Hydraulic Turbine and Associated Equipment

5 x 342 + 1 x 40 MW Demwe Lower HE Project
Doc. No. : 904/ EMTD/ TS-10 Revision : 0
Technical Specification
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Hydraulic Turbine & Associated Equipments
CONTENTS
1. 1.1 1.2 1.3 1.4 1.5
GENERAL ..................................................................................................................................... 2 SCOPE OF WORK ....................................................................................................................... 2 MAIN TECHNICAL PARAMETERS, GUARANTEES AND MODEL TEST ................................ 4 DESIGN REQUIREMENT ........................................................................................................... 12 GENERAL TECHNICAL REQUIREMENTS ............................................................................... 13 CONSTRUCTIONAL FEATURES OF TURBINE COMPONENTS, ACCESSORIES & ASSOCIATED AUXILIARIES ..................................................................................................... 18
1.6
PRESSURE OIL SYSTEM FOR GOVERNORS, TURBINE RING GATES AND TURBINE INLET VALVES........................................................................................................................... 36
1.7
SIGNALISING & INDICATING INSTRUMENTS/ DEVICES IN PRESSURE OIL SUPPLY SYSTEM ...................................................................................................................................... 38
1.8 1.9
HANDLING OF LEAKAGE WITH DRAIN OIL & ITS DISPOSAL ............................................. 38 CONTROLS & INSTRUMENTATION FOR TURBINES, GOVERNORS, BUTTERFLY VALVES & AUXILIARIES .......................................................................................................... 39
1.10 SPARES ...................................................................................................................................... 39 1.11 SPECIAL TOOLS, SLINGS, CONSUMABLES ETC. ................................................................ 39 1.12 DEVICES AND INSTRUMENTS FOR TESTS DURING ERECTION & COMMISSIONING...... 39 1.13 TESTING DEVICES & INSTRUMENTS FOR FIELD ACCEPTANCE TESTS .......................... 40 1.14 DELIVERY, INSTALLATION AND COMMISSIONING .............................................................. 40 1.15 MANUFACTURE, INSPECTION, SHOP ASSEMBLY, MEASUREMENTS & TESTING .......... 41 1.16 INSPECTION & TESTING AT SITE ........................................................................................... 44 1.17 INDEX AND FIELD ACCEPTANCE (EFFICIENCY) TESTS ..................................................... 45 1.18 INFORMATION AND DOCUMENTATION BY BIDDER & SUPPLIER ..................................... 46 1.19 TOOLS AND INSTRUMENTS .................................................................................................... 47
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1.
GENERAL This section describe the basic requirements, general provisions and specifications as well as design requirements, for the Turbine models, Turbines, Governors, Ring Gates, Butterfly Valve and associated equipments. Though Owners preferences have been broadly listed in these specifications, However Bidders may furnish details of Equipments which, from their experience and practice, which shall in all respect, meet the requirement of the Owner with respect to design, performance durability and operation.
1.1
SCOPE OF WORK Scope of work under this section covers the Design, Detailed Engineering, Manufacturing in approved Vendors Factory, Quality Control, Shop Testing, Delivery at Project Site, Unloading and Storing at Site, Site Assembly, Erection, Testing and Commissioning, Performance & Acceptance Testing, Training of Owner's personnel as required, Putting into Commercial Operation and handing over to the Owner of Hydraulic Turbine & Associated Equipments complete with all parts, all items, auxiliaries and accessories, Recommended and Mandatory Spare Parts and warranting a trouble free safe operation for 2 (two) years of Demwe Lower Hydro Electric Project.
1.1.1
Detailed Scope of Supply The scope of work shall be a comprehensive functional system complete in every respect including but not be limited to following: i) ii) Five (5) numbers of Vertical Francis Turbines of rated output of not less than 348979 kW complete in all respect. Five Sets of Hydraulic Operated Ring Gate complete with complete accessories for (i) above.
iii) One (1) number of Vertical Francis Turbine of rated output of not less than 40816 kW complete in all respect. iv) One (1) numbers Butterfly valve for (iii) above. v) 6 (Six) sets of digital electro - hydraulic governors for (i) and (iii) above. vi) 6 (Six) Sets Pressure Oil System for (ii), (iv) and (v) above. vii) Model testing of turbines at (i) & (iii) above. viii) Field Acceptance Testing of Turbines at (i) & (iii) above. ix) Spare parts, Special Tools, Consumables & Testing Devices. Following miscellaneous items shall form part of the supplies of the turbines: i) ii) Necessary walkways, ladders, handrails, chequered plates etc. Illumination and power service points inside the turbine pit.
iii) First fill of governor and lubricating oil including 10% extra. iv) Welding electrodes of suitable material and grade, for site welding & assembly of sections of turbine components.
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v) All handling equipment such as hoists, hoist beams, slings, turn buckles, tie rods, jacks, trolley etc. for handling turbine components inside turbine pit and under water parts of the turbine. The scope shall also include following services: i) ii) Overseas Transportation covering freight &insurance from port of shipment to the port of entry in India (in case of goods of foreign origin) Inland Transportation in India for delivery at site.
iii) Storage and preservation at site till installation & commissioning. iv) Complete assembly, testing, erection &commissioning at site. All other works incidental to and connected with the above services from delivery up to handing over the equipment after successful commissioning.
1.1.2
Handling and Erection Devices i) Two (2) sets of special handling devices and fixtures for the Turbine Units corresponding to Clause No 1.1.1 (i) above and one (1) set of these devices for the Turbine Unit corresponding to Clause No 1.1.1 (iii) above. Two (2) sets of bulk heads for the Turbine Unit corresponding to Clause No 1.1.1 (i) above and one set for the Turbine Unit corresponding to Clause No 1.1.1 (iii) above.
ii)
iii) One (1) set of test head for both type of turbines along with hydrostatic pressure pumps and associated accessories for field testing of spiral casing. iv) Two (2) sets of draft tube & Runner maintenance platform for the Turbine Unit corresponding to Clause No 1.1.1 (i) and one (1) set for the Turbine Unit corresponding to Clause No 1.1.1 (iii).
1.1.3
Control, Monitoring and Related Items and Services i) Six (6) sets of all necessary control, monitoring, safety and metering instruments/devices/system for Turbine Units corresponding to Clause No 1.1.1 (i) &(iii) above Co-ordination and supply of associated interfaces, provision of necessary contacts and/or ports for integration of all turbines, accessories and monitoring systems with plant SCADA system including all hardware, software, services and other inputs.
ii)
iii) Six (6) sets of Winter Kennedy/ Ultrasonic continuous on-line flow measurement system along with required nos. of transducers/ sensors and associated accessories for measuring, monitoring and data acquisition and integration of the system with plant SCADA system.
1.1.4
Common Supplies and Services i) Spare parts as per the clause "Spare Parts" of this Section.
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ii)
Tools and instruments as per the clause "Tools and Instruments" of this section.
iii) Field/ touch-up painting including all painting materials. iv) Performance and field acceptance testing as per the relevant clause of this section and submission of report. v) Training of Owner's personnel including operation and maintenance staff as defined in "Section 1 - General Technical Specifications". vi) All the technical documentation including preparation and submission of O&M manuals. Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s)/ best international practices.
1.2
MAIN TECHNICAL PARAMETERS, GUARANTEES AND MODEL TEST 1.2.1 Type & Rating a) Hydraulic Data Full Reservoir Level FRL Minimum Draw Down Level MDDL TWL under all units running at maximum capacity at MDDL TWL under all units running at maximum capacity and Spill way discharge of 2000 Cumecs TWL under 1(One) Unit running at rated load at FRL Maximum Gross Head Minimum Gross Head Maximum Net Head Rated and Minimum Net Head Normal Maximum Net Head corresponding to all units running at Maximum Load at FRL 424.8 m 408.0 m 303.4 m 304.7 m 300.23 m 124.57 m 103.3 m 123.1 m 100.3 m 119.0 m
** The design head shall be selected by the Bidder suitably between 100.3 m & 119 m.
b) Turbine Basic Data Rated Net Head Head Range Maximum Net Head with one unit running at FRL Normal Maximum Net Head with all units running at Maximum Load at FRL Minimum Net Head with all units running at Rated Load at MDDL 100.3 m 100.3 m 123.1 m 123.1 m 119.0 m 100.3 m
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The best efficiency point shall be selected by the Bidder suitably between
119.0 and 100.3 m
NB: The bidder to note that the above data (net heads) are based on hydraulic loss estimated of water conductor system as per proposed layout in relevant tender drawing. However, bidders to recheck the above mentioned parameters and satisfy themselves while offering the turbine. Not less than 348979 kW and 40816 kW respectively for the Turbine Units as covered in Clause No 1.1.1 (i) & (iii) above. Ten (10) percent over and above the rated output capacity as specified above. To be guaranteed by the bidder. To be furnished by the bidder along with corresponding efficiency & gate opening 55% 35% Not less than 125 rpm for the Turbine unit as covered in Clause No 1.1.1(i) above & 333.33 rpm for the Turbine Unit as covered in Clause No 1.1.1.(iii) above.
Rated Continuous Output Capacity at rated net head of 100.3 m
Maximum Continuous Output Capacity
Operation Capability under Part Load without any adverse effect Continuous output at design head at best efficiency point Maximum Speed Rise on maximum load rejection Maximum penstock Pressure Rise on load rejection
Rated speed
Note: Bidder may examine and quote higher speed as per their design practice to achieve optimum machine performance as well as to mitigate transport limitations and substantiate with calculations as regards the rated speed adopted by them. This shall also be coordinated with the manufacturer of Generator. Turbine setting (Centre Line of Distributor) Bidder may choose as per their best suitability and furnish calculations.
1.2.2
Other Aspects & Requirements Bidder shall compute pressure and speed rise using the parameters of plant and the operating conditions and furnish the detailed study/ calculations. The turbine shall be so designed/ constructed as would enable maximum assembly of components at works and at the same time permit easy transportation. The weights and sizes of the components/ packages shall be within the permissible transport limits for the project (i.e. 125 Tonnes weight, 6.2 Meter diameter and 5.5 Meter Height) The bidder shall include the following information in their offers:-
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Turbine performance data, turbine capacity at heads in specified working head range; velocity diagrams with values of velocities and angles at runner inlet and outlet and absolute velocities at guide vane inlet at rated generator output, maximum 10% over load generator output net heads of 100.3 m, 119 m, 123.1 m including optimal Design Head to be adopted by the Bidder. Safe part load operation limits at various heads, stable regime of operation and other essential data values of critical sigma and plant sigma for the range of operation.
The unit shall be designed to start up and shut down at least 3 (three) times a day. The maximum runaway speed at maximum net head shall be stated and guaranteed by the Supplier. The generating unit shall be designed to withstand the forces and stresses occurring at maximum runaway speed condition for a period of at least 15(Fifteen) minutes without any damage and to safely withstand any transient over speeds. The turbine shall be designed to give satisfactory, quiet and smooth operation, free from excessive noise, vibrations, pressure pulsations, power swings, hunting etc in the required range of operation of heads and outputs including overload output. Turbine design shall be such that it operates through its full range of specified conditions without vibration detrimental to its service life. The vibration amplitude at the shaft shall not exceed the values specified in ISO-7919 (Part-5). The turbine shall be designed to meet the safety requirements in accordance with various applicable standards/ international practices. The connection to the Penstock should be kept to a minimum. All penstock and Tail Water connections should be double valved. Wherever possible all connection to the Penstock and Draft Tube should be embedded. All water carrying pipes should be provided with anti-condensation arrangements.
1.2.3
Standards Unless otherwise stated, rating, characteristics, test and test procedures, etc. shall comply with the provisions and requirements of the latest applicable International/ Indian Standards. The list of applicable standards shall be at least as described below in this section. S.No. 1. 2. Standard IEC 60193 IEC 60609 Description Hydraulic turbines, storage pumps and pump-turbines Model acceptance tests. Cavitation pitting evaluation in hydraulic turbines, storage pumps and pump turbines. Field acceptance tests to determine the hydraulic performance of hydraulic turbines, storage pumps and pump- turbines. Guide for commissioning, operation and maintenance of hydraulic turbines.
3.
IEC 60041
4.
IEC 60545
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Hydraulic Turbine & Associated Equipments Determination of the prototype performance from model acceptance tests of hydraulic machines with the consideration of scale effects. Mechanical vibrations of non-reciprocating machines Measurements on rotating shafts and evaluation criteria of machines set in hydraulic power generating and pumping plants.
5.
IEC 60995
6.
ISO 7919 Part-5
1.2.4
Guarantees for Turbine Output, Efficiency & Penalties for Shortfall The Suppliers shall provide turbines having the specified ratings and highest feasible efficiencies in the permissible range of operation. The turbine Bidder at bidding stage shall supply supporting documents for the prescribed guarantees by means of displaying results from earlier model tests of the model turbine which conforms as much as possible to the one now offered. The output and the efficiencies shall be guaranteed under penalty as given below. The turbine output and efficiency shall be guaranteed by the Supplier. The following requirements and rules for the guarantees apply: i) ii) Rated and Maximum Continuous output at rated net head (Minimum net head) of 100.3 m. Turbine efficiencies at following net heads in the specified working head range: Minimum Net Head, Best Efficiency Head & Maximum Net Head
a) Weighted Turbine Efficiency The model and the prototype weighted turbine efficiency shall be guaranteed. The model average weighted efficiency will be calculated from the model efficiency using the grid of weights under different head and percentage of rated output of turbine specified in the table below: Net Heads > Loads 80% 100% 110% Weighted Average Efficiency 1 3 5 tav 2 4 6 80 =0.4*1 +0.6*2 100 =0.4*3 +0.6*4 110 =0.75*5 +0.25*6 100.3 m 119.0 m Average Efficiency
0.1*110 + 0.8*100+0.1*80
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The prototype weighted average efficiency will be calculated from the model efficiency stepped-up to prototype efficiency according to IEC 60995, using the same grid of weights as above.
b) Efficiency Guarantee and Penalties If the model weighted average efficiency on testing is less than the guaranteed weighted average efficiency the Contract Price for payment purposes, be decreased for each one hundredth of one percent drop in efficiency for each unit as follows: i) ii) @ USD 20,000 for the Turbine Unit as covered at Clause No 1.1.1 (i) above. @ USD 9,000 for the Turbine Unit as covered at Clause No 1.1.1 (iii) above
Adjustments will, however, not be made until after the Supplier has been given an opportunity to correct the defects in performance. Modifications in design, if necessary, shall be made within a reasonable time not exceeding 3 (three) months so that the guaranteed performance can be obtained and the manufacturing shall commence only after satisfactory results are obtained in the model test. In the event of extra time taken by the manufacturer for rectification of design deficiencies, the delivery schedule as agreed earlier shall be adhered to by the supplier. In case of failure to obtain satisfactory results to ensure guaranteed performance, the Owner reserves the right to cancel the contract or to accept the same subject to levy of penalty as specified above. The model weighted average efficiency is the weighted average efficiency calculated from the model test results. If the model weighted average efficiency falls below the guaranteed figure by more than 2(Two) percentage point, then the turbine may be subjected to rejection. i) For comparison of bids the weighted average efficiency as defined above will be used and for equalisation of bids loading at the rate of USD 20,000 and USD 9000 shall be applicable for Turbine Unit as covered at Clause No 1.1.1 (i) & (iii) respectively above for each one hundredth of one percent lower weighted average efficiency for each unit.
c) Capacity and Efficiency Tests Owner reserves the right to carry out capacity and efficiency test at different heads and gate opening on the prototype turbine within one year after commissioning to verify that the power output and efficiency guarantees of the prototype have been fulfilled. The turbine efficiency and capacity tests shall be conducted in accordance with the provisions of IEC Publication 60041, International Code for Field Acceptance Tests of Hydraulic Turbines, under the supervision of a qualified independent expert, unless otherwise mutually agreed upon by the Supplier and the Owner. Any deviation from the IEC-60041 shall be clearly stated in the offer. Efficiency shall be measured by the thermodynamic method or any other applicable method as mutually agreed between the Owner and the successful Bidder. Bidder
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shall furnish details of test method, agency which will conduct the test, provisions to be made for the field testing, calibration of instruments for the purpose of the test and all other relevant details in the offer. Bidder shall be under obligation to accept these tests for purposes of liquidated damages. The Supplier shall make any subsequent adjustments in the turbine working parts as may prove necessary to secure optimum turbine performance.
d) Capacity guarantee and penalties The Rated and Maximum Continuous Output Capacity at rated net head of 100.3 m shall not be less than as specified at Clause No 1.2.1 above. Penalty for one hundredth of one percent variation in output for each turbine unit below the guaranteed value will be applied as follows: i) ii) @ USD 56,000 for the Turbine Units as covered in Clause No 1.1.1 (i) @ USD 15,000 for the Turbine Unit as covered in Clause No 1.1.1 (iii)
For fractional values of the shortfall the penalty amounts will be computed on pro-rata basis. The turbines not fulfilling the guarantees will be subjected to penalty by multiplying the penalties for one (1) turbine by the no. of turbines.
e) Cavitation guarantee The Bidder shall guarantee the guide vanes, runner, discharge ring and other hydraulic passage of the turbine against excessive pitting caused by cavitation for the first 8000 hours of operation, or not over two calendar years after provisional acceptance of the turbine, whichever is the earlier. If the guarantee expires before 8000Hrs of operation the weight loss shall be on pro-rata basis. The cavitation guarantee shall be as per IEC Publication 60 609. Excessive cavitation pitting is defined as the removal of metal from the turbine runner, discharge ring, draft tube cone and guide vanes because of removal of material in excess of the weight defined by the following formula: W = 0.1 x D32 per 1000 Hours of operation during the guarantee period defined above. Where: W = total permissible weight of metal in kilograms removed during the period of operation. D3 = Discharge Diameter of the turbine runner in meters.
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1.2.5
Turbine Model Test a) General Before the supplier takes up the manufacture of the prototype turbine, test on homologous scale model of the prototype turbine shall be carried out to demonstrate that the prototype turbine will meet the guaranteed performance in respect of efficiency, output, smooth operation, pressure pulsations, and other guarantees as stipulated in the specifications.
b) Model Details, Drawings and Homology Before taking up the manufacture of the model turbine, the Supplier shall submit to the Owner in a sequential manner, within 60 days after award of contract, drawings and description covering details of the proposed model, testing equipment to be used, instrumentation, testing procedure, method of interpretation and computation of test results for the approval of the Owner. The turbine model shall be homologous to the prototype in all respects. The water passage of the model turbine shall be homologous with those of prototype right from the Spiral case inlet to the draft tube exit point. The draft tube cone shall be made transparent to permit observation of the vortex flow pattern and cavitation phenomenon and to take photographs of the same. The model scale, minimum size and homology/ similarity to the prototype turbine shall be in conformity with the IEC code 60193.
c) Conducting of Model Test, Test Code, Submission of Report The test shall be conducted in accordance with the IEC publications 60193. The test shall be completed and comprehensive test reports submitted for approval of the Owner within six (6) months after the award of contract. The detailed programme of carrying out the comprehensive model test shall be intimated to the Owner Six weeks in advance of the start of the test for the Owner/consultant to depute their representatives for observation of the comprehensive tests.
d) Tests on Turbine Model The test shall include: Turbine performance (efficiency) tests. Cavitation tests with photo documentation. Runaway speed test. Pressure pulsation (fluctuation) tests for the draft tube frequency at half, full and over load. Hydraulic thrust.
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Hydraulic Turbine & Associated Equipments Guide vane torque. Air admission test for the full sigma range. To determine best location of the Winter Kennedy taps and to determine the exponent co-efficient for the flow calculation on prototype. The model test shall simulate all possible normal operating conditions of the prototype for the entire range of reservoir and tail water levels, guide vane openings, overload etc.
e) Step-up Formulae The prototype efficiencies shall be calculated and derived from the model efficiencies as per the latest edition of IEC-60193 Code.
f)
Presentation of Model Test Report After the completion of the model test, the Supplier shall submit to the Owner, three copies of complete report, which shall include but shall not necessarily be limited to the following. Introduction, dates of test, by which it is conducted. Description of test equipment and test procedures. Drawings showing plan and cross section of the model turbine as well as the prototype turbine giving all principle dimensions and profile. Detailed drawings showing the complete set up of the test. Records of calibration of all test instruments and equipment. Record of all actual measurements made during the test viz. manometer readings, torque, speed, etc. which are used in the calculation of Head (H), Discharge (D), Speed (N), Power Output (P) etc. Comprehensive & complete sample calculation for each computation. Model efficiency curves covering entire operating zone. Curves showing sigma vs efficiency and sigma Vs unit power and unit discharge for specified head with envelope curves drawn. Curves showing relationship between guide vane angle and also guide vane opening in mm vs servomotor stroke related to maximum opening of guide vane and clear opening between two adjacent wicket gates. Prototype performance curves, hill charts and performance in tabular form for various operating conditions. Photographs and sketches of the cavitation phenomenon phenomenon with corresponding operating conditions. and vortex
Pressure pulsation curves for various conditions of operation including air admission test.
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Hydraulic Turbine & Associated Equipments Establishment of hydraulic similarity of the model turbine to the prototype. Statements as to inaccuracy of each class of measurement and inaccuracy on combined measurement shall be indicated. A table showing the comparison of the test results with the guaranteed data, followed by technical conclusions.
g) Witness of Model Turbine Test by Owners/ Consultants Representatives and Model Acceptance: Along with the submission of the comprehensive model test report on the basis of test, the turbine supplier shall include a detailed programme (with at least 4 weeks advance notice) for actual demonstration of the correctness of the model test in the presence of Owners representatives by repeating the tests at important points of operation as selected/ required by the Owner. Should the model fail to meet the guarantees and requirements, it shall be optional for the Owner to conditionally accept the model and direct the supplier to modify the model until it complies with the requirements. All expenses involved for the modifications and subsequent model tests shall be borne by the supplier. Owner reserves the right to get the model turbine tested in an independent laboratory.
1.3
DESIGN REQUIREMENT The turbines shall be designed to give satisfactory, quiet and smooth operation, free from excessive noise, vibrations, pressure pulsations, power swings, hunting etc. in the required range of operation of heads and outputs including over load. The Suppliers shall compute the maximum momentary pressure, and speed rise using the parameters of the plant, and the operating conditions and furnish the design computations of pressure rise and speed rise worked out in their bids. The maximum momentary pressure at turbine inlet, considering the effect of water hammer due to water mass inertia, under worst conditions of load acceptances and rejection and governor closing and opening times, shall be indicated by the bidder. However, the pressure rise shall not be more than 35% of static head acting on the Spiral case with the reservoir at maximum water level. The maximum momentary speed rise after load rejection, under the most adverse combination of load and head, shall be indicated by the Bidder. The speed rise should not be more than 55% of the synchronous speed. The flywheel effect of the turbine in conjunction with the generator shall be adequate to fulfil the requirement of specified speed rise & pressure rise criteria. The turbine shall be so designed and constructed as to enable assembly of components at works and at the same time to permit easy transportation. The weights and sizes of the components/ packages shall be within the permissible transport limits as specified in the General Technical Specification.
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At least the information listed hereunder shall be given by the Bidder. The Bidder may support advantages in his design or of special technical features of his offer by additional documents/ descriptions. i) Compute pressure rise at turbine inlet under the most unfavourable conditions (load acceptance and rejection). Conditions considered as well as governor acting times to be clearly indicated in the computations. Compute turbine speed rise under conditions as above and for following load rejection parameters. From maximum output at maximum head to zero From 100 % rated output to zero From 80 % rated output to zero From 60 % rated output to zero Expected flow characteristics during closing and opening of wicket gates as function of time. Expected performance curves for the design head, maximum net head & minimum net head. The curves shall also show the overload output at maximum possible guide vanes opening extending beyond the guarantee points. Curves showing the critical sigma values. Velocity Diagrams giving values of velocities and angles at runner inlet and out let & absolute. Provide dimensional drawing (cross section) of turbine and associated equipment showing main dimensions. Applicable method and type of vibration monitoring system. Provide information on model or field performance tests performed on a turbine which is hydraulically similar (within reasonable range) to the proposed turbine. Indicate at least the following: Name of the projects & its year of commissioning Place of model or field tests
ii) iii) iv) v) vi) vii) viii)
ix) x) xi) xii) xiii) xiv) xv) xvi)
xvii) Year of model or field tests xviii) Designed rated turbine output xix) xx) Rated net head Rated speed
1.4
GENERAL TECHNICAL REQUIREMENTS 1.4.1 Design & Workmanship The vertical Francis turbines shall be of the plate steel spiral type. The turbine designer shall take into account the site specific factors such as the quality of water and characteristics of silt present in water. Suppliers shall offer turbines to suit the technical
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requirements as specified herein. The turbines shall be manufactured with the best workmanship and the state-of-the-art technology.
1.4.2
Rigidity and Strength of Various Components Various components shall be strong and rigid to withstand forces acting upon them under any conditions of operation with safety and without undue deformations.
1.4.3
Interchangeability All identical components of the turbines and the spares shall be interchangeable with one another. Thus at the time of initial site assembly it shall be possible to use the main embedded components of any turbine with similar components of any other turbine.
1.4.4
Sectionalizing of Components Heavy and large structural components such as spiral casing stay ring, bottom ring, top cover, draft tube cone & liner etc. may need to be split, into two or more segments/ sections as necessitated by inland transport limits as specified. Routine convenience of handling of components during initial site assembly, erection & installation and later for dismantling & removal or maintenance & replacement through stator bore. Special provision for dismantling and removal downwards of runner and other under water components affected by silt erosion, for quick maintenance and replacement (necessitated by presence of silt in water) The number of segments/ sections shall however be the barest minimum as warranted by the above constraints so that the work of initial assembly at site and later for dismantling for removal, replacement and reassembly for maintenance is the least. Sectionalizing of smaller components such as Liners, Cheek Plates etc. may be provided where feasible for easy and quick replacement. The various segments/ sections/ quadrants shall be temporarily assembled at works and match marked before dispatch for ease of site assembly.
1.4.5
Maximum allowable stresses a) General While designing parts subject to alternating stresses, vibration, impact, or shock, adequate safety margins are to be considered. The design of the equipment shall include seismic loads as per IS 1893. Seismic loads may be calculated considering seismic coefficients as h = 0.38g (MCH), h =0.19g, (DBE), v = 2/3h Under the most severe conditions of loading expected in normal operation, stresses in the materials shall not exceed the values listed below except that appropriately lower values shall be used where loading characteristics could cause fatigue failure
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or excessive deflections. Maximum stresses design stresses for materials not listed shall not exceed one-third of the yield strength or one-fifth of the ultimate strength. Turbine parts including bearings shall also be designed to withstand without any damage operation for at least Fifteen (15) minutes at the maximum runaway speed.
b) Direct or combined stresses For materials used in the construction of the equipment, unless otherwise specified, the maximum stress due to maximum normal rated load operating conditions shall not exceed 1/3 of the minimum yield point or 1/5 of the minimum ultimate strength of the material, whichever is lower. Maximum stresses in rotating parts of the turbine due to maximum runaway speed or in parts under hydrostatic test conditions shall not exceed 2/3 of the minimum yield point. Maximum stresses in rotating parts of the generator due to runaway speed shall not exceed 75% of the minimum yield point. Maximum unit stresses in parts of that equipment which is subject to the maximum normal operating conditions, shall not exceed the values in the following table: Material Maximum allowable stresses In Tension Gray cast iron Carbon cast steel and alloy cast steel Carbon or alloy steel forgings Carbon or alloy steel plates for principal parts 1/10 U.T.S The lesser of 1/5 U.T.S. or 1/3 Y.S. 1/3 Y.S. In Compression 70 Mpa The lesser of 1/5 U.T.S. or 1/3 Y.S.
1/3 Y.S.
1/3 Y.S.
1/3 Y.S.
Maximum Stresses in shear shall not exceed 21MPa in cast iron, nor 60% of the allowable stresses for other materials, except that the maximum shear stresses in the turbine / generator main shafts shall not exceed 50 % of the allowable stress in tension. Pre-stressed bolts such as coupling bolts, core bolts etc. stresses may be allowed till 80 % of Y.S. Parts subject to water pressure shall be designed to the applicable provisions ASME Boiler and Pressure Vessel code Section 8, Division 2.
c) Loads on Foundations Bidder shall determine maximum forces emanating from normal and/or emergency operation of the equipment, acting upon equipment foundations or upon adjacent structures. The Bidder shall guarantee that those forces will not be exceeded.
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d) Material Selection and Standards The material specifications and their standards for major components of turbine shall be as shown below. The material grade and classification wherever specified are obligatory and proposed equivalent national/international standard for the same shall only be considered if their chemical composition, mechanical properties, manufacturing methods are same/superior and are suitable for proposed use. The Supplier shall establish the equivalence/superiority for acceptance by the Owner.
e) Components fully under water Item Runner Material and Manufacturing Method Stainless Steel, 13Cr-4Ni, Cast fabricated Material Standard ASTM A 743 Grade CA6NM ASTM A 743 Grade CA6NM Stainless Steel, 13Cr-4Ni, Casting/ fabricated from steel ASTM A240 UNS plate S41500 (Plate version of CA6NM) ASTM A 743 Grade Rotating labyrinth (Upper) and (Lower) CA6NM Stainless Steel, 13Cr-4Ni, Casting/ fabricated from steel ASTM A240 UNS plate S41500 (Plate version of CA6NM) ASTM A 743 Grade Fixed labyrinth (Upper) and (Lower) CA6NM Stainless Steel, 13Cr-4Ni, Casting/ fabricated from steel ASTM A240 UNS plate S41500 (Plate version of CA6NM) Guide vanes Facing plates Discharge ring cladding Bottom Ring Stainless Steel, 13Cr-4Ni, Single piece Casting Stainless Steel, 13Cr-4Ni, Fabricated from steel plate Stainless Steel, 13Cr-4Ni, Fabricated from steel plate Carbon Steel, Fabricated ASTM A 743 Grade CA6NM ASTM A240 UNS S41500 (Plate version of CA6NM) ASTM A240 UNS S41500 (Plate version of CA6NM) ASTM A 537 Class II or 250-300 280-350 Hardness (BHN) 250-300
Runner Cone
250-300
250-300
280-350
300-350 350 max.
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Hydraulic Turbine & Associated Equipments from steel plate ASTM A 516 GR 70 ASTM A 537 Class II or ASTM A 516 GR 70 ASTM A 537 Class II or ASTM A 516 GR 70 ASTM A 537 Class II or ASTM A 516 GR 70 ASTM A 537 Class II or ASTM A 516 GR 70 ASTM 216 GR WCC 350 max. 350 max. 350 max. 350 max.
Head cover Discharge ring Draft tube cone Spiral casing
Carbon Steel, Fabricated from steel plate Carbon Steel, Fabricated from steel plate Carbon Steel, Fabricated from steel plate Carbon Steel, Fabricated from steel plate Carbon Steel, Casting / fabricated from steel plate
Stay ring
ASTM A 537 Class II or ASTM A 516 GR 70
350 max.
f)
Components partially under water Item Material and Manufacturing Method Carbon Steel, Forging Alloy steel NiCrMo, Forged Material Standard ASTM A 668 Class D ASTM A 434 Class BD 280-350 Hardness (BHN)
Turbine shaft Coupling bolts Shaft seal sleeve/liner
Stainless Steel, 13Cr-4Ni, ASTM A 743 Grade Casting/ fabricated from steel CA6NM plate
g) Other components Item Bearing housing Material and Manufacturing Method Material Standard Hardness (BHN) 350 max.
Carbon Steel, Fabricated from ASTM A 283 GR C steel plate ASTM 216 GR WCC Carbon Steel, Casting / fabricated from steel plate ASTM A 537 Class
Guide vane servomotor body, piston and rings
350 max. II or ASTM A 516 GR 70 ASTM A106 GR B / ASTM A53 GR B
Pressure Pipes Carbon Steel, Seamless Cooler tubes Fasteners on parts requiring Cupro-nickel, 70:30 Stainless Steel
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frequent dismantling All embedded pipes relating to Carbon Steel generating units and auxiliaries. ASTM A106 GR B / ASTM A53 GR B
h) Operating Temperature Limits Bearings temperature of the turbine shall not exceed 70 C.
i)
Cooling Water Failure Duration Withstand Capacity: Bearings shall be designed and guaranteed to withstand operation for a period of at least 15 (Fifteen) minutes for the condition of cooling water supply getting cut off for any reason without suffering or incurring any damage. However if during such period the machine cannot be brought to safe stoppage from any abnormal running condition, adequate failsafe emergency cooling water provisions are to be provided.
1.5
CONSTRUCTIONAL FEATURES ASSOCIATED AUXILIARIES
OF
TURBINE
COMPONENTS,
ACCESSORIES
&
The spiral case shall be fabricated from carbon steel plate of pressure vessel quality. The design shall be such that hydraulic losses are minimized. The spiral case shall be supplied in suitable sections to suit the transport limitations. These shall be assembled and welded with stay ring. Complete assembly shall be hydrostatically tested at site. The Supplier shall supply all consumables including electrodes and necessary testing arrangements. Spiral case shall be concreted at prescribed pressure by the Supplier. The casing shall be designed for minimum internal design pressure of 17 bars according to the rules of the Code. Under this design pressure the maximum stress shall not exceed the permissible stresses allowed by the Code. Careful attention shall be given to design of welded joints between the steel plate casing and the stay ring, particularly where cast steel or cast welded construction is used for the stay ring. The Supplier shall provide detailed calculations of stresses at these joints and verify that the stresses permissible by the code are not exceeded. All lugs, jacks, foundation bolts, tie rods and turn buckles, bracing etc., necessary to facilitate assembly and prevent distortion during shipping, pressure testing and concreting shall be supplied by the Supplier. The field joint gaps between adjacent plates after assembly and before welding shall not exceed 6mm. The accuracy of the plate work shall be provided in the shop and all bracing clips, dowels etc. properly fitted before disassembly and shipment. All sections shall be properly match marked before disassembly. A watertight casing manhole shall be provided in an approved location. Supplier shall provide sufficient taps for Winter-Kennedy measurements at appropriate locations.
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A drain outlet complete with heavy removable stainless steel grating, studs and nuts, cast steel body gate type drain valve with all necessary fittings should be provided for complete dewatering of the spiral case through draft tube.
1.5.1
Stay Ring Stay ring shall be of fabricated carbon steel plate of pressure vessel quality plate steel or cast welded construction, heat treated before final machining to relieve locked up casting or fabrication stresses and sectionalized as necessary for handling and shipment. It shall consist of upper and lower rings, rigidly held together by stay vanes, which guide the water to the guide vanes. The stay vanes shall be welded to the Stay rings with full penetration welds. The stay rings vanes shall be designed and shaped to direct the water flow with a minimum head loss and to eliminate vibrations. Machined flanges shall be provided for bolted connections between the stay ring and head cover, between the stay ring and the bottom ring or discharge ring. The pit liner shall be welded directly to the stay ring. The surfaces of the stay ring and welded joints in contact with the water shall be ground to a smooth finish. Suitable number of holes of adequate diameter shall be provided in the lower stay ring to facilitate the placing of concrete. Suitable provision shall be made for sealing of the holes after the concrete is placed. Adequate numbers of tapped holes shall be provided for pressure grouting. After pressure grouting, plugs shall be installed and ground flush. Air-vent holes with sealing arrangement shall be provided through the webs in isolated pockets. The stay ring shall be designed to withstand the forces transmitted to it from the spiral case under the maximum internal design pressure without the stresses exceeding the normal permissible values specified herein. The stay ring shall be designed to transmit the required loads to the concrete based on the design of the generating unit. The trailing edges of the stay vanes shall be shaped to minimize vortex formation. The Supplier shall perform a complete stress analysis of stay ring and identify the most severely stressed areas. The calculated stresses shall not exceed those allowed by the code.
1.5.2
Draft Tube The draft tube shall be elbow type and the hydraulic profile of the draft tube shall be designed so as to gain maximum recovery of the velocity head and thus provide high turbine efficiency. The design shall be such as would prevent pressure pulsations and surges. The draft tube design shall be such that the frequency and amplitude of draft tube pressure pulsations / surges, anticipated on the basis of model test, may not be close to the natural frequency of the generating unit to prevent undue resonance and objectionable power swings. It shall be of structural steel plate heavily reinforced by ribs and anchored in the concrete and bolted/welded to the foundation ring. The cone shall be provided with a hinged
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rectangular manhole door for access to a platform for inspection and repair purposes. A test cock shall be provided below the manhole to determine whether the water level in the draft tube is below the sill of the door. Suitable connection for pressure / vacuum gauge shall be provided. Pockets shall be provided to facilitate erection of platform. It shall be suitably sectionalised keeping in view the transport and handling limitations. The sections shall be welded together at site. The upper portion of the draft tube cone liner shall have sufficient stainless steel lining for protection from cavitation. To prevent damages caused by vacuum vortex, provision of air admission through a cross piece welded to the cone liner shall be provided necessary piping and air valves shall also be supplied. The valve shall open automatically in case of excessive vacuum under the runner. The draft tube bend liner shall be fabricated from structural steel plates, in suitable number of sections to facilitate transportation and handling. The bend shall be provided with adequate stiffening ribs, erection brackets, holding down bolts, anchor rods, turn buckles etc. for anchoring the liner securely into the concrete and for levelling in place. The bend liner shall be welded to cone at site. Adequate number of holes for free passage of air and grout, whilst the liner is being concreted, shall be provided. Suitable plugs shall be installed for the grout holes and ground flush after grouting is completed. The extent of the liner shall be up to a point as mentioned in the technical particulars/ station layout drawings. The liner shall be assembled and match marked in the shop before shipment for convenience of proper assembly and alignment at site. A drain box for dewatering the draft tube with valve and common dewatering pipe shall be supplied. Two nos. piezometer tapping will be provided at diametrically opposite location on draft tube liner, for measurement of net head during field testing. In case based on silt data provided its found necessary by turbine supplier to incorporate bottom runner removal arrangement in draft tube design due to requirement of major maintenance of runners prior to 8 year period the same shall be incorporated in the design.
1.5.3
Pier Nose Liner For the concrete central pier proposed for the draft tube, a pier nose liner shall be provided. The pier nose liner shall be fabricated from welded structural steel plates. The liner shall be adequately braced and provided with base pads and levelling screws for adjustment during the installation.
1.5.4
Pit Liner A pit liner of heavy steel plate, with servomotor pockets, shall be provided. It shall be made in sections with welded connections as necessary for shipment. The bottom shall be prepared for welding to the stay ring with full penetration. The liner shall be adequately ribbed and substantially anchored to the surrounding concrete in order that forces may be transmitted from the structure above the casing through to the stay ring without appreciable distortion of the pit liner. Adequate reinforcement shall be fitted to protect the liner from deformation or strain during transportation and placement for concrete.
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All wiring for meters, relays and other instruments inside the pit liner shall be gathered at the terminal blocks provided in the pit liner. The supplier shall furnish necessary wirings, conduits and also ducts for passing through the concrete barrel.
1.5.5
Head Cover The Head cover shall be fabricated from carbon steel plate of pressure vessel quality. It shall be of heavy construction, adequately ribbed and shaped so as to give rigid support to the turbine guide bearing, regulating ring, and the bearings for the upper stems of the guide vanes. It shall be bolted and doweled to a flange on the stay ring and also along radial joints where the head cover is sectionalized for handling and shipment. All major stress carrying welds shall be fully penetrated and furnace stress relieved. Radial ribs of the head cover may be fillet welded. Balancing pipes with valves shall be provided for releasing the pressure in the annular space between the runner crown and head cover. These pipes shall be adequately sized so that the pressure remains within the acceptable limits even with worn out labyrinths after long operations. The head cover shall be designed to withstand safely and without detrimental deflection the maximum water pressure, bearing load and all other forces acting upon it. The head cover assembly shall have machined seats for the turbine guide bearing, regulating ring, shaft seal, guide vanes and any other auxiliary equipment such as air vent, pipe connections, etc. The head cover shall be so designed as to provide rigid support for the turbine guide bearing. A retaining ring or pads shall be furnished to prevent any lifting tendency of the regulating ring. The guide seat for the regulating ring shall be provided with renewable self-Lubricating liners accurately machined so as to ensure minimum lost motion and friction in the operation of the regulating ring. The lower surface of the head cover shall be accurately machined to provide a smooth surface to the water passage at the entrance to the runner. Replaceable 13Cr-4Ni stainless steel facing plates of adequate thickness in suitable sections shall be provided on the inner surface of the head cover coming in contact with water. Fixing arrangement of liner shall not be susceptible to silt erosion/ damage and shall be easily accessible for maintenance. A replaceable stainless steel labyrinth seal ring or rings, accurately machined to form a water seal with the runner crown and shaped to reduce leakage, shall be secured to the head cover. Any hydrostatic pressure build-up behind the labyrinth seal rings shall be relieved through built-in pressure relief holes. Leakage of water through the labyrinth seal will be directed to the draft tube without building pressure under the head cover. At least four inspection holes shall be provided in the head cover to permit inspection and check on clearances of upper labyrinth of the runner. The inspection holes shall have sealed covers bolted to the head cover. A minimum of three piezometer connections shall be provided on the head cover piped to a common manifold equipped with suitable valves and a pressure gauge. These connections shall be arranged so that radial variations of water pressure under the head
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cover can be measured. The pressure gauge will be mounted on the turbine gauge panel on the pit wall. Walkways around the head cover and turbine bearing shall be provided with gratings or suitable openings to facilitate visual inspection of equipment located below the walkways. Adequate number of eye bolts and nylon rope slings shall be supplied to lift the head cover. Provision through suitable anchors shall be made in the turbine pit to raise the head cover. The head cover shall be designed to pass through the wound generator in one piece during erection and dismantling and with the runner and shaft in place. Suitable access shall be provided in the head cover for maintenance of the shaft seal without removal of the head cover and to facilitate easy removal of shaft seal components. Provision of pipes connected to turbine pit at suitable elevation and the drainage gallery should be made to drain the top cover to avoid ingress of water into turbine guide bearing in any eventuality. This shall be in addition to the gravity drainage and other systems.
1.5.6
Bottom Ring The bottom ring shall be fabricated from carbon steel plate of pressure vessel quality. The welds shall be fully penetrated and stress-relieved before final machining. The bottom ring shall be of heavy rugged construction and all necessary anchors and adjusting screws shall be provided. It shall be sectionalized as necessary for handling, shipment and removal. Bottom ring shall be so designed that it shall be possible to remove the runner by dismantling the discharge ring only without disturbing the bottom ring and guide apparatus arrangement. (In case it is necessary to provide bottom removal arrangement for runner for regular repairs in view of silt data provided) Bush bearings similar to those in the head cover shall be provided for the lower stems of the guide vanes. The bottom ring shall be designed to be adequately bolted and doweled to the stay ring and discharge ring. A replaceable stainless steel labyrinth seal ring or rings, accurately machined to form a water seal with the runner band, shall be secured to the bottom ring. The labyrinth seal ring shall be designed to minimize leakage. Any hydrostatic pressure build-up behind the labyrinth seal ring shall be relieved by the pressure relief holes. Replaceable 13Cr-4Ni stainless steel facing plates of adequate thickness in suitable sections shall be provided on the inner surface of the bottom ring coming in contact with water. Fixing arrangement of liner shall not be susceptible to silt erosion/ damage and shall be easily accessible for maintenance.
1.5.7
Discharge Ring The discharge ring shall be fabricated from carbon steel plate of pressure vessel quality, sectionalised as necessary to facilitate shipment and handling. The welds shall be fully penetrated and stress-relieved before final machining. It shall be of heavy section and adequately ribbed externally to prevent distortion.
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Replaceable 13Cr-4Ni stainless steel facing plates of adequate thickness in suitable sections shall be provided on the inner surface of the discharge ring coming in contact with water. Fixing arrangement of liner shall not be susceptible to silt erosion/ damage and shall be easily accessible for maintenance. The discharge ring shall have a machined surface at the top for supporting the bottom ring. Flanges for bolted connection to the draft tube cone at bottom shall be provided. Necessary adjusting jacks with steel bearing plates shall be furnished to facilitate levelling during erection. Suitable arrangement shall be provided to support the runner and shaft when disconnected from the generator. At least four inspection holes shall be provided in the discharge ring to permit inspection and check on clearances of the lower runner labyrinth seals. The inspection holes shall have sealed covers bolted to the discharge ring.
1.5.8
Guide Vanes The number of guide vanes selected shall be well matched to ensure turbine operation without objectionable vibration. The guide vanes shall be shaped to permit smooth flow of water through the turbine and shall be so proportioned as to maintain closing tendency under any normal operating conditions of the turbine. The turbine guide vanes and stems shall be of 13-4 Cr-Ni stainless steel. Each gate shall be machined smooth and ground to an accurate form and finish. Each guide vane shall be provided with three greaseless self lubricating bush type guide bearings one located in the bottom ring and the other two provided in the head cover straddling the stem packing box. Each stems shall be provided with a thrust bearing to carry the weight of the gate and withstand hydrostatic uplift. Convenient means shall be provided for adjusting and maintaining the vertical clearances of the wicket gates. The upper stems shall be amply designed to withstand, without torsional effects, the hydro-dynamic forces after shear pin breakage. Seals shall be provided above and below guide vanes to effectively reduce leakage of water or air. Segmented seals of proven design shall be used.
a) Regulating Mechanism For Guide Vanes i) ii) All components of the regulating mechanism shall be readily accessible. The regulating mechanism shall have the following features: Link connections with self-lubricated bearings and stainless steel pivots.
iii) Individual and independent means for adjustment of position of guide vanes. iv) Individual connection from gate operating ring to guide vanes comprising a set of levers & links. v) The guide vane lever shall be connected to the guide vane upper stem by a friction joint (or Shear pins)
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vi) The friction connection (or shear pins) shall be designed to withstand the maximum normal operation forces but shall also protect the guide vanes and the operating mechanism from damage and prevent rapid closure if one or more of the vanes are blocked by foreign objects. vii) Limit or micro switch or other means of signalization for alarm / annunciation on UCB & control room if any friction connection become free or out of position. viii) Solid stops for each guide vane. ix) The loose vane and its linkages after reaching maximum shall not interfere with the operation of other gates or turbine parts or cause progressive or cascade failure of other friction joints. x) For friction joint coupling (or shear Pin) test should be performed in the Suppliers workshop xi) All the components of the guide apparatus shall be readily accessible for inspection, adjustment and repair. The gate operating ring shall be made of cast steel or welded plate steel. The guide operating ring and its supporting structure shall be of adequate strength and stiffness to prevent deflection of this ring, guide bearing or the main shaft if the gate operating ring is subjected to the thrust of only one servomotor with the other servomotor blocked or without oil pressure.
1.5.9
Guide Vane Servomotors The guide vanes shall be operated by 2 servomotors of double acting oil pressure type. The servo motors shall have adequate capacity to operate the turbine gates to full opening or closing stroke with minimum oil pressure. The servo motors shall have the following provisions:i) Suitable adjustable by-pass connections for cushioning to achieve retardation in the closing rate during portion of the gate travel from slightly below speed-no-load position to prevent excessive surges in the water passages. Manual locking devices to hold the guide vanes in the closed or open position against maximum oil pressure.
ii)
iii) Limit switches for interlocking circuits and lamp indication of the position of the locking devices (indication on local panel & UCB). iv) Feedback device for feedback of position of the piston to the governor actuator unit / regulator cubicle. v) Scale with pointer indicating guide vane position in (i) tenths of maximum gate opening; (ii) mm of gate opening; or (iii) angle of opening of gates and related servomotor travel. vi) Gland sealing to prevent oil leakage past the piston rod; piston rings of suitable material to prevent internal leakage past the piston. vii) Collection means for leakage oil if any & return of same to the oil sump tank.
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viii) Oil inlet & return pipe connections. ix) Foundation fixtures for the servomotors
1.5.10 Turbine Shaft Seal The supplier shall provide two (2) shaft seals, one as main working seal and another as maintenance seal. The turbine sealing proposed by the Supplier shall be of special design. The arrangement and design of these seals shall be such that they remain fail proof even while the turbine is operating in water having high silt concentration and the maximum leakage shall be guaranteed by the Supplier. The arrangement defined shall be as accepted by the Owner at the time of award of Contract/ detailed engineering. Main working seal shall be provided below the bearing which shall prevent the leakage of water along the shaft. The shaft seal shall be arranged for water lubrication. Two or more connections for water shall be provided, evenly spaced on the periphery to admit a supply of clean water at a pressure to exclude foreign matter from the seal. Any leakage water from the seal shall be removed by drains. The seal shall be so arranged that it may be serviced without disturbing the bearing or de-watering the draft tube. A maintenance seal shall be provided below the main working seal to allow the main seal segments to be serviced without dewatering the spiral casing. This maintenance seal shall prevent leakage along the shaft when the turbine is stationary. Water for shaft sealing shall be drawn from cooling water tank at a suitable pressure. Suitable lifting eye bolts and backing-out studs shall be provided for use in removing and installing the shaft seal parts. The Supplier shall provide the necessary piping and the valves, including pressure reducing valves, filters, piping and fittings within the turbine pit, terminated by unions or flanges at a point outside the turbine pit. A water flow meter of suitable make with adjustable alarm contacts suitable for operation at 220V DC shall be provided in the water supply piping to the seal. These contacts shall be wired to terminal blocks in the turbine terminal box. One additional contact shall be provided to operate and indication light in the gauge panel to indicate that shaft seal water is ON. A duplex pressure gauge shall be provided to indicate the pressure beneath the seal and in the supply line. All bolts, nuts, screws and hardware used in connection with the shaft water seal shall be of stainless steel. The seal housing shall be designed to operate a minimum of 8,000 hours without replacement of any element. The sealing elements shall be of a self-compensating type and capable of being automatically adjusted for wearing during their full service life. Automatic sealing elements wear indicators shall be provided.
1.5.11 Ring Gate Each Ring Gate shall comprise following items: i) One mobile cylindrical shell located between the stay vanes and Guide Vanes,
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ii)
Several operating hydraulic servomotors to move the cylindrical shell,
iii) One mechanical/ Electrical synchronization device of the servomotors position, iv) One hydraulic control system for the servomotors, v) Operating and control equipments such as pressure switches, limit switches, position detectors, etc. vi) The oil power unit of the hydraulic control system may be combined with Governing System of the Turbine.
a) Operating conditions The Ring Gate shall be the closing safety device of the Unit and will work only in either fully open or fully closed condition. The Ring Gate shall never be used in a partial open position to adjust the water discharge. The closing of the Ring Gate shall be performed either in normal conditions after each Unit distributor fails or when one of the guide vanes is uncontrolled by the operating device of the Distributor and remains alone in fully open position. Under such emergency conditions the Ring Gate shall be able to cut-off the corresponding water discharge. The beginning of opening of the Ring Gate shall be always performed before the opening of guide vanes, without water flow. The opening of the Ring Gate shall be carried out by hydraulic servomotors. If possible the Ring Gate shall be of self-closing type due to its own weight. The Ring Gate shall be designed to cut-off the maximum water discharge through the Turbine, in the most unfavourable conditions of the guide vanes opening and runner velocity. The minimum closing time (including emergency closing when the Ring Gate cut-off the water discharge) shall be defined so as not to generate an upstream overpressure greater than the maximum permissible pressure in the penstock. The Ring Gate shall operate smoothly and more especially at the end of closing under water discharge. For that purpose the Ring Gate bottom edge which is applied on the lower seat in closed position, shall have an appropriate shape. And in closed position the Ring Gate shall have a tendency to remain fully closed and watertight under its own weight and under the hydraulic loads due to the upstream and downstream water pressures. In open position, when the Unit is running, the Ring Gate shall be subject to no vibrations and its bottom edge shall be flush with the upper surface of the distributor in order to have no turbulence area which can cause a cavitation phenomenon downstream the Ring Gate. When the Unit is running, the Ring Gate shall be kept in fully open position by a permanent oil pressure in the opening chamber of the hydraulic servomotors supplied by the hydraulic control system. The means of safety must be provided to avoid any jamming of the Ring Gate during closing. arranged to check its good positioning.
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Closing of the Ring Gate shall be stopped in case of an abnormal load generated by at least one of the hydraulic servomotors. The Ring Gate shall be provided with a mechanical locking device. The mobile cylindrical shell shall be made of carbon steel plate and its thickness shall be defined both to withstand the most unfavourable operating or testing conditions of the Ring Gate and to limit the deformations of the shell to values not detrimental to the operation of the Ring Gate. The mobile cylindrical shell shall be guided by the trailing edges of the stay vanes. The guiding surfaces of the mobile cylindrical shell and stay vanes shall be made of corrosion resistant material. The guiding surface of each stay vane trailing edge shall be a stainless steel welded the guiding surfaces of the mobile cylindrical shell opposite the trailing edges of the stay vanes shall be made of removable parts made of self lubricated material. Piston Rods of hydraulic servomotors shall be made of stainless steel as they are immersed in water. The lower seal between the bottom edge of the mobile cylindrical shell and the seat shall be of metal. The upper seal between the top edge of the mobile cylindrical shell (which is connected to the rods of the operating servomotors) and the corresponding fixed seat shall be of metal type. Lower and upper metallic seals of the mobile cylindrical shell shall be dismantled and replaced with the Ring Gate in its place.
1.5.12 Runner The runner shall be of cast / fabricated stainless steel preferably and shall be designed to provide the best hydraulic profile so that it gives the maximum efficiency with minimum cavitation. The runners shall be homologous with the model runners. The runner shall be provided with renewable labyrinth wearing rings. The runner shall be designed to safely withstand loading due to normal and abnormal operating conditions including effects of blade thickness reduction due to cavitation erosion, introduction of stress due to on site welding of damaged blades, increased pressures at transient conditions and discharge related to maximal guide vane opening. The runner shall be designed to withstand stresses due to resonant vibrations. The Supplier shall clearly present his calculation criteria with respect to maximal possible stresses in the runner, related to mechanical properties of the runner material. The coupling between shaft & runner shall be combination of friction and shearing type fastened by means of hydraulically pre-stressed coupling bolts & shearing pins. When detached from generator shaft and seated on a ledge at discharge ring, the runner shall be capable of withstanding the shaft weight. During turbine operation, leakage water from the upper runner labyrinth seal shall be shall be drained through a relieving pipe from the upper turbine cover to the draft tube to minimize hydraulic thrust. Sufficient vertical clearance between turbine rotating parts and the surrounding stationary parts shall be provided.
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The finished runner shall be balanced statically in the manufacturers shop according to ISO 1940, class G 6.3. The Supplier shall state the guaranteed runner unbalance after final treatment. The conformity of the blade shape to the design drawings shall be verified by use of templates or other shop control devices. Templates for guidance in restoring blade and bucket shapes to original contour shall be supplied with the runners. The geometrical deviations may not exceed tolerances set out in IEC Publication 60193-1. Supplier shall make templates for profile geometry control, to be used for checking of the prototype homologous geometry with accepted model geometry A set of these templates are to be supplied with first runner.
a) Materials The Turbine Runners shall be made of stainless steel of 13% chromium, 4% nickel (ASTM A 743 CA 6 NM), with ultra low sulphur and nitrogen content. The minimum Charpy V-notch impact strength at 10 C shall be 30 J, to be fulfilled by each of 3 specimens. Castings and forgings shall be furnished by a foundry or a forge shop having the necessary skill, experience, and capacity for this type and size of work. The runner manufacturing method as well as the name of the intended foundry or forge shop shall be listed on the Technical Data Sheets. All welded joints have to be examined by relevant NDT methods (Any repair in weld joints in stressed area has to be radio graphed)
1.5.13 Shaft, Coupling and Alignment The turbine shaft shall be of forged steel properly heat-treated. The shaft shall be hollow bored and of ample size to transmit torque and run at maximum run-away speed without detrimental vibration or distortion. The central bore shall be of sufficient diameter along the entire length of the shaft to permit visual inspection. The turbine shaft shall have integrally forged coupling flanges for bolting to the runner and to the generator shaft and shall conform to the relevant international standards. For calculating critical speed and determining the shaft diameter of turbine and generator, factors such as characteristics of mechanical parts, forces due to turbine during starting, stopping and running etc. shall be taken into consideration. Supplier shall furnish to the Owner the calculations of critical speed and shaft diameter. Supplier is responsible for the alignment and coupling of turbine and generator shafts and the unit as a whole at site.
1.5.14 Turbine Guide Bearing The turbine guide bearing shall be of the oil self lubricating type with babbit lined bearing pads. It shall be located on the inner head cover as close to the runner as possible but above the turbine shaft gland. It shall permit vertical movement of the shaft to facilitate adjustment and dismantling of the generator thrust bearing and clearing the male and
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female portions of the shaft coupling. It shall be designed to withstand safely and without damage natural retardation from maximum over-speed without application of generator brakes. The bearing housing and shell shall be split to two or more sections to facilitate dismantling and shall be dowelled securely. The bearing shall be lined with suitable high grade antifriction material such as babbit. The lining shall be bonded securely to the shell, and shall be suitably bored and grooved to cause lubricating oil to circulate over the bearing face without the aid of a circulating pump. The bearings shall be adequately insulated where considered necessary, to prevent any harmful circulating current from passing through the bearings surfaces. The design shall be such that no water shall enter the lubricating system and there shall be negligible loss of oil by leakage or overflow from any part of the oil system under any condition of normal operation. A water detector device with alarm contacts shall be provided at the lowest point of the oil sump. The turbine guide bearing shall be designed for the following conditions: That the normal working metal pad temperature shall not exceed 70OC for turbine operating at all loads up to permitted overloads. Continuous operation at any speed from 30% to 110% of rated speed. Capability of operating safely at maximum allowed load for a period of 15(fifteen) minutes without cooling water supply. Safely withstand turbine going to run away speed due to any fault for a period of 15(fifteen) minutes with cooling water supply intact and subsequent closing down period without any damage to the guide bearing. Withstand safely and without damage the natural retardation from maximum over speed without application of generator brakes. Withstand operation at low speed (4-5% of rated speed) for a period of at least 30 (Thirty) minutes.
a) Water, Oil, Air & Misc. Pipes And Valves The Bidder shall include in the scope of supply all internal piping associated with the turbines for various functions relating to air, water, oil, drain, vent etc. along with associated valves and equipment not specifically mentioned, but are essential. The pipes shall have suitable surface treatment for corrosion resistance. The pipes shall be of suitable class of steel iron. The valves shall preferably be of butterfly type where technically feasible. All raw cooling water pipes shall be of stainless steel.
1.5.15 Turbine Governors a) General The electronic governor which shall be of digital type shall comprising of redundant micro processor based controls, interfacing cards, relays, communication
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devices, MMI, manual push buttons, Indicators etc. required for auto/ manual governing operation. All electrical wiring shall be neatly concealed inside the cubicle and terminated in readily accessible terminals. At least following controls/ indications are to be provided on electronic governor cubicles: Power, Speed, Guide vane position & limiter, droop setting indicators shall be provided shall be provided on governor. Turbine start/ stop push button Emergency trip push button Speed set point raise/ lower push button Opening set point raise/ lower push button Opening limiter raise/ lower push button Regulation system shall have provision for set reference limit, speed and/ or Guide vane opening as required.
The hydraulic actuator cubicle/or unit shall house all the hydraulic mechanical equipment comprising pilot valves, auxiliary servomotor, main distributing valves; various devices for automatic shut down, emergency shutdown, devices for adjustment of governor closing and opening times.
b) Control Requirements The Turbine Governor shall perform following governing tasks for the regulation and control of the generating units: Speed/ frequency Control Power control
The electronic governor shall have provision for both automatic operation as well as manual control through the hydraulic actuator. The governor shall come into action automatically when the turbine start signal is given from the unit control board. It shall then regulate the speed of the generating unit in operation. It shall provide stable governing in all possibilities, stages or conditions of operation of the generating units viz. Speed-no-load Isolated operation Operation connected with grid power system
The governor shall regulate the turbine unit/ generating unit to a uniform speed free from hunting or instability at all loads. It shall have provision for optimization of speed governing parameters, servomotor positioning parameters and turbine loading rate.
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The speed governing of the generating unit shall be carried out by a combination of proportional, integral and differential actions and non-linear characteristics in order to provide best quality of control. The governor shall have high sensitivity, quick response to speed/load changes, least possible dead band time and wide adjusting ranges in respect of the various parameters.
c) Governor Function The governor should work as different controllers at different times. Sometimes they may be in simultaneous operation and sometimes they may work individually depending on mode of selection. The basic controller for the function of governor should be as follows:-
d) Speed Controller The speed actual value shall be compared with speed set value and resultant error normalized with a gain factor. This signal shall be summed with permanent and temporary droop signals. Comparing the gate setting value with gate position feedback shall derive the droop signals. The adjustable range of rated speed setting shall be 90% to 110%. The no load opening should be compensated automatically in the speed controller to allow favourable synchronism for all operating points.
e) Guide Vane Opening Controller The opening set point shall be adjustable between 0 to 100% of guide vane opening. By comparing the guide vane position with the set value, the required guide vane position shall be achieved.
f)
Power Controller The power controller set point shall be adjustable between 0 to 110% Output. The actual power signal shall be derived through a watt transducer and a filter. The required guide vane position shall be derived by comparing the power set point and actual power measured.
g) Flow Controller The flow set point shall be adjustable between 0 to 110% output. Actual flow shall be computed from the head measured and guide vane position.
h) Water Level Controller The set point of water level controller is a predefined parameter. It may only be modified via a service terminal, an operator panel or a communication interface. The
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operation mode water level control may only be selected when the unit operates in parallel. The water level signal should come through a signal filter. The filter time constant should be adjustable. If the water level signal fails, the last valid value should be stored. The water level controller should determine the flow set point by calculating the difference between the set and actual water level value.
i)
Guide Vane Opening Limiter As standard feature the opening limiter should be adjustable between 0 to 110%. The actual value of the opening limiter should limit the opening set point of the guide vanes via a minimum selection. The different controllers when not active shall be tracking the respective actual values for bump less transfer.
j)
Software Programme Features The software for the microprocessor based speed governor shall be capable of quick programme running. In case of any power supply failure the programme and parameters shall remain indefinitely retained. The governor shall have auto test programme for checking permanently for correct operation of the main governor components. The correct execution of the software shall also be permanently checked for which suitable "watchdog monitoring circuit shall be part of it. The software shall prohibit the programming of the parameters beyond the allowed values. Supplier shall provide governor software with adequate literature and training to the Owners engineers for future use during operation & maintenance stage.
k) Other Provisions The speed governor shall be provided with the following provisions: Main processor of the Governor shall be redundant with bump less transfer feature in case of failures of one processor. Facility of data communication i.e. exchanging information through serial communication link. Provision for data exchange with automatic systems of the power station for remote indication, logic information and remote control, the governor shall also be connected in intra plant bus for SCADA, and all the parameter mentioned above should be interfaced to SCADA. If the governor system is not compatible to be connected along with unit sequence panel to SCADA, separate transducers for governor parameters shall be provided for interfacing to SCADA. The system
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Hydraulic Turbine & Associated Equipments connection to SCADA shall also accept analogue commands from SCADA for speed regulation, power regulation and speed droop regulation to achieve desired outputs.
The Governor for smaller Turbine Unit (as covered in Clause No 1.1.1(iii) ) shall be suitable for islanding operation of the Unit and shall operate in a stable manner even when feeding only the station load in isolation from Grid.
l)
Maintenance/ Replacement Provisions The electronic governor of microprocessor based type shall have modular construction with suitable configuration to enable quick and easy maintenance/replacement in case of faults. The maintenance operation of the speed governor shall be feasible by use of an automatic internal checking programme and also by step by step manual internal checking programme with the help of instruction manual. Adequate number of test points and electro lucent diodes on the front face of each card for an easy detailed analysis of each sub-assembly shall be provided.
m) Fail Safe Provision Electronic governor and hydraulic actuator shall be designed on the basis of failsafe principles. (Guide vanes shall close in case of any failures resulting in loss of governing)
n) Governor Operating Time Adjustment The adjustment for guide vane closing and opening times shall be possible without dismantling the main distribution valves of the actuator. DC/ AC Control & Power Supply for Governor The DC Power/ Control supply will be made available by the Owner at 220 V DC and 415 V AC, 50 Hz or 230 V.AC, 50Hz as required. In case DC power voltage requirement are different than 220 V. DC, the bidders shall include DC/ DC converters of requisite power and voltage in their scope of supply. Similarly in case AC, power voltage requirement is different from the above, the bidders shall include the required step down equipment in their scope of supply.
o) Hydraulic Quantities Measurement System The system is intended to measure the following hydraulic parameters: Headrace and tail water levels. Net head on turbine. Turbine flow.
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The headrace and tail water levels shall be measured by sensors to be installed in front of the water intake structure and behind the outlet portal of the tailrace channel. The data shall be displayed at the main control board. Net head on each turbine shall be measured by means of a head differential measuring device. The output signal shall be displayed at the unit control board and be fed in to the speed governor which shall automatically set the guide vane limit according to the available head.
1.5.16 Turbine Main Inlet Valves One (1) number Butterfly Type Valve is required to be provided at inlet of the turbine Unit as covered in Clause No 1.1.1.(iii). The valve opening and closing time shall be adjustable in a wide range. The valve shall be suitable for joining with the Spiral casing inlet of the turbine. The valve will be designed for automatic control with start and stop impulses from the turbine governing system, from the control room or from an independent control desk. The valve will be designed for completing closing with the counter weights. a) Basic Data The Butterfly Valves shall be designed for the following operational design data and system:2500 mm dia (clear bore) or matching with the Inlet diameter of the associated Turbine Unit. 45 m3/s
Diameter/ size of valve Normal flow through valve equivalent to rated full load discharge of two units at rated head at turbine Maximum static head on valves when all the six generating units are stand still (Normal Design Head) Maximum head at maximum upsurge
135 m 182.25 m
b) General Description & Operation Of the Inlet Valve (For 40MW Turbine) The butterfly valve shall comprise of valve body and disc, single acting servomotor(s) for opening operation and counterweights for closing operation of the valve, control gear for operation, a penstock inlet pipe piece, outlet pipe piece with compensator and dismantling joint, and other essential accessories and auxiliaries viz. by-pass valves, air valve, piping with valves for water, air and oil, master switch, slide valves with electromagnets etc. Erection devices, tools and special keys etc. shall form part of the supply. The butterfly type inlet valves shall be designed to close against full discharge in emergency and to open under balanced conditions. The closing operation of the MIV shall ensure positive and reliable closure with the counter weights. Service seal shall get engaged with seat when the valve closes.
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There shall be provision of applying the maintenance seals by moving the maintenance seal seat by hydraulic cylinders mounted on the periphery of valve body spaced equally to ensure the application of seal uniformly without deflection of the seat. There shall be provisions for locking the maintenance seal seat against maintenance seal so that one could safely work on the downstream side for replacement of service seal etc. Water for maintenance seal application shall be filtered using duplex filter with provision of back washing. The water system for closing maintenance seal shall be provided with two isolating valves connected in series on penstock. The valve shall be of such a design, & construction features and uses such materials of construction as would resist silt erosion. A broad list of materials of construction and manufacturing method of the components is given in Table 5. The bidders shall also furnish a detailed list of actual materials of construction and abrasion resistant hard coating and facings on susceptible and vulnerable components in their offers.
c) Butterfly Valve Materials of Construction of Components Sl. No. 1. Manufacturing Method Material Standard SuHardness BHN ASTM 743 Gr/CA6NM ASTM 537 Cl II modified St plate Carbon Steel SS 13-4 or better Self lubricating PTFE compound with integrated rubber O-ring Bronze 1456 Gr. A ASTM 743 Gr/CA6NM 300 max -
Component Maintenance & Service seal Seal seat a) Valve disc
Material Acrylo Nitrile Rubber SS 13-4 or better
2.
300-400 300 max
Casting/ WPFS Forging Casting/ WPFS Casting
Steel plate
3.
b) Rotor trunnion c) Valve Body
4.
Bypass valve body Bypass valve Needle and seat
5.
300-400
6.
Trunnion gland seals
7.
Trunnion bearings
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The disc sealing edge against and trunions shall have overlay of 13-4 Cr-Ni material or better. The life period of maintenance seal shall not be less 20 years. The butterfly valve shall be supplied with independent manually operated locking device provided on valve bodies to safe-guard personnel working in the penstock during maintenance period. The valve shall be provided with fool proof arrangements to prevent accidental opening and closing.
d) Control Gear The control gear of the butterfly valve and its by-pass valve shall be suitable to provide for Manual electrical operation from the local and remote panels. Automatic controls for opening and closing in synchronism/ sequence with the automatic start-stop operation of the generating unit. Emergency auto closure of the butterfly valve in case of turbine over speed (failure of governor). For test and maintenance purpose, a control panel shall be provided and located close to the MIV. It shall be equipped with a local /remote selector switch, control switches and other elements required for operation of the valve.
All necessary limit switches, instruments (pressure gauges, level gauges etc.) and position indicators shall be provided and mounted on the butterfly valves. These instruments shall conform to the international standards/ codes. Ladders, platform, walkways, hand holds, etc., necessary to give safe access to various components of the Butterfly valve needing inspection, maintenance and repair shall be provided.
1.6
PRESSURE OIL SYSTEM FOR GOVERNORS, TURBINE INLET VALVES 1.6.1 General
RING
GATES AND TURBINE
Each turbine shall be provided with a pressure oil system of operation of turbine guide vane servomotors through governors, Ring Gate servomotors or Butterfly valve operation as applicable. The pressure oil system shall consist of oil sump tank, oil pumping unit, oil pressure accumulator (OPU) with nitrogen bottle battery backup, pipes, valves, fittings, instrumentation and switchgear and controls for manual, electrical and automatic operation and sustenance. A common pressure oil system for Guide Vane servomotor and ring gates for bigger turbines and guide vane servomotor and Butterfly valves for smaller turbines is considered. However Bidder may offer separate independent system with all necessary actuators/ controls as per their standard design practice.
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1.6.2
Sump Tank, Oil Pumping Sets & their controls The sump tanks shall be made of fabricated electrically welded plate steel and shall be of sufficient size/capacity to hold all the oil required / contained in the governing system and to supply the same to the Guide Vane servomotors, Butterfly Valve servomotors, Ring gate Servomotors. The sump tanks shall also serve as a collector of return oil from the governor, ring gate and MIV hydraulic system. The tanks shall be totally enclosed and provided with a manhole, oil level gauge, strainers, breather and connections for filling and draining of oil etc. The interior surface of sump tank shall be suitably coated with oil resistance paint to prevent any deterioration of the metal. Provision for abnormally low oil level alarm shall be provided, the alarm to be on UCB (Unit Control Board). Two oil pumping sets shall be mounted on or near the sump tanks, one acting as main and the other as standby. The pumps shall be rotary screw type suitable for auto start/ stop operation with the help of pressure switches. Each pumping unit shall be complete with pump, electric motor, necessary starting, control and protection switchgear & devices on wall mounted type panel. The motors shall be suitable for operation on 415 V, 3 phase 50 Hz, AC supply. The control system for the pumps shall comprise: Manual selector switch control of main-standby role of 2 pumps alternatively. Manual selector switch for auto/manual control for each pump. Pressure switches in OPU for auto control of pumps & alarms. Main pump start when OPU pressure falls to a pre-set value. Standby pump start when OPU pressure falls further to a still lower pre-set value. Low oil pressure alarm when OPU pressure falls still further to lowest pre-set value and causing the unit to trip. Necessary motor switchgear, control & protection devices, relays, meters, push button, indications etc. on a wall mounted type panel.
1.6.3
Accumulator The oil pressure accumulators shall be made of fabricated welded plate steel and shall be designed and tested in accordance with ASME code for pressure vessels or any other approved code. The oil pressure accumulators shall have sufficient oil volume under pressure to meet all the requirements of the governors, guide vane servomotors, Ring Gates, Main inlet valves servomotors etc. Accumulators shall have sufficient volume to perform close-open-close with oil pumps being out of operation. Means shall be provided to prevent entry of air into the oil system under conditions of lowest oil level. The oil pressure unit shall have compressed nitrogen gas in bottles. Pressure switches - for control (start/ stop) of oil pumps & low pressure alarm & unit trip.
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Level switches/ relay for low oil alarms, trip, high oil level alarm and very low level trip. Level switches/ relay for giving alarm when oil rises above a pre-determined value. Oil level gauge glass suitably shielded/ protected and with auto valves for safety on accidental glass breakage. Provisions of oil inlet, pressure gauges, oil drain connections with valve, manhole etc.
1.6.4
Oil Piping, Control Gear, Operating Mechanism The oil piping shall comprise all oil supply and return piping between the pump sets, sumps and the servomotors and also all control oil tubing. i) The control gear shall comprise hydraulically or electrically operated multiway/ port type distributor valves, non-return valves etc. and pressure switches, pressure gauges to start/stop the pump and indicate the oil pressure. The inlet oil to the servomotors shall have suitable throttling devices for regulation of oil flow into and out of servomotors. After setting these devices the specified closing and opening time can be obtained. These devices shall be having locking arrangement at set positions.
ii)
iii) All oil supply piping shall be made of seamless stainless steel and pressure class to suit the specified oil pressure. These piping shall be in accordance with relevant Indian, International or other approved standards. Before commissioning, the piping shall be subjected to hydraulic test pressure equal to 1.5 times the working pressure which shall be maintained for a period of 24 hours. Any leakage/defects, if observed, shall be rectified by the supplier and piping rechecked hydraulically and test results shall be recorded.
1.7
SIGNALISING & INDICATING INSTRUMENTS/ DEVICES IN PRESSURE OIL SUPPLY SYSTEM A gauge panel for signalizing relays, indicating instruments/devices for oil levels, oil pressure gauges etc. shall be provided for various purposes. The level and pressure signalizers shall give alarm and indications for low level & pressure.
1.8
HANDLING OF LEAKAGE WITH DRAIN OIL & ITS DISPOSAL Any leakage from the oil servomotors past glands etc. shall be collected in a small cavity box around the glands and shall be fed through pipes to the sump tank by gravity without exposure to the atmosphere and no pumping shall be provided. The relative levels of the oil sump tank vis-vis the servomotor may be fixed to enable this drainage. For draining of the servomotors (during maintenance or emergency) into sump tank, means comprising normally a closed valve and piping shall be provided.
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1.9
CONTROLS & INSTRUMENTATION FOR TURBINES, GOVERNORS, BUTTERFLY VALVES & AUXILIARIES Bidders shall cover in their offers all sensors / sensing elements and Instrumentations which are embedded within or mounted on the turbine (including ring gates) governor, butterfly inlet valve etc. or on turbine gauge panel (located close to the turbines, as their integral part). Successful bidder shall intimate all the controls and indications of turbine( including ring gates), governor, butterfly inlet valve, cooling water etc. to the control equipment/SCADA supplier to enable him to incorporate all control and indications on the unit control board and SCADA system.
1.10 SPARES The Bidder shall include and quote for essential recommended spares, in addition to specified mandatory spares, sufficient for first 5 years of normal operation in their tender listing items, their particulars, make, unit rates, total prices etc. List of Mandatory spares identified is given in section named Mandatory Spares. The Bidder shall review this list and recommend any modification, deletion or addition with reasons thereof. The spare parts shall be interchangeable with and shall be of the same or better quality than the original component. The spares shall be delivered with initial deliveries and shall be packed for long storage. In addition, the Contractor shall supply sufficient number of erection and commissioning spares based on their experience so that erection, testing and commissioning work progresses smoothly and is not hampered for want of such spares. These spares shall be in addition to the mandatory and recommended spares.
1.11 SPECIAL TOOLS, SLINGS, CONSUMABLES ETC. Bidder shall include all normal and special tools, slings, lifting devices, jacks, turn buckles, foundation plates, bolting material, consumables etc. required for the site assembly, erection, handling and routine testing of the turbines, governors, butterfly inlet valves & auxiliaries as well as for their maintenance, dismantling etc. Complete list of the items, descriptions, make and quantities with technical particulars, etc. shall be given in the tender. All tools shall be supplied in proper tool kits or cabinets. The quantity and technical particulars for welding electrodes required for turbine and other components shall be indicated in the bid and details of equivalent electrodes available in India shall also be furnished. Oil and grease required for the first filling of various equipments along with ten (10%) percent excess quantities shall be included in the offer giving quantities, brand, grades, technical characteristics and the equivalent brands available in India.
1.12 DEVICES AND INSTRUMENTS FOR TESTS DURING ERECTION & COMMISSIONING All devices and instruments required for testing of turbine components, sub-assemblies, governors, MIV and auxiliary equipments during erection and commissioning shall be covered in the offer. This shall cover bulk head, test ring etc. for pressure testing of Spiral casing. A detailed list of items giving description, make, and quantity shall be covered in the offer.
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1.13 TESTING DEVICES & INSTRUMENTS FOR FIELD ACCEPTANCE TESTS All instruments/devices for the set-up required for conducting field acceptance tests for demonstration of fulfilment of efficiency and output guarantees shall be listed in the offer and provided by the supplier on rental basis. The rental charges for such devices shall be included separately in the price schedule.
1.14 DELIVERY, INSTALLATION AND COMMISSIONING 1.14.1 Packaging, handling and site storage The Contractor shall follow the general requirement of Packaging, Handling and Storage elaborated in Transport and Installation" of "General Technical Specification (GTS)". The Contractor shall pack all the consignment in sea worthy packaging strong enough to withstand rough handling during transit to the site. All machined surfaces shall be suitably protected against scratches, corrosion, shocks, impact etc. Packages shall be suitably and distinctly identified for type of handling and kind of storage. The Contractor shall supply all the required tools and handling equipments like mobile crane, forklifts, trailers, trucks for loading, handling in transit areas, unloading and storage of cases and packages. The Contractor shall finalize and submit site/ intermediate storage plans and schedules. The Contractor shall plan well in advance logistics for heavy/ ODC consignment and make necessary arrangement for receiving and storing of these without causing inconvenience to others.
1.14.2 Installation Procedure Contractor shall submit detailed schedule of activities and procedure to be followed during erection, testing and commissioning well before the start of such activities. The Contractor shall maintain the installation records including installation quality control. The Contractor shall provide full access to the Owner for supervision/ inspection of the assembly for verification of the erection according to specified documents (including levels, clearances, pertinent fits, alignments etc) and quality of workmanship.
1.14.3 Erection of embedded parts Foundation/ supports details of any embedded components which is required to be provided by Owner shall be intimated by the contractor during detail design stage. The Contractor shall furnish and install all foundation bolts/supports. All embedded piping and conduits etc. shall be furnished, installed and tested by the Contractor. All parts shall be firmly secured in position to ensure that no movement takes place during placing of concrete and grout. All metal surfaces that are to be embedded in concrete shall be free from loose rust, loose mill scale, oil, or any other foreign matter.
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1.14.4 Alignment The alignment procedures with accepted tolerances shall be furnished by the Contractor at detailed design stage.
1.15 MANUFACTURE, INSPECTION, SHOP ASSEMBLY, MEASUREMENTS & TESTING 1.15.1 Material Tests The material tests include chemical analysis, mechanical tests and non-destructive tests. a) Chemical Analysis For all main components and components exposed to high stresses and/or conditions where the composition is of importance, chemical analysis of the material will be taken in accordance with normal practice to verify that the components conform to the required specifications.
b) Mechanical Tests Mechanical tests will be carried out on all main components according to normal practice and relevant standards to ascertain that material properties conform to the requirements and specifications. Such tests will include the determination of the yield strength, UTS, elongation/contraction and impact strength in aged/non-aged condition as required. Bend tests of plates and sheets will also be performed as required. All Turbine and Main Inlet Valve components subjected to penstock pressure or mechanical stress and those used for the exposed Draft Tube should have proven ductility and should be tested by Charpy Impact Tests and should have Charpy Impact Values not less than 35J at -20C.
c) Non-Destructive Tests Non-destructive tests include ultrasonic tests, x-ray tests, magnetic particle tests and dye-penetrant tests. The section VIII of the ASME Boiler and Pressure Vessel Code will be applied. The test & visual examination will be carried out on all principal castings and forgings which are subjected to, or affected by, high service stresses. Major defects, if any, will be removed by suitable means and soundness of metal will be checked by means of magnetic particle or dye penetrant inspection. Plates which are subjected to high service stress impact, fatigue, or vibration stress, will undergo visual inspection and ultrasonic testing prior to use for manufacture and welding. All full penetration Welds shall be 100% radio-graphically tested. Alternatively these shall be subjected to ultrasonic examination. Defects in welds disclosed by ultrasonic or radiographic testing or dye penetrant/ magnetic particle testing will be completely removed by chiselling.
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Hydraulic Turbine & Associated Equipments After re-welding, the new weld will be again subjected to radiographic examination.
d) Pressure Tests All parts subject to internal or external pressure or containing any liquid or gases temporarily or permanently during operation will be tested prior to painting as per relevant standards. As far as possible these tests shall be done in the shop. If any liquid, which may cause corrosion, is used for the test, all equipment and piping will be thoroughly cleaned immediately after the test. Pipe systems will generally be pressure tested with water. Oil might be used when special precautions against damage are taken. The test pressure will generally be 150% of the design pressure. The pipe systems will be cleaned thoroughly, before tests. Embedded systems shall be pressure tested before embedding. Testing of Parts exposed to Gas Pressure The parts subjected to gas pressure during operation, e.g. Governor Pressure tanks, pressure air tanks etc. will be inspected and tested according to the specified regulations in respect of design, construction, fittings, etc. The pressure test is to be executed by applying the prescribed test pressure in accordance with the relevant standards.
e) Testing of parts exposed to liquid without over pressure The exposed parts subjected to small pressure, e.g. bearing housing, oil containers, etc. shall be tested for tightness with a suitable liquid of small viscosity.
1.15.2 Tests on Steel Plates Steel plates used for manufacturing shall be certified by the steel plate producer, highlighting the following information: i) ii) Charge No. Chemical analysis of melt.
iii) Plate thickness and size iv) Following tests along rolling direction Yield strength, tensile strength & elongation at rupture. Three ISO, V-notch toughness tests at 0 deg. C. in the thickness direction
The findings will conform to minimum requirements of the specifications for the material approved for the relevant structure. Ultrasonic test will be on all plates subject to lateral stresses. Each plate will be stamped in the mill, showing
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Hydraulic Turbine & Associated Equipments Charge No. Plate number Quality designation
Sound quality control and inspection procedures shall be adopted during the shop manufacture and fabrication. All bought out items shall be of reputed manufacturer and conforming to standards and engineering practice. Owners and consultants representatives/engineers will regularly and periodically verify that the manufacture is being carried out according to the laid out procedures and norms. The supplier shall provide free access and facilities for each inspection. The first turbine shall be assembled in shop to the maximum extent feasible. The turbine components/sub-assemblies shall be match-marked and dowelled to ensure correct assembly and alignment in the field. For other sub-assemblies suitable dowels shall be furnished for insertion after field assembly and drilling. The components which operate under pressure of water, air, oil etc. (excepting those which cannot be pressure tested in shop) shall be subjected to hydrostatic pressure tests in shop using a test pressure of 150% (one hundred and fifty percent) of the working pressure for a duration of 120 minutes. All turbine components shall be given the dimensional & other checks applicable, in respect of the following: i) ii) Runner & Shaft Dimensional checks, static and dynamic balancing, homology of runner, Interchangeability. Guide Vanes Clearance, free movement Stroke, free movement, pressure tests Hydraulic pressure test
iii) Servomotors
iv) Guide bearing coolers
v) Governor oil pressure unit Hydraulic pressure tests, operation test vi) Electro-magnet valves Working operation test vii) Important casting forgings plate steel fabricated structures Material tests (mechanical and chemicals) composition. viii) Turbine assemble Geometrical similarity (homology) with model All motors, accessories and auxiliary equipment forming parts of turbines shall be tested in accordance with the requirement of the latest relevant standards. Each mechanical and electrical sub-assembly shall be tested for proper functioning and continuity of the electrical circuit. The first governor shall be assembled in the shop and tested as per the IEC 60308 or IEEE Standard 125 or other applicable code in the presence of Owner or his authorized representatives. The bidders shall furnish a list of shop tests and inspection items on governors in their bids. Tests and checks to be carried out at site shall also be furnished in the bids. The first butterfly inlet valve shall be completely assembled and pressure tested in the shop at a pressure equal to 150% of max. pressure, (i.e. 150% of 135 m = 170 m) for 120 minutes. Leakage tightness of both service and repair seals shall be carried out at 170 m
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and demonstrated. Servomotors and oil piping shall also be pressure tested at 1.5 times working oil pressure. All butterfly inlet valves shall be thoroughly inspected, assembled & dimensionally checked. Their operation shall be demonstrated comprehensively covering all main working parts, accessories, attachments. The bidders in the bid shall furnish a list of all items for inspection and testing. On auxiliary equipments viz. pumps, compressors, etc., routine and type tests shall be carried out in the shop as per standards and test certificates shall be submitted to the Owner for approval before dispatch.
1.16 INSPECTION & TESTING AT SITE All full penetration welding done at site shall be subjected to 100% radiographic examination to detect cracks, blow hole etc. All essential tests at site shall be performed on the turbines during the course of assembly, erection, pre-commissioning and commissioning. The supplier shall furnish a comprehensive and exhaustive list of all such tests for approval, which shall cover but not limited to the following:i) ii) Spiral casing Hydraulic pressure test at 150% of the maximum dynamic head including water hammer. Turbine components like pressure tanks, governor oil sump tanks, greasing equipment, valves piping system Hydraulic pressure tests, leakage tests operational tests etc.
iii) Governors, MIVs, auxiliaries Pressure and other relevant tests. Pre-commissioning checks/ inspection measurement as below shall be performed: i) ii) Draft tube Spiral casing Welding inspection Welding inspection, hydraulic pressure test Clearance, operation, running Clearances Clearances, openings for starting & no load run Performance test Alignment check and run out check
iii) Guide bearing iv) Runner & turbine top cover v) Guide vanes vi) Gov. oil pumping system vii) Shaft
In addition following tests to be performed on Ring gates at site: The mobile cylindrical shell of the Ring Gate shall be tested at site in the Turbine under a water pressure of 1.5 times its maximum operating pressure applied on the outer surface of the shell. A leakage test of the Ring Gate shall be performed under the maximum static water pressure (equal to the maximum upstream level minus the Ring Gate level) applied on the outer surface of the mobile cylindrical shell. The supplier shall furnish a detailed procedure for commissioning of the turbines and other associated equipment and shall submit the same to the Owner not later than 12 (twelve) months prior to the scheduled date of the commissioning of the first unit. The supplier shall calibrate all instrument and equipment prior to commissioning. Commissioning tests shall be carried out by the supplier, as per IEC commissioning guide. The supplier shall take
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full responsibility for operation and safety of the equipment during site testing and commissioning. All applicable commissioning tests listed in IEC commissioning guide (chapter-II of publication No.60545) shall be carried out according to the test procedures specified therein. The pre-commissioning tests and checks shall cover but not limited to the following: i) ii) Transient pressure rise and speed rise for various load throw offs (110, 100, 75, 50 and 25 percent of the rated load), at various heads in the head range, Bearing heat run test.
iii) Setting of Butterfly valve opening and closing time. iv) Setting of governor closing & opening times v) Setting of Ring gates closing & Opening time. vi) Time-rpm deceleration curve, without excitation on the generator from rated speed to stand still. vii) The machine shall be designed to withstand the runaway speed test for 15 minutes and runaway speed test is envisaged to be carried out on completely assembled turbine generators at site by the Bidder, at the discretion of the Owner. The tender shall quote charges for conducting this test separately. In case of failure, the Bidder shall rectify the damage and inherent defects and make such modifications as will make the turbines capable of withstanding the designed Runaway Speed. The Bidder shall demonstrate the same by conducting this test again. viii) During the commissioning period, a closing test of the Ring Gate shall be performed under the maximum operating discharge of the Turbine corresponding to maximum opening of the guide vanes under maximum water head.
1.17 INDEX AND FIELD ACCEPTANCE (EFFICIENCY) TESTS The Index tests shall be conducted on each unit in order to verify and confirm that the shape of efficiency curve is in order and the guaranteed power output is achieved. The values from the efficiency tests shall be used to calibrate the turbine flow-meter. The index tests shall be performed in accordance with the latest IEC code for field testing. Field acceptance tests using appropriate method for turbine discharge measurement shall be conducted as per IEC field test code No.60041, at the earliest opportunity after the unit has been installed and commissioned into service. The Owner reserve the right to call on the supplier or any other independent agency to conduct field acceptance tests to determine whether or not any turbine purchased under the specification meet the guarantees in respect of efficiency and output. The test will be carried out in accordance with the stipulation of the latest IEC code and the price for this test shall be separately quoted in the bid. The method of discharge measurement shall be proposed by the turbine Bidder in their tender in order of suitability, application and accuracy, in consonance with the water conductor system of the project. Work at site for the conduct of the tests shall be the responsibility of the supplier and no extra cost shall be applicable in this regard. Complete details of the test, required duration, list of equipment, etc. shall be furnished before conducting the test. In case the tests are to be got conducted by other agencies, the supplier shall
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depute his supervisors for observation & witness of tests and for acceptance of the test results and liabilities.
1.18 INFORMATION AND DOCUMENTATION BY BIDDER & SUPPLIER The bidders shall quote their prices and furnish technical and other particulars strictly as per the formats/annexure annexed with this section. Technical deviation shall be brought out clearly giving reasons. The bidders shall also enclose various supporting drawings and design materials pertaining to the equipment offered by them. These shall cover Assemblies, sub-assemblies, components. Layout, arrangement of equipment giving dimensions levels, setting. Control, hydraulic control, instrumentation, electrical schematic. Assembly, disassembly, maintenance, repair, replacement procedures & time required for same. General technical literature, manual catalogues, copies of relevant publications. Details of labyrinths, cheek plates, guide vane clearance seals, shaft seal, and guide vane stem bushes/ bearings. Curves/ graphs for turbines' expected performance. Set-up for field acceptance test of turbines.
Supplier shall also furnish following drawings/ documents. Comprehensive Turbine Model Test Report including universal characteristics (3 copies) and one soft copy. Three (3) copies of detailed drawings including cross-section through the complete unit drawn to the scale, design, computation, material specification technical literature, equipment catalogues etc. One soft copy each of the above may also be supplied. Drawings for assemblies, sub-assemblies, components, profiles (Spiral casing, runner, guide vanes, draft tube etc.), layout embedment, electrical and mechanical schematic drawings, turbine Governing and hydraulic control drawings, assembly/disassembly repair/ maintenance procedures. Three (3) copies of Operation & Maintenance Manuals, within 2 years after award of contract. One soft copy of the manual may also be supplied. Detailed Factory and Field Quality Plans along with reference documents and acceptance criteria within six months of award of contract. Detailed setup, procedure, computation sample for field acceptance test on turbine. Inspection and test reports. Other essential drawings & literature.
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1.19 TOOLS AND INSTRUMENTS 1.19.1 Special tools Special Tools shall be supplied by the Contractor as necessary for erection, installation, operation and maintenance, etc. of each item of equipment supplied under this Contract. All special tools shall be clearly marked to identify their use and shall be made available for the erection to be undertaken by the Contractor. Special tools shall be shipped with the first consignment of equipment to be erected. After completion of the job tools shall be delivered to Owner prior to taking over, in perfect working condition.
1.19.2 Customary tools Customary tools shall be supplied by the Contractor for operation, maintenance and overhaul work after Taking Over. They shall in no case be used for erection and/or installation purposes during the construction of the plant.
1.19.3 Tools for erection and installation The Contractor shall bring his own tools, devices, testing instruments/ equipments to site in order to erect and install the complete equipment delivered under this section. These shall remain the property of the Contractor unless otherwise agreed to take over any / all of these at mutually agreed conditions.

Hydraulic Turbine and Associated Equipment

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Hydraulic Turbine and Associated Equipment

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5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

1. 1.1 1.2 1.3 1.4 1.5

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

119.0 and 100.3 m

Rated Continuous Output Capacity at rated net head of 100.3 m

Maximum Continuous Output Capacity

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

ISO 7919 Part-5

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

ii) iii) iv) v) vi) vii) viii)

ix) x) xi) xii) xiii) xiv) xv) xvi)

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments

300-350 350 max.

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Head cover Discharge ring Draft tube cone Spiral casing

ASTM A 537 Class II or ASTM A 516 GR 70

Turbine shaft Coupling bolts Shaft seal sleeve/liner

Guide vane servomotor body, piston and rings

350 max. II or ASTM A 516 GR 70 ASTM A106 GR B / ASTM A53 GR B

5 x 342 + 1 x 40 MW Demwe Lower HE Project

Doc. No. : 904/ EMTD/ TS-10 Revision : 0

Hydraulic Turbine & Associated Equipments