that pressure and load fluctuations remain within + two (2) percent at any output between 100 % and 50 % load. Noise in the turbine pit shall not exceed 90 dBA at any load between 100 and 50 %. In the event of the prototype turbines exceeding above levels then immediate corrective measures shall be taken without affecting the units operating range. 1.1.5.6 PRESSURE RISE, SPEED RISE Refer to sub-clause 1.04 1.1.6 FAILURE TO MEET GUARANTEES 1.1.6.1 OUTPUT Should the turbine acceptance test outputs show that -except for a maximum tolerance of 0.5% - the turbines will fail to deliver 35.5 MW (each) under a net head of 98.0 m, the Contractor shall undertake immediately all effective measures (adjustments, modifications, re-testing of the model turbine, etc.) in order to obtain the guaranteed output within the 0.5% tolerance. If despite of such measures the prototype will still fail to deliver by more than 0.5% the 35.5 MW under 98.0 m net head liquidated damages corresponding to 200,000 per unit per each 50 kW output deficiency shall be payable to the Employer. If the prototypes' output under 98.0 m net head falls short by more than 1000 kW (including a 0.5% output tolerance) then the turbines become subject to
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rejection. The same liquidated damages shall apply when the guaranteed full load output under 90.0, 93,0, 95,0, 100.0 and 105.0 m respectively falls short by more than 0.5%. 1.1.6.2 EFFICIENCY Should the turbine acceptance tests show that the overall weighted average efficiency as defined under sub-clause 1.0.5.2 will fall short by more than a tolerance of max. 1.5% (absolute), the Contractor shall undertake all effective measures (adjustments, modifications, re-testing of the model turbine, etc.) in order to obtain this guaranteed weighted average efficiency. If despite of such measures the prototypes' overall weighted average efficiency will still fall short by more than 1.5% (absolute) liquidated damages corresponding to Euros 200,000 per each 0.1% (absolute) efficiency deficiency per unit shall be payable to the Employer. If the prototypes' overall weighted average efficiency falls short by more than 4% (absolute and including the 1.5% tolerance) then the turbines become subject to rejection. 1.1.6.3 CAVITATION In the event of excessive cavitation the stipulations as per sub-clauses 1.0.5.3 and 1.0.7.2 shall apply. 1.1.6.4 PRESSURE RISE, SPEED RISE Pressure rise and speed rise shall be tested and carefully measured already during commissioning. If one of both parameters exceeds the guaranteed limit the governor shall be adjusted to keep the pressure rise in any case below the guaranteed limit.
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1.1.7 MODEL TESTS The guaranteed performance characteristics (discharge, output, efficiency, runaway speed, hydraulic axial thrust, guide vane torque, cavitation behaviour, pressure pulsations, air admission, etc.) of the turbine shall be determined basing on tests on a model turbine. The results of these tests shall serve as proof of the figures and data guaranteed for the prototype turbines. Field acceptance tests according to IEC-Publication 41 will be carried out after commissioning during the guarantee period. For efficiency tests the thermodynamic method will be applied. The following stipulations shall be understood as a requirement for acceptable completeness of the model tests carried out already in the past. The Tenderer shall provide sufficient information about the scale model of the turbine he proposes to furnish. The model tests shall have been conducted in according with the applicable provisions of the "International Code for Model Acceptance Tests of Hydraulic Turbines" (IEC - Publication 193), first supplement hereto (IEC - Publication 193 A, 1972) and modification No. 1 (of September 1977). The test model shall be essentially homologous to the prototype design in its hydraulic parts, including the spiral casing and draft tube, and shall include a sufficient length of water passages ahead of the spiral casing inlet and beyond the end of draft tube to assure flow distribution similar to that of the prototype. Design features affecting hydraulic thrust shall have been modeled as accurately as practicable, to permit prediction of prototypes' thrust loads. The minimum discharge diameter of the runner shall be 300 mm. All significant dimensions of the hydraulically effective parts of the model shall be accurately measured and recorded for use in checking the geometrical similarity of the prototypes, and the measurements shall have been witnessed by an independent engineer or institute.. 1.1.7.1 EFFICIENCY AND OUTPUT TESTS Scaling-up of the model efficiencies shall be by the following formula:
Whereby: m = maximum (optimum) efficiency measured on the model (in %) p = maximum (optimum) efficiency of the prototype turbine (in %) Dm = runner outlet diameter of the model Dp = runner outlet diameter of the prototype turbine All efficiencies of the model measured at other points than the maximum shall be scaledup proportionally.
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The power outputs of the turbines shall be calculated as follows:
Whereby: Hm = model test net head Hp = prototype net head m and p = as per the above 1.1.7.2 CAVITATION TESTS The cavitation performance of the turbine shall be ascertained and guaranteed. The Tender shall therefore be complemented by charts with = f ( ) showing distinctly o, s and 1 as defined in IEC. - Publication 193A. Such charts shall cover the prototype turbines' full net head range and be given for 100%, 85%, 70%, 50% and 40% of the turbines' respective full load. Plant sigma ( p ) for these operations shall be fixed at min. 1.1o or min. 1.7s (whichever is greater) and guaranteed as such. The charts shall be accompanied by distinct photograph of topmost quality showing formation and extent of cavitation at 1 , s , o and p under the conditions stipulated above.
The correctness of 1 , s , o and p as indicated and guaranteed respectively shall have been demonstrated under the specified conditions on the model turbine and test rig as used for the output and efficiency tests. 1.1.7.3 AIR ADMISSION TESTS Provisions shall have been included in the model turbine for determining the effects of compressed air admission and /or other means of suppressing draft tube pressure pulsations or of smoothing turbine operation.
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Measurements of the quantity of air, the resulting change in the amplitude of pulsations and the effect on turbine performance shall have been determined and recorded. 1.1.7.4 OTHER TESTS The model tests shall comprise also tests to verify the guarantees of maximum thrust and of maximum runaway speed, to determine the guide vane torque characteristics and other characteristics as may be found desirable to investigate. 1.1.7.5 MODEL TEST REPORT The Tenderer shall submit with the Tender a test report, which shall contain at least the following particulars: a) b) c) d) e) f) g) h) i) j) Copies of all summary data sheets and curves compiled during the tests Model performance curves Hill charts of the test results Hill charts of the prototype turbines (as calculated and scaled-up from the model test results) Cavitation test charts Air admission test charts Runaway test charts Hydraulic axial thrust test charts Guide vane torque test charts Tables and charts of all calibrations made on the testing equipment.
1.2 RUNNER The runner shall be entirely of stainless steel G-X5 Cr Ni 134 (No. 1.4313) or equivalent. Testing and acceptance of the runner casting shall be done according to standard CCH 70 2. Samples of the material shall subject to impact strength testing by the Charpy V-notch method (at 0 C) whereby a minimum impact strength of 5 mkp/cm shall be obtained on each of three (3) samples. The casting shall be furnished by a foundry having the necessary skill, experience and capacity for this type and size of work. A reference list for the foundries proposed will be submitted with the Tender and before awarding of the subcontract by the Contractor to the foundry. This is subject to approval by the Engineer. The runner shall be free from internal stresses and casting imperfections. All surfaces of the runner exposed to the water flow shall be carefully machined and finished smooth to templates. There shall be no hollows, depressions, waviness, projections and/or other surface imperfections that might lead to local disturbances, erosion and/or cavitation. The runner inlet and outlet edges shall be properly shaped and finish-machined in accordance with the actual dimensions of the tested model runner.
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Both, the upper and lower rotating labyrinth and wearing rings respectively shall be either integrally cast - on or securely fixed independent ones. In the latter case material G-X 22 Cr Ni 17 (No. 1.4059) shall be used. In order to prevent galling or pick-up in case of contact the hardness of these rings shall differ by at least 50 Brinell points from that of the stationary labyrinth and wearing rings (see item 1.5.4). The design of the rings shall enable safe anchoring and easy and expeditious renewal or replacement. This design principle shall be applied also for the flange connection for coupling the runner to the lower coupling flange of the turbine shaft. Coupling bolts and boltholes shall be designed so as to warrant perfect interchangeability of the runner and safe transmission of the torque under all operating conditions. A removable cast or fabricated steel hood shall be provided to ensure proper and smooth guiding of the water leaving the runner. The runner shall be capable of supporting its weight, together with the weight of the lower turbine shaft and intermediate shaft when the assembly is uncoupled from the generator and lowered to rest on the bottom ring. Dismantling of the runner (for major repairs or reconditioning) shall be possible upwards as well as downwards. An appropriate design shall be provided. For the finish-machined runner and its inspection and testing the stipulations as per CCH 70-2 (Cahier des Charges de Reception des Pieces en Acier Moule pour Machines Hydrauliques) shall apply. Surface quality classes shall be as indicated in the enclosed sheet "Surface Quality of Finish-Machined Runners The finish-machined runner with its labyrinth and wearing rings fixed shall be subject to static balancing in the manufacturer's shops. As an alternative to the supply of runner and rotating labyrinth rings in solid stainless steel, these parts, and any other affected components in other sections of this specification shall be tendered also with a wear-resistant coating or overlay. The Tenderers are strongly encouraged to review the operating conditions in which the turbine and other components exposed to water-borne sand, sediment and silt will be required to perform, and to examine the extent and nature of the water-borne particles and their potential to cause abrasion to the components. Tenderers are expected to be able to propose systems to extend the maintenance and operating period life of the various components involved by applying to these parts either a single or a combination of factory applied coatings or overlays, such as ceramic material, or other similar hard or other sacrificial or ablative material. In order to support the Tenderers proposals for such coatings, the Tenderer must provide evidence satisfactory to the Engineer and the Employer that the application of such coatings or overlays: Is proven in long term use (in use for a period exceeding 5 years, and supported by references from the plant operating agency where such coatings or overlays are utilised)
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Can be repaired or replaced in the field without special equipment Can be replaced or repaired economically Provides an efficient cost benefit over uncoated components in the long term for the expected use protocols of MMHEP Is suitable and appropriate for the water quality and silt/sediment/sand content of the expected turbined water at MMHEP SHAFT
1.3
The shaft shall be of forged, open-hearth or electric furnace carbon steel, dimensioned to operate at any load and any speed up to and including the maximum continuous runaway speed without undue vibrations and/or distortions. The material shall be free from injurious flaws and/or other imperfections. The shaft shall be perfectly round and machined accurately all over and polished on the sliding face in the guide bearing. Two (2) concentrically true, polished surface bands of sufficient width for dial-type eccentricity indication shall be provided on the shaft. These bands shall be conveniently accessible and located immediately above the guide bearing and below the upper coupling flange to the generator respectively. Permanent marks for dial indicator readings shall be provided and located 90 apart. The USAS - Standard B 49.1 - 1967 ("Integrally Forged Flange Type Shaft Couplings for Hydroelectric Units") shall apply to the shaft flanges. The shaft shall be designed and machined for matching the shaft seal specified in Clause 1.3. All rotating parts of the shaft seal fixed on the shaft shall be removable and renewable and shall be fastened securely to the shaft. Effective means shall be adopted to prevent corrosion of the shaft underneath such parts. The permissible run-out tolerances shall not exceed 50 percent at those recommended in the latest edition and/or revision of the NEMA - Standards for "Vertical Hydraulic Turbine Generator Shaft Tolerances" or equivalent other standard. Accuracy of the finished shaft shall be measured by rotating the shaft and recording the trueness of the important faces and journals. All coupling bolts, bolt bushings, nuts, locks, etc. for the upper and lower shaft coupling shall be supplied with the turbine shaft. A concentric axial bore throughout the entire length of the shaft, not less than 150 mm in diameter, finished smooth, shall permit visual inspection (boroscopic examination) of the shaft center.
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Design of the shaft assembly for the complete set (turbine and generator) shall be done jointly by the turbine and generator manufacturer. They will be jointly responsible for the calculation of the first critical speed. Both manufacturers will be held responsible for the correctness of the shaft lengths and coupling flange fit. A works run-out test of the complete shaft line (generator and turbine shaft) shall be performed. Drilling of the coupling bores in the turbine shafts' upper coupling flange and lower generator coupling flange shall be performed commonly in the generator manufacturer's shops. Fitting and alignment of the combined turbine and generator shaft at site shall be performed under the direction of the erection superintendent of the generator manufacturer who will also bear the responsibility for the final alignment. Balancing of the combined generator/turbine rotor shall be performed according to ISO 1940/1 and shall be satisfactory at both rated speed and overspeed. 1.4 SHAFT SEAL The shaft seal shall be mounted on the head cover and shall be designed so that sealing elements can be inspected, adjusted or replaced without dismantling of the guide bearing. The seal shall be of the axial sealing face type (Trist-type or equivalent) with filtered fresh water lubrication (available at a pressure of 4 bar). The supply shall comprise the split seal housing, the rotating seal ring, the stationary seal plate, remote wear indicator and a stainless steel shaft-protecting sleeve. All metallic parts in contact with water shall be rustproof and resist also wear and tear. The shaft seal shall be complemented by a static revision seal enabling maintenance or replacement of the shaft seal components during standstill of the unit without dewatering the turbine. Sealing shall be effected between inflatable or press-on type rubber ring and the shaft protecting sleeve. The following shall form part of the shaft seal supply (per turbine): - the sealing water feeder line tapped at the unit's main cooling water supply line, including one front and one end isolating valve, one duplex-type fine filter (if required), one flow relay (with alarm contacts) one manostat and one check valve - one pressure tap for remote pressure indication on the turbine instruments cubicle - all other water piping as required for the possibly hydraulic revision seal mechanism.
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1.5
GUIDE BEARING
1.5.1 REQUIREMENTS The turbine guide bearing shall be located above the shaft seal and completely selflubricating. It shall be of ample size and located as near to the runner as possible and capable of operating at all speeds up to and including the maximum runaway speed without injury or loss of oil. The guide bearings shall also be guaranteed for correct and safe functioning during start-up and shutdown of the machine set, even without generator brakes (normally application of the brakes will be taking place at about 20% of the rated speed). The bearing arrangement shall be so as to allow vertical movement of the runner and shaft of an amount required for adjustment and dismantling of the thrust bearing, and of an amount sufficient for clearing and separating the turbine and generator shafts. Corresponding arrangements shall be made between the turbine and generator manufacturers. The bearing design shall be such that no water can enter the lubrication system through leakage or condensation, and there shall be no appreciable loss of oil by leakage, evaporation or overflow from any part of the oil system. Further, the design will be such that maintenance of the shaft seal shall be ensured without the need of dismantling the bearing. 1.5.2 TYPE AND DESIGN The bearing shall be of the adjustable multi-segment type with spherical segment rests. The babitt-metal lining shall be 3 - 4 mm in thickness (after machining) and anchored firmly in the bearing segments. A complete and positive bonding with the base metal has to be guaranteed and proved by non-destructive testing. The active surfaces of the lining shall be machined with utmost care and fit the shaft with an accuracy to exclude any vibrations. Lifting eyes and backing-out screws shall be provided for use in removing and installing the bearing segments. The bearing housing shall be split vertically and to a degree enabling easy dismantling of the bearing segments. When assembled it shall be dowelled securely and supported firmly on the respective structure provided at the head cover. The oil reservoir shall be subdivided in accordance with the requirements for expeditious and easy maintenance and dismantling. All parts shall be securely fixed to each other. Perfect oil sealing shall be provided at the partitions and attachments. The major portion of the bearing shall be immersed continuously in the oil to provide initial lubrication when starting and stopping the unit. All circulating devices, strainers, sight level gauges and other accessories shall be provided, including a reservoir cover with an opening (with cover) for visual inspection. Connections shall be provided at the oil reservoir to permit oil purification in place. The respective unions shall be of an approved type to match the hoses of the oil purifier.
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Filling connections with strainers and a drain connection (with hand-valve) shall also be provided. The lubricating system shall be equipped with heat exchangers or cooling coils of copper or of another approved material. These exchangers or coils, including the cooling water supply and discharge connections, shall be designed for a pressure of 6 bars. The same make and grade of oil shall be used in the turbine and generator guide bearings, thrust bearing and turbine governing system. Preferred will be an oil corresponding with ISO VG DIN 51519 with a viscosity of approx. 68 mm /s at 40 C. The rinsing oil and first oil filling shall be included in the bearing supply. 1.5.3 TEMPERATURE / GUARANTEES The temperature in the bearing metal shall be restricted to 65 oC under any operating condition within the turbines' entire head range. This limit figure shall be guaranteed and understood at the segments' hottest point just underneath the babbit-metal lining and for new labyrinth and wearing rings. In the event of this temperature being exceeded during the Defects Liability Period the final acceptance of the respective turbine shall be withheld until this deficiency is remedied. The Tenderer shall also guarantee that the guide bearings will be capable to operate without damage: continuously at any speed from 85% to 110% rated speed at no load condition for 15 minutes at any speed between the rated and maximum runaway speed for not less than 15 minutes at rated speed and full load without cooling water supply.
1.5.4 INSTRUMENTATION The following shall be included in the supply (per bearing):
- three (3) thermostats installed in three individual bearing segments (set 120 apart) just
below the bearing surface, with individually adjustable double-contacts for alarm and tripping one (1) thermostat immersed in the bearing oil, with individually adjustable double contacts for alarm and tripping two (2) resistance-type temperature sensing elements installed in two opposite bearing segments just below the bearing surface, for remote temperature indication (on the turbine instruments cubicle) one (1) resistance-type temperature sensing element immersed in the bearing oil, for remote temperature indication (on the turbine instruments cubicle) one (1) thermometer for local indication of the temperature in the bearing segments one (1) thermometer for local indication of the bearing oil temperature one (1) oil level switch with adjustable double-contacts for alarm and tripping at low oil levels
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- one (1) cooling water flow relay (in the heat exchanger's discharge line), with contact
for alarm. Note: Resistance - type temperature sensing elements shall be Pt 100 and comply with DIN-Standard 4367. 1.6 DISTRIBUTOR The distributor includes all fixed and adjustable turbine components required for guiding and controlling the water flow between the stay ring and the runner. The general layout and design of the distributor shall be in accordance with the following criteria in order to minimize idle time of the turbine due to maintenance: - The assembly of head cover with mounted wicket gates and gate levers shall be interchangeable as one piece without dismantling the regulating ring and servomotor - For removal of the head cover with wicket gates it shall be possible to lower the runner with shaft after removal of the draft tube cone. - The regulating ring shall be arranged outside the wicket gate pitch circle. Only one servomotor shall be provided and arranged as shown in dwgs. in Volume D. - The bottom ring shall be removable downwards - The shaft seal shall be well accessible for inspection and replacement of wearing parts without disassembling parts of the wicket gates regulating mechanism or guide bearing. Alternatively to the supply of the wicket gates, facing plates and stationary labyrinth rings in solid stainless steel these parts shall be tendered also with wear-resistant coating or overlay. 1.6.1 HEAD COVER The head cover shall be of welded steel plate construction and furnished to site sectionalized if required by shipping and transport limitations. Nevertheless, supply as one unsplit piece is preferred. All welds employed (whether executed in the works or at site) shall be of the full penetration type, and there shall be a thorough stress-relief of the cover after welding. The head cover shall be flanged for bolting to the stay ring and for support of the regulating ring, the guide bearing and shaft seal. There shall be no distortions or undue deflections under any operating condition, and the whole structure shall be perfectly watertight. All axial and radial forces shall be distributed evenly over the cover and transmitted safely over the stay ring to the foundations. The portion of the head cover outside of the wicket gate pitch circle shall be designed for a pressure of 16 bar. The portion between the guide vane circle and the runner seals shall be designed for not less than 70 percent of that pressure and the portion inside of the runner seals shall be designed for not less than the pressure due to tailwater level at its probable maximum elevation. The underside of the head cover shall be designed to minimize hydraulic friction losses in the space above the runner. This space shall be adequately drained of leakage from the
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runner seals so as to relieve water pressure under the head covers and to minimize hydraulic thrust on the runners. Sufficient clearance for moving the runner axially shall be provided. The head cover shall have a radial clearance in the stay ring or other provisions to permit adjustment for precise centering. Any water collecting on the head cover shall be drained to the drainage gallery through one or two of the stay vanes, which shall be designed accordingly. The head cover shall be provided with bearing boxes for housing the upper wicket gate stem bearings and seals. The self lubricating bearings shall be bonded Teflon - fabric type or alloyed Teflon with backings of stainless steel or of another equivalent material approved by the Engineer. The head cover shall be equipped with the following: One set of wicket gate stops. The stops shall limit the angular movement of the wicket gates in the event of failure of the regulating linkage. Stops protruding into the water passages will not be accepted. The gate stops shall be protected by shock-absorbent pads. One set of evenly distributed air inlet openings with valves, acting at sudden load reductions or rejections. Such air admission can be also through the discharge ring, but no tripod - type air admission will be accepted. One gauge connection for remote indication (on the turbine instruments cubicle) of the pressure between cover and runner. Drainage of shaft seal water leaking by gravity to the stay ring.
BOTTOM RING
The bottom rings shall be of welded steel plate construction and furnished to site unsplit. All welds employed shall be of the full penetration type and there shall be a thorough stress-relief of the ring after welding. Fastening of the bottom ring to the stay ring shall be provided by bolted flange. There shall be no distortions or undue deflections under any operating condition and the whole structure shall be perfectly watertight. The bottom ring shall incorporate bearing boxes for housing the lower wicket gate stem bearings and seals. The self-lubricating bearings shall be bonded Teflon-fabric type or alloyed Teflon of high specific loading capacity or another equivalent material approved by the Engineer. 1.6.2 FACING PLATES Removable and renewable facing plates shall be provided on the head cover and bottom ring opposite to the faces of the wicket gates. They shall be sectionalized to facilitate handling and replacement. The facing plates shall be of X 10 Cr Ni 18 9 (No. 1.4541) and attached by corrosion resistant metal screws that shall be flush with the plates and suitably locked in place to prevent loosening during operation. The Brinell hardness of the facing plates shall be at least 50 points higher than the Brinell hardness of the wicket gates (see 1.5.5)
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The minimum thickness of the facing plates shall be 8 mm after machining. 1.6.3 LABYRINTH AND WEARING RINGS Both the head cover and bottom ring shall be provided with removable and renewable stainless steel labyrinth and wearing rings. They shall be located opposite to the rotating labyrinth and wearing rings and have sufficiently dissimilar characteristics (50 points higher Brinell hardness) so as to prevent galling or tearing of the metal in case of accidental rubbing. The rings shall be fixed securely in the head cover and bottom ring respectively, but afford easy and swift renewal or replacement. Adequate inspection openings or holes with watertight cover plates or plugs shall be provided to permit checking the radial clearances between the rotating and stationary labyrinth and wearing rings respectively in the upper and lower parts of the runner. There shall be four approximately equally spaced (90o ) such points around the labyrinth and wearing rings. 1.6.4 WICKET GATES The number of wicket gates shall be coordinated with that of the stay vanes and runner vanes to ensure a vibration-free operation of the turbine over their entire operating range (including up to 40% partial load). The wicket gates shall be cast or forged and made preferably of the same stainless steel as the runners (G-X5 Cr Ni 134, No. 1.4313). They shall be provided with integral stems, which shall be supported in three (3) bearings, provided with self-lubricating bushings. The Brinell hardness of the wicket gate material shall be at least 50% lower than the material of the facing plates (see 1.5.3) Both, the wicket gate blades and stems shall be designed and constructed to withhold the maximum dynamic pressure (gross head plus maximum pressure rise) with ample safety. Special attention shall be paid that the contact faces of neighbouring wicket gate contact each other firmly over their entire height in fully closed position of the operating mechanism to minimize leakage. The wicket gates shall therefore be accurately machined all over and have no casting defects, depressions or other irregularities. Interchangeability of the wicket gates shall be ensured, and the upper and lower faces of the gate blades shall be machined to very narrow tolerances. The wicket gate material shall be subject to impact strength testing by the Charpy V-notch method (at 0 C) whereby a minimum impact strength of 5 m kp/cm shall be obtained on each of three (3) specimens. The upper stems shall be provided with renewable thrust faces to take up upward and downward thrust in order to admit adjustment at the upper and lower gap clearance
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between wicket gates and facing plates of head cover and bottom ring. Convenient means shall be provided for readily adjusting and maintaining these gap clearances. The stems shall be finished finely in accordance with the requirements for the bearing material. Seals of approved design shall be arranged around the stems in the head cover and bottom ring. 1.6.5 REGULATING GEAR The regulating gear (gate levers and links), together with the gate regulating ring and servomotor, has to be of ample strength to withstand the maximum loads occurring under the most severe operating conditions. The whole shall be designed and constructed so as to ensure a smooth and safe turbine regulation over its entire operating range without hunting and undue deflections of the mechanism. With the exception of the wicket gates, all parts shall be mounted outside of the water passages and designed so that the shaft seal and guide bearing can be dismantled without disassembly of the regulating mechanism. Each wicket gate shall be provided with easily replaceable and/or adjustable safety devices avoiding damage of the gate stem in case that any foreign matter is jammed between two adjacent wicket gates. The safety devices shall in any case incorporate a friction device on each gate stem or lever in order to avoid a cascade failure of several wicket gates. 1.6.6 GATE REGULATING RING The regulating ring shall be designed and dimensioned so that all wicket gates show simultaneous and identical opening at all positions. It shall be of most sturdy and rigid design, centered accurately and be free from tilting or gripping. Welded construction shall be used, and all welds shall be properly stress-relieved. Guiding of the regulating ring shall be in Teflon-lined guides shielded against water and dirt. In order to give convenient access to the guide bearing and shaft seal without disassembly of the regulating mechanism, the regulating ring has to be arranged outside the wicket gate pitch circle. The structure supporting the regulating ring shall be of adequate strength and stiffness to prevent excessive deflections of the structure or other parts because the gate-operating ring is subjected to unbalanced thrust of one servomotor. The gate-operating ring shall be designed to receive the gate servomotor connecting rod and pin at maximum radius. The point of engagement of the servomotor piston rod with the regulating ring shall be provided with self-lubricating bushing and stainless steel pin. Transmission of the servomotor force to the regulating ring shall be provided by a flange segment in order to minimize local deflection of the regulating ring. 1.6.7 GATE SERVOMOTOR The turbine shall be equipped with one oil pressure operated double-acting servomotor. The servomotor shall be located in a recess in the turbine pit and mounted on machined surfaces embedded in the concrete. The oil for operating the servomotor shall be from the
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turbine governor oil system, and the servomotor components shall be designed for the maximum governor oil pressure. The servomotor shall have a capacity sufficient to operate the wicket gates under all conditions of head and load, and to move the gates throughout the full opening or closing stroke, with oil supplied in sufficient quantity at a minimum pressure differential at the servomotor piston corresponding to the minimum operating pressure in the governor air/oil pressure receiver. The servomotor cylinder and cylinder heads shall be made of steel and provided with flanged connections for the oil piping and with rod packing boxes or seals to prevent leakage of oil along the piston rod. The servomotor piston shall be of steel or nodular cast iron, and each piston end shall be fitted with the necessary number of piston rings to prevent leakage of oil past the piston. Suitable drain valves and piping shall be provided at convenient points for draining oil from each end of the servomotor cylinder and for bleeding entrapped air. Pressure gauge connections with stopcocks shall be provided at both ends of the cylinder. If deemed necessary by the Contractor to meet the stipulations regarding maximum permissible pressure rise as per sub-clause 1.0.4, an adjustable device for reaching stepped closing and retarding for the rate of guide vanes operation shall be provided. A mechanical locking device of the screw-type operated by a hand wheel, or similar means shall be provided on the servomotor, so that the wicket gates may be held securely in the open or closed position against maximum governor oil pressure. A scale with pointer affixed to the servomotor shall show the percentage of the gate opening. An automatic oil-operated locking mechanism shall be provided to hold the regulating gear in fully closed position whenever the turbine is shut down. It shall be designed to safely and positively hold the wicket gates closed against any accidental or involuntary opening tendency and mounted on the servomotors or on the regulating ring. It shall be of rugged construction and of sufficient size and strength to withstand any stresses up to those due to the maximum opening force of the servomotor. A limit-switch with two independent ungrounded contact circuits, arranged to close or open circuits as required when the locking device is released and fully withdrawn, shall be provided. A second limit-switch with two independent ungrounded contact circuits, arranged to close or open circuits as required when the locking device is fully engaged, shall be provided. The servomotor piston rod shall be of high-quality forged steel with integral heads. Oil pans shall be provided below the servomotor to receive possible leaked oil. The pans shall be designed and enclosed so that accumulation of dirt, insects and other foreign matters is excluded. For returning leakage oil to the governor oil tank a respective pipe and oil pump shall be provided.
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The supply of the regulating mechanism shall include also all necessary oil pressure piping, discharge piping, fittings, valving, feed-back devices, gaskets, packings, etc. 1.7 SPIRAL CASING The spiral casing shall be designed and constructed for a maximum operating pressure (including waterhammer) of 14 bar. The hydrostatic test pressure will be 21 bar. No support from the surrounding concrete shall be assumed. The interior of the spiral casing and stay ring will be free from dimensional irregularities, depressions, projections, etc. Welding seams will be ground off. All necessary stiffeners, pads or brackets for the application of jacks and tie-rods during site-erection shall be provided. These appendages, including the jacks and tie-rods themselves shall be designed to support and position the stay ring/spiral casing assembly during all conditions of installation and levelling, including the hydrostatic pressure test 1.7.1 STAYRING The stay ring shall be a welded steel plate construction or a combination of cast steel components and plate steel. In order to meet transport limitations, there may be a corresponding sub-division. Assembly at site may be either by flange connections with subsequent sealing by welding, or by a completely watertight weld assembly. One or two of the stay vanes have to be provided with an amply dimensioned hollow space for drainage of water leakage from the head cover (shaft seal, wicket gate stems) to the pump sump. The necessary number of pipes for concreting the spiral casing, and vent holes in the stay ring to facilitate placing concrete under same shall be provided. Closing of these holes after termination of the concreting work shall be through threaded and weld-sealed plugs. 1.7.2 SPIRAL CASING SHELLS The spiral casing shells shall be of welded steel plate construction and supplied in sections in order to meet transport limitations. All such sections shall be properly supported to prevent distortion during transportation, storage, fitting and welding. Joining of the spiral casing sections to each other, as well as to the stay ring shall be carried out at site by welding. All butt and tee pressure welds employed in the stay ring and spiral-casing shells shall be of the full penetration type. All attachments, flanges, facings, etc., subject to penstock pressure shall be for butt welds only. The circumferential joints between sections of the spiral casing plates shall be arranged so as not to coincide with any joint between stay ring sections. All shop-welds shall be stress-relieved thoroughly. The fit of the spiral casing and stay ring sections shall be checked and the sections properly match-marked at the manufacturer's works during a shop assembly. Preparation of the edges to be welded at site shall be completed in the manufacturer's works.
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1.7.3 INLET PIPE The cylindrical inlet pipe of approx. 3 m length shall be provided with a thrust ring, combined with the flange for connection of the turbine inlet valve. The thrust ring will transmit the hydraulic force of the closed turbine inlet valve to the concrete structure and will ensure the exact position of the spiral casing, jointly with the pit liner, under all operating conditions. The connection flange for the drain pipe (150 mm diam.) of the spiral casing shall be incorporated in the thrust ring. 1.7.4 MANHOLE A manhole of 600 mm diameter shall be provided on top of the spiral casing. The manhole cover shall be provided with a rubber seal of O-Ring type, corrosion resistant bolts, washers and backing-out screws. The portion of the spiral adjoining the manhole shall be reinforced without ribbing (block flange type). The cover interior shall conform to the interior of the spiral casing. 1.7.5 PIT LINER The conical portion of the circular pit below the spiral casing shall be provided with an adequately dimensioned steel liner, to serve as welded formwork for concreting as well as for rigid anchoring of the spiral casing in its position, acting jointly with the thrust ring at the inlet pipe. 1.7.6 COMPRESSIBLE WRAPPING The upper side of the spiral casing shall be provided with a compressible wrapping in order to minimize cracking of the concrete cover above the spiral. The wrapping shall cover at least the upper half of the spiral casing, except the inlet pipe at a length of 1.2 m upstream of the connection flange. The wrapping material shall be of high quality, proven for the purpose in similar installations. 1.7.7 AUXILIARY PIPING The following auxiliary piping, connections and tappings shall be provided:
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One 200 mm i.d. drainage connection at the lowest point of the spiral casing, with the corresponding drainage pipe extending up to the draft tube. The piping shall include a flanged hand-operated shut-off valve, a 25 mm diameter compressed air connection upstream of the valve and a sleeve-type coupling to facilitate removal of the valve for maintenance. One 200 mm i.d. bypass connection and piping between penstock upstream of the turbine inlet valve and spiral casing. The bypass line shall be provided with a manually operated guard valve of the gate type at the upstream connection and with an automatically operating control valve. The control valve shall be operated by oil pressure from the governor oil supply system.
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One automatic air bleeder valve arranged on top of the spiral casing near the bypass connection. One group of net head piezometer connections, consisting of four pressure taps on the inlet section of the spiral casing, located and arranged in accordance with the recommendations of the "International Code for the Field Acceptance Tests of Hydraulic Turbines" (lEC-Publication 41) for net head measurements and for connection to the spiral casing pressure gauge which will be mounted on the instruments cubicle. One group of four piezometer connections for measurement of the turbine discharge (differential pressure method according to Winter-Kennedy). Location shall be at points where conditions are most favourable for accurate flow measurement. The definite locations, type and construction of the piezometer tappings shall be in conformity with the respective standards.
1.8 DRAFT TUBE The draft tube shall be of the elbow type without center pier in the horizontal part. It shall be designed and dimensioned so as to yield the maximum energy recovery. The lowest point is at elevation 508.5 m a.s.l. 1.8.1 SUCTION CONE The suction cone forms the water passage between the runner outlet and the draft tube elbow. It shall be dismountable sideward in order to facilitate access to the lower part of the runner for inspection, repair and replacement. The upper part of the suction cone forms the turbine discharge ring and is connected with the lower cone by bolted flanges. The cone angle and length shall be such that growth of the cavitation vortex and pressure pulsations are minimised. Demonstration of these requirements shall be included when performing the cavitation tests on the model turbine. The stainless steel discharge ring shall have a length of at least 1000 mm and a thickness of not less than 30 mm. Alternatively the discharge ring may be stainless steel clad (minimum thickness of the cladding 6 mm). The remainder of the cone shall be of welded steel plate and have a minimum thickness of 20 mm. Connection of the lower end of the cone to the elbow steel liner shall be provided with a telescopic flange joint. The inner surface of the cone shall be smooth and have no abrupt changes in direction. Welding seams will be ground off. The outside of the cone shall be adequately ribbed and provided with four brackets at the lower part for attachment of wheels for removal of the cone. A manhole with a net diameter of 700 mm with hinged outward-opening cover, with handles, stainless steel hinge pins and corrosion-resistant bolts, washers, backing-out screws and rubber seal of O-ring type shall be provided. The door's interior shall be absolutely flush with the cone interior.
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A second circular opening of 250 mm i.d. with flush-mounted cover shall be provided opposite of the manhole to facilitate introduction of fresh air, cables and hoses in case of repair work to be done inside the cone. A platform (common for both turbines) shall be provided to facilitate inspection and maintenance of the runner. This platform shall be designed for quick and easy erection through the manhole. Its main cross members shall be supported in suitable pockets in the liner. Covers shall be provided for the pockets when not in use so that a smooth passage is presented to the water. The Contractor shall demonstrate to the satisfaction of the Engineer the erection of the platform in the suction cone of the first turbine to be installed. The cone's upper part shall be provided with a stainless steel or bronze pressure tap for remote pressure / vacuum indication on the turbine instruments cubicle. 1.8.2 ELBOW LINING The draft tube elbow shall be steel-plate lined (minimum thickness 12 mm in the embedded part, 20 mm in the upper circular part below the flange) and extend approx. 4 m downstream from the turbine axis, depending on the design and shape of the elbow. Connection of the elbow lining to the suction cone shall be through telescopic flange. The whole liner structure shall be heavily ribbed and reinforced externally and provided with an ample number of anchor straps for securing it to the surrounding concrete. The elbow liner shall be designed against full outside hydraulic pressure corresponding to the probable maximum flood level (530 m a.s.l.) and atmospheric pressure on the inside. The elbow's interior shall be smooth and free from any abrupt changes in direction. The supply shall include all levelling screws, holding-down bolts with turnbuckles, etc., as required for centering, levelling and securely maintaining the lining aligned during embedding. Threaded grout and vent holes shall also be provided for pipe connections as required for grouting behind the liner. After grouting the holes shall be closed by threaded plugs and weld-sealed. Each elbow liner shall be provided at and near its lowermost bottom point laterally with two appropriate drainage connections. These shall consist of a metal clad water collecting duct (with removable flush mounted vertical grating) and 200 mm i.d. heavily inside and outside galvanized unwatering pipes extending up to the unwatering sump. The unwatering pipes shall be equipped with hand-operated isolating valves (with prolonged stem and hand-wheel for operation from the valve floor, elevation 513.20 m a.s.l.) and a valved compressed air connection (for cleaning-off purposes). 1.9 AIR ADMISSION If previous experiences of the Contractor or the turbine model tests show that at particular heads or partial loads air has to be admitted between guide vanes and runner, or below the runner to ensure smooth and vibration-and pulsation-free operation at such heads and/or loads a corresponding system shall be supplied for each turbine.
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The air admission system arrangement shall be for quick automatic opening of an air admission control valve, either cam-operated through an adjustable connection to the wicket gates regulating mechanism or through other appropriate means. It is left to the Contractor's discretion to provide either a fully independent compressed air system (per unit) or to provide a supply system tapping air from the atmosphere at an elevation above probable maximum flood level (530.0 m a.s.l.). In case of compressed air being required the necessary compressed air unit (including the ac-drive, common base plate, coupling guard, coolers, filter, check-valve, unloader valve, manostat, pressure gauge, piping and all controls) shall be supplied. All parts and pipes of the air admission system exposed to water shall be of stainless steel. The main compressed air feeder line shall be equipped with a drip-proof check valve to prevent reverse flow. An isolating valve in the feeder line shall permit inspection or removal of the check valve without unwatering the turbine. Even though the contractors previous experience and/or the model tests have not indicated the necessity of an air admission system, all provisions shall be made already in the turbine for future connection or installation of an air admission system in case it proves to be required by operating experience under certain load conditions. These provisions shall include properly dimensioned vent holes, closed by threaded plugs or blind flange covers, arranged and distributed in such a way that future installation of the air admission system is possible for central air admission through the runner cone as well as for circumferential air admission through the discharge ring without machining any part of the turbine. 1.10 WALKWAYS, PLATFORMS, RAILINGS The turbine shall be provided with walkways and platforms complete with non-slip type floor plates or gratings. Stairs, ladders and hand railings shall be furnished where necessary or desirable to provide convenient and safe access to all operating equipment. All pit walkways, platforms, stairways and similar equipment shall be easily removable, as necessary for dismantling the turbine. Individual floor plate sections shall be not heavier than 25 kgs. The railings shall be of the pin-connected, flush-joint type, not less than 800 mm high and have a diameter of approx. 30 mm and be provided with machined fittings to provide rigid connections. It may be also of rigid construction made of welded tubing with all welds ground smoothly. All such equipment shall be easily removable for dismantling of the turbine. 1.30 CONTROL AND PROTECTION DEVICES The instruments, alarms and protection devices listed below shall be considered as those required as a minimum for each turbine. If further items are proved useful or deemed necessary by the Contractor they shall be provided.
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1.30.1 INSTRUMENTS The following instruments and indicators shall be provided with transmitters, which shall transmit the measurements to the control room. The make and dial shading shall be coordinated with the supplier of the instruments and indicators in the control room
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One (1) pressure gauge for the pressure at the spiral casing inlet (in bar ) One (1) pressure/vacuum gauge for the pressure in the draft tube cone (in bar ) One (1) pressure gauge for the pressure underneath the head cover (in bar ) One (1) pressure gauge for the shaft sealing water (in bar ) One (1) pressure gauge for the governor oil pressure (in bar ) One (1) speed indicator (in rpm) One (1) creep detector (standstill detector) of the turbine shaft One (1) turbine inlet valve position indicator Two (2) thermometers for the temperature in the guide bearing segments (in C) One (1) thermometer for the temperature of the guide bearing oil (in C) One (1) thermometer for the temperature of the governor oil in the governor oil tank (in C) One (1) thermometer for the shaft seal with alarm and tripping contacts One (1) turbine discharge meter
The turbine discharge meter shall - in connection with the piezometer tappings stipulated under sub-clause 1.6.7 - indicate and record (in m/s) the discharge through the turbine. The accuracy of the discharge indication shall be within 2-2.5%. The supply shall include all necessary stainless steel piping (with Ermeto - type or equivalent couplings), the high precision pressure differential apparatus, the necessary electric transmitters (transducers), the respective receivers in the control room, as well as the indicators and recorders. Means shall be provided to protect the transmitters from silt and dirt. The supply shall be complemented by all fasteners, tools and other equipment for proper maintenance of the installations. 1.30.2 ALARMS The following alarms shall be signalled:
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excessive guide bearing segments temperature (from 2 segments) excessive high guide bearing oil temperature excessive governor oil temperature low level and high level in guide bearing oil reservoir turbine inlet valve closing involuntarily air admission unit (if required) failing to operate governor oil pump failing (switching over to standby governor oil pump) too low oil pressure supplied too low pressure in oil pressure accumulator too low level in governor oil tank cooling water supply to cooler of governor oil failing (through flow relay) cooling water supply to cooler of guide bearing oil failing (through flow relay)
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lubricating water to shaft seal failing (through flow relay) pressure of lubricating water to shaft seal failing (through manostat) inundation in draft tube access passage (through float switch) draft tube stop log not in open position
One float switch shall be installed in each of the two draft tube access passages and located as near as possible to the draft tube cone. It shall be arranged in a screen-protected recess some 100 mm above the passage floor. In case of heavy leakage from the manhole and resulting inundation of the access passage the switch shall initiate alarm and trip the generating unit concerned. 1.30.3 CABINETS Above instruments, indicators and alarm annunciaters shall be installed in one or - if more convenient in a maximum of two cabinets on the turbine floor adjacent to the governor cabinet or unit control board. They shall be of the sheet-metal type and comply with requirements of the Technical Provisions of the present Tender Documents. External wiring will be performed by others. The design, dimensions and shade of the cabinets shall be coordinated with that of the cabinets supplied by others. 1.40 HOIST EQUIPMENT In order to minimize idle time of the turbines due to repair or replacement of parts, special facilities have to be provided for lifting and transport procedures of heavy loads as follows: For transporting the assembly of head cover and wicket gates or the turbine shaft a special bridge crane shall be provided to be used for both turbines. The travelling and hoisting mechanism of the crane shall be operated manually. This crane will be used also for separately lifting and transporting the regulating ring or the servomotor. Due to these duties the lifting capacity of the crane may be considerably lower than the travelling capacity. The crane bridge of special design shall be supported by rails or steel beams arranged on each side of the passage from the central unloading shaft to the turbine pit. The crane bridge shall be U-shaped in order to allow positioning of the crane bridge below the center of the turbine / generator unit. After positioning a cross beam shall be bolted to both free ends of the U-frame, converting it to a rigid closed square structure, able to support two or more hoist mechanisms or turnbuckles at different points of the structure. For extension of the rails outside the passage ducts two detachable end pieces with supporting steel columns at the ends shall be provided. They shall be set and removed by the powerhouse crane and shall be used for both turbines.
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For lowering the discharge ring, bottom ring and turbine shaft with runner (after removal of the draft tube cone) the powerhouse crane shall be used. For this purpose a special cable fed through the generator shaft bore (150 mm i.d.) shall be provided. This cable will be used also for lifting and lowering the head cover with assembled wicket gates with levers. 1.50 TOOLS AND MAINTENANCE DEVICES All tools, devices and equipment for proper handling, maintenance, assembly, erection and disassembly of any part of the turbines shall be supplied with the first turbine. All such tools, devices and equipment shall be stamped or marked for identification. The supply shall comprise the following tools and equipment, and the following list is to be considered as a minimum and, as necessary, to be complemented by additional tools and equipment:
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one (1) set of case - hardened wrenches, spanners, screw drivers and the like mounted on a lockable board or cabinet one (1) set of lifting slings one (1) set of all lifting eyebolts, shackles, jacks and other lifting devices required for the proper and safe lifting of major turbine parts by the powerhouse crane and the auxiliary crane specified under Clause 1.40 one (1) lifting bracket for attaching to the upper end of the lower turbine shaft, for lifting the assemblies of shaft, runner, head cover, wicket gates etc. one (1) lifting bracket for attaching to the intermediate shaft for lifting it with the special crane as specified under Clause 1.40 all special tools, devices and equipment that may be required or useful for the most expeditious assembly or dismantling of any part of the turbines one steel - made sturdy cart with pneumatic tires with a capacity of not less than 2 Mp and with steerable axle and handle one (1) movable platform (approx. 3 x 3 m) with 4 fixed wheels, supported on embedded steel rails, for transport of discharge ring, runner or bottom ring of the turbine through the access passage to the draft tube cone
An itemized list of these special tools, devices and equipment furnished shall be submitted with the Tender.
1.60 SPARE PARTS The following spare parts that comprise the total required for two turbines called for under this specification shall be furnished and their itemized cost entered in the price list:
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one (1) spare runner one (1) finish-machined assembled and readily mountable assembly of head cover and wicket gates with gate levers one (1) set of rotating and stationary labyrinth and wearing rings, finished and complete with their attachments
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one (1) finish-machined bottom ring with facing plates and bushings for the lower stem bearings of the wicket gates one (1) set of finish-machined guide vanes, including the bushings for the stem bearings two (2) split coupling bolt sleeves two (2) self-resetting safety link assemblies, with all elements for connection to the wicket gate stems and levers respectively two (2) complete sets of the active shaft seal elements if any one (1) set of the active revision seal elements two (2) shaft seal protecting sleeves, finished and with fixing elements two (2) sets of upper and lower facing plates, complete with their attachments one (1) set of finish-machined guide bearing segments two (2) complete sets of all packings, gaskets and jointing material used throughout the turbines, including those for the servomotors and for the draft tube manhole cover two (2) sets of servomotor piston seals one (1) instrument and indicator of each type used one (1) solenoid coil per solenoid used four (4) shaft seal water filter elements one (1) flow relay and manostat of each type used two (2) sets of all annunciator lamps two (2) cabinet lighting lamps one (1) thermostat of each type used one (1) resistance type temperature detector of each type used one (1) limit switch of each type used one (1) set of discharge meter parts and elements subject to wear and tear the necessary recording charts for 3 years operation ten (10) percent of all bolts, screws, nuts and washers
1.70 SHOP ASSEMBLY AND TESTS Before leaving the shops each turbine and its associated equipment shall be subject to shop assembly and a number of shop tests. 1.70.1 SHOP ASSEMBLY Each turbine shall be assembled or sub assembled in the shop to verify the design, construction and machining for proper alignment, fits and clearances. Parts shall be properly match-marked, identified, and doweled to ensure correct assembly and alignment at site, except that, where necessary, suitable dowels shall be furnished for insertion after site-assembly and drilling. The draft tube elbow liner shall be assembled and match-marked at precisely established points to ensure easy and accurate reassembly in the powerhouse. The spiral casing with stay ring shall be assembled together and shall be included in the shop assembly of the turbine.
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1.70.2 SHOP TESTS Further to the tests and checks specified in the Technical Provisions the following tests, checks, examinations, inspections, etc. shall be carried out in the manufacturer's shops, whereby -if required - further tests, checks, examinations and inspections, or repetition of same shall be at the discretion of the Engineer. Tests on unfinished and semi-finished components
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Magnaflux inspection and ultrasonic examination of the rough machined runners Magnaflux inspection and ultrasonic examination of the rough machined wicket gates and stems Hardness tests on facing plates, stationary and rotating labyrinth and wearing rings Ultrasonic examination of the rough machined shafts and boroscopic examination of the shaft centre Ultrasonic examination of the rough machined coupling bolts Ultrasonic examination of the rough machined servomotor piston rod 100% ultrasonic testing of all welds of stay ring, spiral casing, head cover, bottom ring, draft tube suction cone and elbow liner Radiographic inspection of all cross points of welds and of zones and transitions not accessible to ultrasonic examination and of all welds showing doubtful ultrasonic indications
Tests on finished components and assemblies Dye-checking and ultrasonic examination of the finished runners, and visual inspection Static balancing of the finished runner (VDI 2060, quality Q 5 or better) Dye-checking and ultrasonic examination of the finished shafts Dye-checking and ultrasonic examination of the finished wicket gates stems and piston rod heads Dimensional checks on runners, wicket gates, discharge rings, labyrinth and wearing rings, servomotor stroke and other important parts Ultrasonic examination of Babbitt-metal adherence Inspection of roughness and evenness of Babbitt-metal lining on guide bearing segments Radiographic inspection of the servomotor cylinder Check of the fit of runner and shaft coupling flanges and control of alignment with respect to axis of rotation Hydrostatic pressure testing of the assembled servomotor (with 1.5 times the maximum operating pressure) for a period of 60 minutes Hydrostatic pressure testing of the guide bearing coolers (at 6 bars) Performance tests on the air admission compressors (if any) Check of surface protection and painting
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All shop assemblies and tests / checks, examinations, inspections, etc. will be witnessed by the Engineer. The Contractor shall submit the time schedule for the tests sufficiently in advance. 1.80 SITE TESTS The following tests, checks, inspections, etc. shall be carried out at site. If deemed necessary by the Engineer they are to be complemented by additional tests, checks, controls, etc. to verify the design, construction, functioning and behaviour of the equipment. Hydrostatic pressure testing of the spiral casing and stay ring assemblies, incl. inlet extension and if possible turbine inlet valve: for 2 hours at a pressure of 25 bars for 1 hour at a pressure of 16 bars for 1 hour at a pressure of again 25 bars
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Ultrasonic examination of all site-welds, except cross-points that shall be subject to radiographic examination. Ultrasonically examined welds showing doubtful indications shall be rechecked radiographically. Tightness tests on all pressure oil and water piping Functional tests on all turbine equipment (in connection with governor equipment) Start-up and load rejection tests (in connection with the governor equipment) Runaway tests during 2 minutes Trial runs at different loads.
1.90 PARTICULAR TENDER DOCUMENTS Further to the particulars called for in the foregoing clauses and sub-clauses the Tenderer shall furnish with its bid the following additional documents:
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Detailed turbine outline drawings in scale, comprising plan view, longitudinal and transverse sections and showing the complete turbine including the entire draft tube and shaft up to the connection with the generator shaft, etc. All main dimensions and elevations shall be indicated in these drawings. A condensed description of the equipment proposed, including mentioning of possible outstanding design features envisaged. A comprehensive governing stability analysis of the units, with the data and characteristics of the upstream waterways according to the dimensions shown in the drawings. Individual charts for 90, 93, 95, 98, 100 and 105 m net head respectively showing efficiencies and discharges versus output, whereby the latter shall be from 105% to 30%. Speed /no load discharges for 90, 93, 95, 98, 100 and 105 m net head respectively. A chart showing the maximum continuous runaway speed for 120 - 80 m-net head. Cavitation charts for net heads of 120 - 80 m and outputs of 105 - 30%, whereby o, s and 1 as defined in lEC-Publication 193 A shall be clearly shown. Reference lists and drawings of output - and size -wise comparable turbines with their main data, including date of commissioning.
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6395102 120291197.doc
An as detailed as possible construction schedule showing separately for each turbine the design, manufacturing, transportation, erection and commissioning periods (in calendar weeks)
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FICHTNER JV
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Turbine

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NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

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100 Design point for generator Pt = 35,9 MW

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NEA Middle Marsyangdi HEP

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The power outputs of the turbines shall be calculated as follows:

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NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

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NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

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NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

NEA Middle Marsyangdi HEP

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