Ide for Commissioning, Operation and Maintenance of Hydraulic Turbines_commission Electrotechnique Internationale_spln 20a_1978

7/30/2019 Ide for Commissioning, Operation and Maintenance of Hydraulic Turbines_commission Electrotechnique Internation

1/23

Publication45SPLN "ZD+i i;Ii

I:. tj

:\ \G MM SS 0 { E r G TR TEC f 0 UE | } t T E N A T I N A L E

(af f i l i6e '0rganisationnternationaleeNormalisat ionlS0)N ( I R M E E A C E I

I N T E R N A T I ( l N A LL E C T R ( l T E C H N I G A L( l M M I S S I ( l I {(aff i l iatedo the nternationalrganizationorStandardizationlS0)IECSTANDARD

Publication45Premidredit ion First d i t ion1 9 7 6

Guideoura 6ception,'exploitationt 'entretienesurbinesydrauliques

Guideorcommissioning,perationndmaintenancefhydraulicurbines

Droitse eproduction6servds Copyrightal l ightseservedBureauentrale a Commissionlectrotechniquenternationale

1, ue eVarembdOendve,uisse


2/23

R6visionde a pr6sentepublication Revisionof this publicationLe contenu echnique espublicationse a CEI est constam- The echnical ontent f IEC publicationss keprunder onsranlment evupa r a Commission fin d'assureru'il reflete ien 'etat review y the EC , thus ensuring hat he conrenr eflects urrentactuelde a technique. technology.Les enseignementselatifs ce ravailde rdvision, I'etablisse- Information n theworkof revision.he ssue irer sed ditionsmentdeseditions evisdest auxmises ou r peuventOtre btenus and amendment heetsma!' be obtained -ronr EC \ationalaupres esComites ationaux e aCEI et en consultantesdocu- Committees nd rom the follorving EC Sourir-imentsci-dessous:

O Bulletinde a CEI O IEC BulletinO Rapportd'activit6 e a CEI O Reporton IEC ActivitiesPublieannuellement Published earlvO Catalogue espublications e a CEI O Catalogue f IEC PublicationsPublieannuellement Published earlv

Terminologieutilis6edans a pr6sentepublication Terminologyused n this publicationSeuls ont definis ci es ermes peciaux e apportant la pr- Onlt'specialtermsequiredorthepurposeofhispublicarionrr.:sente ublication. defined eretn,En cequ iconcernea erminologie6nrale,e ecteur e eportera Fo rgeneralerminology,eaders re eferredo I E C PublicariondlaPublication 0 de aCEI: Vocabulaire lectrotechniquenter- 50: International lectrotechnicalocabulary I.E.V.),uhich isnationalV.E.l.), uies tetablie ous ormedechapitres6par6srai- issuedn the form of separatehapters ach ealing it h a specifictant chacun 'un sujetdefini, ' lndexgnral tantpubliesepare- field, he Generalndexbeingpublished sa separateooklet. ul lment.Desdetails omplets ur e V.E.l. peuvent treobtenus ur details f the I.E.V.will be supplied n request.demande.

Symboles raphiqueset litt6raux Graphicaland letter symbolsSeuls es symboles raphiquest litt6raux peciaux ont nclus Only special raphical nd etter symbolsare ncluded n thisdans a prdsente ublication. publication.Le recueil ompletdes sy'mbolesraphiques pprouves ar la The complete eries f graphical ymbols pproved y the IECCEI fait 'objet e a Publicationl7 de a CEI. is given n IEC Publication17 .Les ymbolesitteraux tautres ignes pprouvsar aCE font Letter symbolsand other si gns approved y' the I E C areI'objet e a Publicatio .n2Te a CEI. containedn IEC Publ icat ion7.

.i

Autrespublications e a CEI etablies ar e m6me Other IEC publications prepared bt the sameComit6d'Etudes TechnicalCommitteeL'attent iondulecteurestatt i rdesurlapage3delacouverture,qui Th e attent ionof readerss drawn ro the insideof rh e backcover.

enumdre lesaut respub l ica t ionsde laCEl reparespar leComi t which l i s t s o the r IEC publ ica t ions ssued b l ' the Techn ica ld'Etudes qu i a etabli la presentepublication. Committee which has prepared he presenrpublication.


3/23

C.D. U. U. D. G. 621224.00141 42.W4.1.004.2.004.5(083.85)

c 0M | | s s 01 {E r c TR0TEc H1 {0uE I { T E 1 { A T l1 { A L E(affili6e '0rganisationnternationaleeNormalisation180)

N( IRMElE LA CEI

I } I T E R N A T I ( l I I A LT E C T R ( l T E C H I I I C A L( l M M I S S I t l N(affiliatedo the Internationalrganizationor StandardizationlS0)

I E CS T A I { D A R D

Publication45Premidredition First dition1 9 7 6

SPIIV- "2o4 t

Guideoura 6cepti0n,'exploitationt 'entretienesurbinesydrauliques

Guideorcommissioning,perationndmaintenancefhydraulicurbines

p i i r ! " i l " l ! I t t NPt fS{T Pf Y r . l i t . ' : i l i l l l ,A r * ! f K-L l$Tf , ( l93359 DECg?7

Droitse eproduction6serv6sCopyrightll ightseservedAucune artie e cette ubticatione peuttre eproduitei utilis6e ous No part of this publication ay be reproducedr utilizedn anyquelqueormcque ce soit et par aucun roc6d6,lectroniqueu m6ca- formor byanymeans, lectronicr mechanical,ncludinghotocopyingnlque,comprisaphotocopiet esmicrotilms,ans 'accordcrit e '6diteur. and microfilm, ithout ermissionn wrlling rom he publisher.

Bureau entrale a Commissionlectrotechniquenternationale1, ue eVaremb60endve,uisse

FilX,t5., 4g.btl


4/23

- 3

CONTENTSFonewonoPmrecE,

CHeprsn I: GENEnnr-Clause1. Scope ndobject . . .2. Terms and definitions.3. Data on operating onditions.

CuaprER II: CoTTTvISSIoNING

Page5

779

4.5.6.7 .8 .

13131315t 7

9 .10.1 1 .

CHeprEn II: Ops,neTIoN23

Cuepren IV: MITNTENANCE12 . G e n e r a l . . . 2 913. Basis or maintenance ctivities14. Restorationo optimumcondition . . . . .311 5 . R e - s t a r t i n g . . . . . . . . . . 3 1AppnNox Measuremen ts . . . . . 33


5/23

- 5

TNTERNATIONAL ELECTROTECHNICAL COMMISSION

GUIDEFOR COMMISSIONING,OPERATIONAND MAINTENANCEOF HYDRAULICTURBINES

FOREWORDl) The formal decisions or agrcemntsof the IEC olr technical matters, preparcdby Technicat Committes on which all the NationalCommittes havitrg a special nterest therein are rcpresented,express,asnearly aspossible,an intemational consensusof opinion on thesubjectsdealt with.2) They have the form of recommendations or intemational us and they are acceptdby the National Committees in that snse.3) In o.der to promote international unification, the I EC expresseshe wish that all Natio[al Committes should adopt the text of the I ECrecommendation or thefu national rules in so far as national conditions i{ill permit. Any divergencebtwen he IEC recommndationandthe conspondingnatioml rules should, as far aspossible,be cleady indicated in the latter'

PREFACEThis standard asbeenprepared y IEC TechnicalCommitteeNo. 4, HydraulicTurbines.Work concerninghe commissioning, peration ndmaintenance f hydraulic urbineswas nitiatedduringthemeeringheld n Madrid n 1959. he Committeeof Action confirmed hat this activity el l within the scope fTechnicalCommitteeNo. 4. After the meetings eld n Aix-les-Bainsn 1964 nd n Paris n 1966, first draft

waspreparedn 1970 nda revised raftwascirculatedn1972.Asa resultof themeetingheld n Munich n1973,a draft. Document4(CentralOffice)30,was submitted o the NationalCommittees or approvalunder the SixMonths' Rule n February1974.The followingcountriesvoted explicitly n favourof publication:

Australia PortugalAustria RomaniaBelgium SouthAfrica (RePublic 0Canada SPainFrance SwedenGermany SwitzerlandItaly TurkeYJapan Union of SovietSocialistRepublicsNorway United KingdomPoland United States f America

Other IEC publications quoted in this standard:Pubrication'**,;l;IlHffilillxl3:::i:;ililiflJ,','"','3Ji'.*':??1,t111il'fff0,'1"'l93A: First supplemento Publication193 1965).308 : InternationalCode or Testingof SpeedGoverningSystemsor HydraulicTurbines.


6/23

- 7

GUIDE FOR COMMISSIONING, OPERATIONAND MAINTENANCE OF HYDRAULIC TURBINES

CHAPTER I: GENERAT

1. Scopeand objectThe purposeof this guide s to establish,n a generalway, suitableproceduresor commissioning ydraulicturbines and associated quipment,and to indicatehow such turbines and equipmentshouldbe operatedand

maintained.It is understoodhat a publicationof this typewill be binding only if, and to the extent that, both contractingpartieshave agreed pon it.The guideexcludesmattersof purelycommercialnterest,except hose nextricably ound up with the conductof commissioning, perationand maintenance.The guideapplieso impulseand reaction urbinesof all types,and especiallyo large urbinesdirectlycoupledto electricgenerators.t appliesalso o pump-turbineswhen operatingas turbines.

The guide is not concernedwith water conduits,gates,valves, drainagepumps,cooling-water quipment,,generators, tc., exceptwhere hey cannotbe separatedrom the turbine and its equipment.Wherever he guidespecifieshat documents, rawingsor informationshallbe suppliedby a manufactureror

by manufacturers), ach ndividual manufacturer hall be required o fumish the appropriatenformation or hisown supplyonly.

2. Terms and definitionsTerms Definitions2.1 Commissioning Testing of new equipment o check its conformity with contractualspecifications, s well as operationof the equipment until formallyaccepted y the purchaser.2.2 Operation Utilization of the equipment o produceenergy,or a stateof readinessfor suchproduction.2.3 Maintenance Activity on the equipment directed o its conservation n a state ofoptimum operating ondition.2.4 Pre-start ests Test betweencompletionof erectionof the equipmentand initial run.2.5 Initial run2.6 Test un

First movementof rotatingpartsafter erection.Operation o obtain one set of data or a specific est.

) I Testoperation Utilizationof the equipment or testingpurposes.1.8 Tesroperation eriod Testperiod ollowing nitial run and followedby test service.t includesno-load uns for checkingpowerplant equipment,aswell as oad runsand oad eiection ests.


7/23

- 92.g. Test ervice Operationof the equipment or an agreedperiod,during which themanufacturersgenerallyesponsibleor heway n which t isoperated.

2.I0 Comrnercialentice Operationof the equipment,under the purchaser'sesponsibility,oproduce nergy, r a stateof readinessor suchoperation.

2.Il Commercialenice eriot! Period tarting fteracceptancend ncluding ervice eriods, swellas

2.12 Guaranteeeriodperiodswhen the equipmentmay be out of operation or maintenance,inspection,epairs, tc.Time, extendingthiough an agreedpart of the commercialserviceperiod,duringwhich the manufacturer as commercial bligationsocorrectdefectsn hisequipmentn order o bring t into conformitywiththe contract.For this purpose,ests n accordance ith the appropriatepartsof Sub-clause7.I.4,shallbe performed.Check on the condition of equipment..13 Inspection

2.I4 Maintenancenspection Inspectionat regular ntervals,often combinedwith incidental epairs.2.15 Repair2.16 Modificarion

Restoration fterwearor damage.Change ntended o improveperformance.

2.17 Overhaul Complete inspectionwith necessary epairs and/or modificationsintended o bring the unit or part of it to, or nearly o, the optimumfunctioning ondition.

3. Data on operatingconditions3.1 A fundamental equirementor properoperation nd maintenances a satisfactory nowledge f the turbineand its accessoriesy the purchaser's ersonnel.The manufacturer manufacturers) hall deliver to the purchaser's esponsible epresentatives ll necessarydocuments,nstructions nd nformation.They shall nclude:- generaldrawingsand data;- material ists, descriptions nd test certificatesor main parts;- function diagrams;- instructions or operation,nspection ndmaintenance f his supplyand ables f measurements sgiven n the

Appendix;- assembly nd dismantling nstructionsand/or exploded iew of the parts;- safety nstructions;- list of original spareparts,as stated n the contract.Thesedocuments, ven n apreliminary orm, shallbegiven o thepurchaser'sepresentativesssoonas equiredand, n any case,before he initial run.3.2 The documentssubmittedby the manufacturer manufacturers)hall nclude he following data,some ofwhich may be amendedaccording o experience atheredduring commissioning.

1) Diagram suchas a hill diagram) elatingheads, ailwaterelevations,low and output,wicket-gate peningsand operatingimits; also,whereapplicable,unnerbladeor deflector osition.


8/23

- 1 12) Statement f similitude of model and prototype,accordingo IEC Publication193, nternationalCode orModel Acceptance estsof HydraulicTurbines, f appropriate;3) Information on turbine nlet and outlet gates, alvesand pressureeliefvalves.4) Wicket-gateopening or needleopeningof impulse urbines) or no-load,starting and cavitation imits, asfunctionsof head and tailwater evelsalso,whereappropriate,unner bladeor deflectorposition.

5) Turbinegovernorand servomotor haracteristics.6) Adjustment of overspeed rotectiondevice.7) Characteristics f the fluids for the governingsystem.Filter specificationsnd information on purificationfrequencyand method.8) Maximum steady-stateunawayspeedand maximum momentaryspeedandpressure ariationsat variousoperatingheads.9) Minimum continuous operatingspeed or initial run (dependingon design of thrust bearingand otherbearings).10) Description of lubricationsystems,stating amount and characteristics f lubricantsand frequencyofreplacement.11) If applicable,ataon jackingsystem or rotatingpartsand maximum time after shut-downbefore e-startwithout operatinghe ackingsystem.12) Speed imits belowwhich operationof the thrust bearingoil injectionsystem s necessary.13) If applicable, aximum and minimum speedsor brakeoperation.14) Intermediateoil levelsand pressures t which pumpsand compressorshould be startedor alarmsgiven;alsodata or automatic ignalling nd emergency evices.15) Maximum and minimum temperaturesn bearings, eals nd n the oil or fluid pressure ircuits alarmandshut-down alues).16) Maximum and minimum pressures,lows and evels n oil or fluid pressure ystems ndbearings, ccordingto control system alarmand shut-downvalues).17) Maximum and minimum pressures nd flows in coolers alarmand shut-down values).18) Maximum water evels n drainage its (alarmand shut-downvalues).19) Data on electricmotors,pumpsand other accessories.20) Safety nstructions for test and operatingstaff.21) Other data of importancewhich are considered ecessary y either purchaser r manufacturer or safeoperationof the equipmentor for instructionof personnel.

3.3 The manufacture(s) hallgiveappropriatenstructions o the purchaser's taffand provide he informationstated n Sub-clause .2 on operating he equipmentduring the final stageof erection, nitial run, test runs andtest serviceperiod,particularly or all items not previouslyusedby the purchaser.

Duringthefinalstage f erection, he start, he test uns and estservice,hepurchaser hallmakehisstaffavailableto the manufacturer or instruction and training in order hat they may becapable f operatingproperly he turbineand associated quipment.3.4 During the guarantee eriod, he equipmentshall not be operated utside he limits stated n the contractwithout agreementwith the manufacturer.


9/23

- 1 3

CHAPTER II: COMMISSIONING

-t. General-t.l Commissioningoccursafter first erectionof a new unit. Similarproceduresmay alsobe utilized with orr.rthout formal acceptancefter repairor overhaul.1.2 Theoperatingequirements iven n Clause3 shallbe compliedwith during commissioning.f the operatingconditions f thepowerstationprevent ommissioning ithin these equirements,hepurchaser nd manufacturershall agreeon the commissioning rocedure.4.3 For correct nterpretationand determination of the causesof any unexpectedphenomena, t will beadvantageouso make simultaneous ecordingsof significantparameterson a recording nstrument. Eachrecording hall mention the time and date.4.4 It is the purchaser'sesponsibility o obtain from all the authoritiesconcerned, greements n specifiedconditions flow, grid, etc.) or testoperation

5. Test co-ordinatorA testco-ordinator hallbechosen y the purchaser,he maincontractors nd he manufacturers. e s n chargeof drawingup the programme f commissioning. is programme hallbe checked nd approved y the purchaser,the main manufacturers nd contractors eforeand during the tests f changes ppearo be necessary. e shallconduct he tests and check he results.The testco-ordinators responsibleor the executionof all testsup to the beginningof the testserviceperiod.Operatingand commissioningpersonnelshall report to the co-ordinatoron all operationsperformedon theequipment.

6. Pre-start tests6.1 Prior toJilling waterways

Before he turbinecasing s filledwith water, he generator, swell as auxiliaryand stand-byequipment,shallbe checked.At least he following temsshall be checkedand results ecorded y the test co-ordinator.l) Inspection f all he turbinewaterways ndremovalof all foreignor ooseobjectsthesemight cause amage).If required, he measuring ections nd pressureaps or future turbine acceptanceestsshall be checkedandconfirmedas satisfactory nd dimensions ecorded s appropriate.2) Calibration f scalesor wicket-gate penings nd,whereapplicable,or runnerblades, eedles nddeflectors,including heir cam relationships; lsomeasurement f clearances.3) Operationof pressure il units, hydraulicshut-off valves,pressureelief valves,governors, utomaticandmanually-operatedtartingand stoppingdevicesand signallingdevices.4) Oi l levelsand pressuresn governor ystem; onditionof all oi l filters.i) Protective evices,,uch asoil level and temperature larmsand relays,with adjustment f needed.


10/23

- 1 56) Timesof opening ndclosing f goveming lements,.e .wicketgates,mnnerblades f turbineswith movableblades, eedles nddeflectors f impulse urbines,pressureeliefvalves ogetherwith safetydevicesor pressurereliefvalve malfunctionand, f possible, ommandsignaldeadband'7) Valve or gateopeningand closing imes.g) Bearingand sealclearances.n the caseof pressure-lubricatedearings,he oil injectionsystemshall bechecked.9) Operationof leakage nd drainage umpsand separately-drivenubricatingpumps.

10) Oil, grease nd water supply o all bearings nd seals equiring ubricationor cooling.

11) Operationof the brakingsystemof the unit.12) Proper asteningof all man-holecovers.13) Bladesof movable-bladeurbinessetat restposition.After the abovechecks,he valvesor gates hallbe closed,he wicketgatesof reaction urbinesor the needles

of impulse urbinesshallbe closed and ocked, f applicable),he brakesappliedandthe controlboardenergized'

When satisfiedhat all conditionshavebeenmet, the testco-ordinator hallgive nstructionsor the waterwaysto be hlled.6.2 Afterfilling watetwaYs

The tailwater alveor gateshallbeopenedirst.Depending n the tailwaterevel,acheck or eaksshallbemade'

The wholewaterway hallbe illedslowly,andpreferablymanuallyeither hrougha by-pass r a smallopeningof the gateor stoplogs.When the waterwayhas beensufficiently illed, the gateshallbe openedor the stop-logsremoved.If there s a turbine nlet valve, he turbinecasingshallbe carefully illed,pressurized nd checked efore hemainvalve sopened. he operation f automatic rotection eviceswhich actuatehis valveshall henbe checkedand the functioningof the valve itself tested'

Automaticprotectiondeviceswhich actuate he intakeor outlet gateor valveshallbe checked, speciallyheemergency ate. f the protectivedevicesand the emergency atework satisfactorily nd no unusual eakage rdeformationhas beenobserved, n operationalest shallbe carriedout:- on the pressureeliefvalve. f any;- on the needles f impulse urbines with deflectors iverting);- on the tailwaterdepressionystemof impulse urbines, f applicable.

7. Initial runAfter the test co-ordinator asgivenpermission,locking evices ndbrakesare eleased nd he turbinewicketgates r needles reopened ndermanualcontrol,accordingo themanufacturer'sequirements,o bring he speed

up to at least he minimum statedvalue(seeSub-clause '2. Item 9).If any noise,scrapingor other abnormalphenomena s observed, r if an authonzed epresentative f any

manufacturer o equests,he unit shallbeshutdown mmediately.A tendencyor the unit to rotatewith leakageflow only shallbe noted.)


11/23

- t 7

8. Test runs8.1 l{o-load tests8.1 1 Theunit is keptundermanualcontrolat or above he starting peedseeSub-clause.2,,Item )until bearingtemperatures re satisfactoryo the manufacturers' epresentatives.If any temperature s excessive r increasesoo rapidly, the unit shall be shut down and the causesof thisphenomenonnvestigated nd conected.If all goeswell, the unit speedshallbe increasedn pre-arrangedtepsup to the ratedvalue, remainingat eachsuccessive peed until the rate of rise of all bearing temperatures s satisfactory o the manufacturers'representatives.8.1.2 During eachspeed tepof the test run, at least he followingmeasurementsnd/or observations hall bemade:

1) Deformationof coversand bearingsupports.2) Noise or vibration n the turbine and/or generator.3) Water supplypressuren water-lubricatedearings nd packings, nd coolingof shaft-sealing evices.4) Operating onditions f standby, urbinesafetyand signaldevices,n particularhosewhich couldnot beproperly estedbeforewater wasadmitted and the unit rotated.5) Operating onditions or the oil pressure nd otherpumps.6) Conditionof oil in the bearings ndpressure il systems.f water sobservedn oil, he eaks hallbe ocatedand eliminated. f oil foaming s observed,he cause hallbe ocated nd eliminated.7) Oil pressuren pressure nd ubrication ystems; ressure, irculation nd inlet and outlet emperature fcoolingwater.8) Levelsof oil in lubricating ystems f bearings nd n oi l pressure ystems.9) Temperatures f bearings, ackingsand lubricationoil.10) Shaft runout at turbine and generator earings nd axialdisplacement f rotatingparts, f possible.

At someagreed peedvalue,usuallyafter the rated-speed o-load est, the action of the braking system alsobraking ets of impulse urbines)shallbe checked.8.1.3 The functioningof the governing ystemmay be checked t this time and,with the governor peratingconectly, he urbinemay beused or dry-outandbalancing f theunit, testson the electrical quipment, rotectionand automaticdevices, tc.8.1.4 When the no-load est at ratedspeeds completed,he turbine speeds carefully ncreased,till undermanualcontrol, or checking he action of overspeed rotectiondevices.The set speed or eachdeviceshall be measured nd any necessary djustmentsmade.After the load rejection ests,a further adjustmentof the overspeed evicesettingmay be required.


12/23

- 1 9 -8.2 Load run and oadrejection ests8.2.I General

When the generatorand switching equipmenthave been declared eady for operation, he unit may besynchronized. uring the load rejection ests,all necessaryrecautions hallbe taken o ensure hat ratedvaluesof penstockand turbine stresses ill not be exceeded.Suchprecautionsmay includesettinggovernor iming at a slower-than-designate.

When adjustmentsare made on governoror regulatingdevices,all testswhich might be affectedby theadjustmentshallbe repeated.8.2.2 Purposes

The purposes f loadrun and load rejection ests are:1) to check,with an agreed ccuracy,he outputof theunit, comparedo the documentsisted n Sub-clause.2;

to check he unit for instability,vibrationor cavitation n the rangeof guaranteedoads;to check he functioningof governorand regulatingdevices,aswell as that of the entireunit;to determine he momentarypressure nd speed ariationsof the unit and to find their extremevalues;

5) to adjust he closing imes of the wicket gates,needlevalves, unner blades,deflectors nd pressureeliefvalves o minimize overspeed f the unit within the permissibleimit of pressure ariations;6) to permit estingof the operation f other hydraulicandelectrical quipment,ncludingprotection nd otherautomaticdevices.

8.2.3 ProcedureThe load shall be increased n stepsand a load rejection est made at successively igher loadsup to themaximumexpectedo beplaced n the unit (forexample, ejectionsmay be madeat 25%o50% ,75 %o nd 100oAof rated oad, aswell as from the maximum loadthat may be agreed pon).Two rejections hallbemadeat eachoad.One ejections madeundergovernor ontrol o no-loadgateor needleopening, he other shall be an emergency hut-downby the stop solenoid.If specified,oad rejection estsshall alsobe made by meansof the emergency ateor valveor by any otheremergency evice.After the completionof each oad rejection est, he pressureise and turbinespeed isedata shall be analyzedto ensure hat the specified afe imits will not be exceeded uring the next higher oad rejection est.

8.2.4 Observations, easurementsnd recordingsDuring thesetests, he test co-ordinatorshall ensure,where possible, hat the following observations ndmeasurements remadeand recorded:a) Steady-stateperation

1) Headand tailwater evels or pressures).2) Generatoroutput.3) Wicket gateor needleopening whereapplicable, ladeor deflectorposition).

Pressure t turbine inlet and outlet.Axial thrust.

2)3)4)

4)s)


13/23

;21 -

6) Pressuresnd evels n oil pressureystems.7) Operating imesof oil pressure umps.8) Pressure ifferentials n servomotorsequired or wicket-gate r needleclosure n relation o pressuresetting or emergency ate ripping.9) Temperaturesn bearings nd seals.10) Noise evels, f valuesare specifiedn the contract.11)Abnormal oises,f any.12)Vibrationand other displacement f rotating and fixedparts.13)Actionof air admission evices,f any.

b) Load rejection ndsubsequentests1) Headand tailwater evels orpressures).2) Generator utput.3) Strokes nd closing imesof wicketgatesor needleswhereapplicable, f bladesor deflectors).4) Pressure t turbine nlet and outlet.5) Level variationsat intake and surge anks.6) Time/speedelationshipf the unit.7) Maximumaxial hrust (if possible).8) Openingstrokesandopening/closingimes for pressureeliefvalve, f any.9) Pressure rop n the oil pressureystemn theprocessfgoveming, ndvariationoflevel n the oilpressurereservoir.10)Noise evels,f values respecihedn the contract.11)Abnormal oises,f any.12) Vibrationand otherdisplacementf rotatingandfixedparts.13)Actionof vacuum reakingalves,f any.14) Action of emergencyalveor gateunder flow, if specified.

Ifpossible,an estimate f leakagehrough he turbinewith closedwicketgates houldbe made, referablyustafter he loadrejetion ests.It is recommendedhat after he test operation eriod Sub-clauie .8),an nspection f the unit be carriedout,e.g. o check or anypossibleubbingcontactwhichmay haveoccurre.d.If during he tests Sub-clause.2)unusualphenomenar vibntion havebeenobserved, r if a runaway peedtesthasbeen erformedSub-clause1.1.6),his nspetion ustbecanied utprior o thestartofthetestservicperiod Sub-clause.9).


14/23

- 2 3

CHAPTER III: OPERATION

9. GeneralTheoperation eriodncludeshe followingparts:- test servlce,- commercialervice, ivided nto:guaranreeeriod,post-guaranreeeriod.Thesub-clausesn test service nd theguarantee eriodshallbe applied o new units after first erectionandcommissioning, r to any unit afterrepairor overhaulcarriedout by a manufacturer r acontractor.Clause12on commercial erviceafter he guarantee eriodmay be appliedas ong as he unit is in operation.

10. Testserviceperiod10.1 If nothing unusual hasbeenobserved uring the load run and oad rejection ests, he test serviceperiodshall follow. As the manufacturer s generally esponsibleor his equipmentduring test serviceand also or theway in which it is operated,t is recommendedhat the purchaser's ersonnel perate he equipmentunder themanufacturer's uidanceduring test service.After the first erection, he testservice eriodshouldbe ong enough o satisfy he purchaserhat all componentsare n satisfactory perating ondition.After an overhaul, he testservice eriodcanbe shortened r evenomitted.I0.2 The duration of the hnal part of the test serviceperiodduring which the unit must operatewithout anyinterruptionshall be stated n the contract.10.3 During the test service eriod, he purchaser'staff shallstudy he functioningof the equipmentand recordat regular ntervals at eastoncea day, at the beginningoncean hour or evenmoreoften, and after any changeof head, low or output). These ecords halldeal with the items in the following ist where hey apply:- upstreamand downstreamwater evels;- pressures t turbine nlet and outlet;- output andpowerswings;- rateof flow (if possible);- wicket-gate r needleopening,and,whereappropriate,unner bladeor deflectorposition;- temperaturesn bearings, ealsand lubricatingoil;- temperatures nd pressuresn pressure il systems;Observations hall alsobe maderegarding:- functioningof governorand pressure il units aswell as all auxiliaries;- actionof interlocksand signallingdevices;- deformationof the turbine casingor cover;- air admission extentand effectiveness);- circulationof lubricatingoil and coolingwater;- effectiveness f lubricationat variouspoints, iltersand coolers; il quality;- water evels n drainagepits and presence f leakingoil;- load-carrying bility of the machine;


15/23

- 2 5- ambient air temperature nd surface emperature f sunounding machines suchas electrical enerator).

The staff shall alsoobservenoise,pressure ulsations, avitationphenomena, angs,vibration, eakage, tc., nthe unit and recordsuchphenomenaand the circumstances nderwhich they wereobserved.10.4 At the endof the testservice eriod, he pressureluid systems nd he ubricating ystems hallbe checkedfor impurities.10.5 When the testservice eriodhasbeensuccessfullyompleted, ommercial erviceunder he responsibilityof thepurchaser egins.At the same ime, he guarantee eriodbegins Sub-claue2.12) nd hecontracting artiesshall both place his on record.

11. Commercial ervice11.1 Guaranteeeriod11.1.1 Measurementsnd obsentations

The measurements nd observations pecifiedn Clause10 shall also be made during commercialservice.Depending n operating onditions,he ntervals etweenmostmeasurementsanbeextended. he imeanddatefor eachmeasurement r observationhallbe recorded.11 .1 .2 .S l tu r - t l ov ' r t

If an1' rouble ccurs ndcannotbe mmediatell' orrected,.g .a suddenemperatureise n bearings r pressuredecreasen pressurei l unit . he unit shal lbeshutdown.

11.1.3RepairWhen inspectionndicateshe need or a repairduring the guarantee eriod,such repairshould be madeonlyby agreementwith the manufacturer.

ll.L4 AcceptanceestsAcceptanceestsmay be completedn accordance ith the following:1) Efficiencyand power estsshouldbe performedaccordingo I EC Publicatio 4l,InternationalCode or theField Acceptance estsof HydraulicTurbines,whereapplicable;therwise y agreement etweenmanufacturerand purchaser.2) The maximum openingvaluesof the wicketgatesor needles,ndicatedby the manufactureraccordingoSub-claus3.2,shallbechecked nd operatingimits shallbeestablished,onsidering oiseevelor powerand/orefficiencydecrease.If continuousoperationsconsideredndesirableverany oad ange,he imits of this range hallbeestablishedand an agreement hallbe madeon how to eliminate he trouble and/or how to pass hrough this range.3) In the caseof movable-bladeurbines, t is recommendedhat the cam relationship everifiedby the indexmethodof testingand a corrected am, f required,be installedas soon aspossible.

11.1.5 Speed-governingystemsThe acceptanceestsof speed-governingystemsshould be performedaccording o IEC Publication308,InternationalCode or Testingof SpeedGoverningSystemsor HydraulicTurbines,whereapplicable, therwiseby agreement etweenmanufacturerand purchaser.


16/23

IIiII- 2 7

11.1.6 Field estsfor unaway peedField tests or runawayspeed hallbe performedonly in exceptional ases ndthen, f specifiedn the contract

for both turbineand generator.All appropriate recautions hall be taken.

ll.l.7 GuaranteenspectionThis sub-clause oncernsonly the guaranteetems in the contract.On a date agreedby manufacturerandpurchaser usually ust before the end of the guaranteeperiod),a guaranteenspectionof the unit shall beperformed.n particular, ll of the componentso whichcavitationpittingguaranteespplyshallbe nspectedsee

IEC publicationon cavitationpitting evaluation,under consideration).The manufacturer'sepresentativehallbe invited to takepart in the guaranteenspection.The guaranteenspection hallcoveroperations nd checks iven n Sub-clause3.1.Theparties manufacturer ndpurchaser)hallmakea oint recordof theresultsof the inspection. hese ecords

shall ist all measureso be taken,name the party to perform hem and which party shallbear he expense ndprogrammehe work.

Il.2 Post-guaronteeeriodThe measurements nd observationspecifiedn Clause10 may be continuedafter the guarantee eriod.The

intervalsbetweenmeasurements nd their extentare determinedby the purchaser imself.If any unusualphenomenons observed r noted on a recording,he purchaser halldecidewhether he unitcontinues o operate r whether t must be shut down for inspection.

11.3 Special perating onditions11.3.1 Coldweather peration

Coldweatheroperationequires articular ttention o smallwaterconduits,especially here heypasshroughunheatedareas.f the water velocity s low and the conduit s not insulated, t may becomeblockedby ice.*

When a unit has beenshut down for some ime at low temperatures,t may be necessaryo heat the oil inbearings nd governorsystem o reduce ts viscosity.

As long asa unit is running, ts losseswill usuallyproduceenoughheat o maintaingood ubricationpropertiesof oil.

11.3.2 De-watered perationDe-watered peration equiresparticularattention o cooling equirements.Separate oolingwill be necessary

at the shaft seal and, particularlyfor high-head reactionturbines with small runner clearances nd highperipheral peeds, eparate oolingof theseclearances ay becomenecessary. he manufacturershallprovideinstructions or suchoperation,f applicable.

x Ice can alsocause lockage f largewaterways, articularly t trash-racks nd wicketgates.


17/23

- 2 9

CHAPTER IV: MAINTENANCE

12. Generall2.l Maintenance onsistsof preventiveand restorative ctivities repair).Onepurposeor both preventiveandrestorativemaintenances to searchor causes f damage ndwearwith theobjectof eliminating hem.The purposeof preventivemaintenances to reducewearand the probabilityof damageor breakdown.The purposeof restorativemaintenances to restoredamaged nd/or worn parts o their optimum condition.12.2 Maintenance ctivitiesconcernall partsof the turbine and associated quipmentsuch as:- waterpassages;- fixed and rotating urbine parts;- controland regulatingdeviceswith their associated quipment;- lubricating, oolingand drainage ystems;- automaticsequencing nd safetydevices;- control boardand measuringapparatuselated o the turbine.I2.3 Loss of efficiencyand/or strengthof machinerycan generallybe traced o one or a combinationof thefollowing causes:

a) weardue to silt or other abrasivematter n the water;b) cavitationphenomena;c) fatiguestressphenomena;d) defeclivematerial,not previouslydiscovered;e) operation r maintenance ot in accordance ith manufacturer's ecommendationsnd/or instructions;fl failures n electrical onnections r mechanicalinkages.

Weardue to silt or other abrasive ontent n the waterwill usually appear n needles, ozzles, eflectors, unnerbucketsor blades,unnerhub, wicketgates, alveseats n general,wearing ingsand/or seals.

Cavitationpitting will usually appear n needles, eflectors,unner bucketsor blades, unner hub, wicketgates,runner chamberand/or throat ring.Impulse urbine runnersaresub.jecto high fatiguestresses.n general,atiguestressesn reactionurbinesdo notreachseriousevelswithout being evidenced y vibration.I2.4 Experience f wear and/or cavitationpitting during the first part of commercialservice i.e.during theguarantee eriod)can be used o estimate he dateof the next inspection.12.5 Repairs uring he guarantee eriodshallbe madeaccordingo Sub-clause1.1.3.Repairs nd overhaulafter he guarantee eriodshallbemadeby the manufacturer r by any otherqualifiedparty.

13. Basis or maintenanceactivities13.1 A number of observations nd checksshall be made o providea basis or maintenance ctivities; heseinclude:


18/23

- 3 1

a) During rated speedoperation:- operationof all mechanical arts any knocking,abnormalnoise,excessive ibration, emperatureise);- oil and/or water eaks;- lubricating,coolingand drainage ystems levels, lows,pressures,nlet and outlet temperatures);- governorand associatedluid system;- valuesset for the action of safetydevices,as comparedwith initial values;- powerand flow (or an indexvalueproportionalo flow), head,wicket-gate r needleopening or generation,

aswell as for no-loadoperation.b) During transients:- maximum momentaryspeedand pressure ariations;- pressure hangen the oil pressure ystem.Closing imes of wicketgates,needles nd pressureeliefvalves;- time to shut unit down;- unusualphenomena any knocking,abnormalnoise,excessive ibration, eaks,etc.).c) At standstill:- pressures;- levelsand temperatures f lubricatingoil or governor luid;- closed ositions f wicketgates, eedles, eflectors,unnerblades,nlet andoutletgatesandvalves,governorand servomotor,as comparedwith initial values.d) During maintenancenspections nd during repairactivity:- wear,damage nd crackson otherwisenaccessiblearts,e.g. unners,needles, ozzles, eals,wearing ings,

bearings nd linkage.The shut-down prior to regular inspectionshould be a full-load rejection n order to check the regulatingmechanism.I3.2 It is convenient, or these observations nd checks, o follow a check ist preparedbeforehand or theparticularunit andstatingexplicitly he frequency f theseobservations nd what shallbe notedduring differentstages.When carryingout the observationsndicatedn Sub-clause 3.1,Itemd), themeasurements hallbe recorded nsheetssimilarto those n the Appendix to this guide.14. Restoration o optimum condition

In the restorationactivity,two courses re open,namely:- to replaceworn or damaged arts;- to repair hem.In the lattercase, echniques uch asgrinding,welding,sprayingor solderingmay be used.

Procedures houldbe chosenwith dueconsiderationo localconditions,purchaser'sequirements,egulationsand experience.15. Re-starting

When startinga unit after overhaul, he samegeneralproceduremay be followed asfor the initial start.Theresultsshallbecompared ith thoseof the original estsand he causes f any undamental ifferences scertained.


19/23

- 3 3 -

APPENDIXMEASUREMENTS

1. GeneralDimensions o be measured uring erection ncludeamongothers:- referencemarksand measurementsor locationof fixed partsand shaft alignment;- gapsandclearancesetween unnersand covers, unnersandwearing ings, unnerbladesandcasings,wicketgatesand wearingplates,etc.Cross-sectionrofrlesmay beplottedbeforeor duringerectionandcomparedwith the correspondingemplates.The differences etween he surfaceprofileand the templateshallbe recorded.

2. Adjustmentvalues or shaft alignmentThe following orms shallbe completed, singFigure1,page35, or horizontalunits andFigure2, page 7 for

verticalunits.

3. As applied o a reaction urbineMain data and dimensionsas measuredduring erectionare insertedon a suitablesketchprovidedby the

manufacturer.Figure 3, page39, is a generalsketchfor a Francis ype reaction urbine and Figure 3, page41, gives the

correspondingable or resultsof measurements.


20/23

r- 3 5Powerplant: Unit No.:

FIGURE 1 MEASUREMENTS DURING ERECTION - HORIZONTAL UNIT

l r i r - tA l e

Shaftalignmentsketch

Checkoncouplingflanges

t lmffi B c If the unit isfitted with three bearings,thebearingB is only an auxiliarysupport or erection

Shaftalignmentsketch(continued)

Parallelismand buckle check

PositionFlange

90" r80' 270"

PrPz

A and B: feelergauges

Concentricerectioncheck

PositionFlange

0" 90" l 80' 270.

^gw#ft+-| LJdPosition

Flange0' 90' 1 0" 270"

PrPz

Checkoncouplingflanges(continued)

Coupling f langes disengaged Coupling flangesengaged

B C D B D

90 'l 80"210"

Gradientofjournalsand spindles(1/1000mm/m)

PointBearing 1 8 9 10

Journal ower clearancesvertical section)

#NPoint

Bearing 5 6

ABL

D

Journal side-clearan ceshorizontal section)

, ,rN\\.\.-. I_ . ! - - - - - r -' r z N l - o I

PointBearing 2 3 4

BCD

Clearancesnbearings none singleposition

Forsha f t l i gnment , th i cke rgaugesave tobep lacedunderbear i ngs := . ' . mm -S= . . .mm -Q= " 'mm -D= ' "mm

Observations:


21/23

- 3 7Powerplant: Unit No.:

FIGURE 2 MEASUREMENTSDURING ERECTION _ VERTICAL UNIT

Which shaft s to be turned dependsupon the thrust-bearing ocation

IN NA- B EA.B SA-B wA- BD,

Pz

N E S wCheckon couplingflanges

)R Nr Sr Wt Nz q . F . WzB

C

Clearancesin bearings(1/1000mm )

;..-x' 90 ' 180" 270" 360'Nr or 2

S t o r l

Et o rz

W t o r 2

computed eccentricity Permissible ccentricitydo -- ' ' ' mmdo =0.03* rn*t)

a = o . s , l 6 1 f i G j w f l , = d i s t a n c e b e t w e e n t h r u s t r i n g a n d m e a s u r e m e n t p o l n td A = . . . . . . . m m D = d i a m e t e r o f t h e t h r u s t r i n g

d B = . . . . . . m m

;.N 0' 90 ' r80" 2'10" 360"N t o r :

S t o r 2

E t o r :

Wt or l

Eccentricityin bearings

Four positionsfor shaft1: upperpart2: lowerpart


22/23

- 3 9 -

FIGURE 3

Powerplant: Unit No.:

APPLICATION TO A REACTION TURBINE

I DIMENSIONSto be plotted(in practicedimensionswillbe plottedon asketchprovidedby themanufacturer)


23/23

- 4 r

FIGURE 3(continued)

Powerplant Unit No.:

APPLICATION TO A REACTION TURBINE

2 Clearancesbetween openwicket gatesan drvearingplates( 1 / 1 0 0 0 m )

Wicket gate No. 1: see below No.4 - marked point I - next down the f low

Wickel gatePoin t

2 3 4 5 6 1 8 9 1 0 l 1 t2 13 t4 t5 1 6 t 7 l 8

Ll)cD i

J Clearancesbetween the edgeand the surfaceof the closedwicket gates(1/1000 m)

2 l 4 5 6 1 8 9 l 0 11 t2 t3 T4 l 5 t6 1 1 l 8

4 Checkon thestayring surface

Parallelismhorizontal nit)p Fr F F

Gradient vertical nit) (1/1000mm/m)Mr-r Mz-+ Nr . : Nz-+

5 Parallelism fwearingplatesnmillimetres

E E " F ,

6 Maximumpermissiblevalueof shaftdisplacement. m m

Horizontal displacement. m m

7 Clearancesbetween unnerand wearingringsFour positionsfor runnerFourmeasurementsfor eachposition( l /1000mm)

These measurements take place at the end of erection; the rotating parts are pushed around after oil injection on thrust bearing or after lifting.

8 Observations:

Documents

Ide for Commissioning, Operation and Maintenance of Hydraulic Turbines_commission Electrotechnique Internationale_spln 20a_1978