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GBT 8564 2003 Specification For Installation of Hydraulic Turbine Generator Units
GBT 8564 2003 Specification For Installation of Hydraulic Turbine Generator Units
140
F 22
NATIONAL STANDARD OF
中华人民共和国国家标准
GB/T 8564-2003
Replace GB/T 8564-1988
GB 8564-2003
1 Scope............................................................................................................................................. 7
2 Normative standards................................................................................................................... 7
3 General principles....................................................................................................................... 8
4 General regulations..................................................................................................................... 9
5 Installation of vertical type reaction turbine .......................................................................... 12
5.1 Installation of built-in fitting......................................................................................... 12
5.2 Runner installation ........................................................................................................ 21
5.3 Preassembling of the guide apparatus.......................................................................... 24
5.4 Emplacement and installation of rotatable parts ........................................................ 26
5.5 Installation and adjustment of guide blade and/or servomotor................................. 27
5.6 Installation of water conduit and main shaft seal ....................................................... 29
5.7 Installation of fittings..................................................................................................... 30
6 Installation of tubular turbine ................................................................................................. 31
6.1 Installation of built-in fitting......................................................................................... 31
6.2 Installation of principal axes ......................................................................................... 34
6.3 Installation of guide apparatus ..................................................................................... 34
6.4 Installation of guide apparatus ..................................................................................... 34
6.5 Installation of the principal axes, runner and runner chamber ................................ 35
7 Installation of impulse turbine................................................................................................. 35
7.1 Installation of diversion conduit ................................................................................... 35
7.2 Installation of case.......................................................................................................... 36
7.3 Installation of the bearing of turbine shaft .................................................................. 36
7.4 Installation of turbine shaft........................................................................................... 36
7.5 Installation of sprayer and servomotor........................................................................ 37
7.6 Installation of runner..................................................................................................... 37
7.7 Installation and adjustment of control mechanism..................................................... 37
8 Installation and debugging of speed regulating system ......................................................... 37
8.1 Installation and debugging of oil pressure devices...................................................... 37
8.2 Installation of speed governor....................................................................................... 39
8.3 Oil filling adjustment test of speed regulating system ................................................ 41
8.4 Simulation test of speed regulating system .................................................................. 42
9 Installation of vertical type hydrogenerator........................................................................... 42
9.1 Combination of framework........................................................................................... 42
9.2 Grounding and scraping of bearing shell..................................................................... 43
9.3 Stator installation........................................................................................................... 44
9.4 Rotor installation............................................................................................................ 50
9.5 Overall installation......................................................................................................... 56
9.6 Installation of excitation system and devices ............................................................... 64
10 Installation of horizontal hydraulic generator ..................................................................... 65
10.1 Grounding and scraping of bearing bush .................................................................. 65
10.2 Installation of bearing pedestal................................................................................... 66
10.3 Installation of stator, rotor and/or fitment ................................................................ 66
10.4 Checking of each part of the bearing and clearance adjustment............................. 67
11 Installation of bulb-type hydraulic generator ...................................................................... 68
11.1 Installation of stator..................................................................................................... 68
11.2 Installation of rotor...................................................................................................... 68
11.3 Installation of principal axes and composition bearing ............................................ 68
11.4 Generator installation.................................................................................................. 69
12 Installation of pipelineand and fitments................................................................................ 70
12.1 Fabrication of pipe fittings and fitments of pipeline ................................................. 70
12.2 Pipeline welding............................................................................................................ 72
12.3 Installation of pipeline ................................................................................................. 73
12.4 Treatment of the inner wall of pipeline...................................................................... 75
12.5 Test of the conduit and pipe fittings ........................................................................... 75
13 Installation of butterfly valve and ball valve ........................................................................ 75
13.1 Installation of butterfly valve...................................................................................... 75
13.2 Installation of ball valve............................................................................................... 76
13.3 Installation of flexible connector................................................................................. 77
13.4 The installation of hydraulic control valve and air valve ......................................... 77
13.5 Installation of operating mechanism .......................................................................... 77
14 Electrical test of water-turbine generator set ....................................................................... 78
15 Trial run of water-turbine generator set............................................................................... 82
15.1 General specifications .................................................................................................. 82
15.2 Water filling test of assembling unit........................................................................... 83
15.3 Zero load trial run of unit ........................................................................................... 83
15.4 Test over paralleling in of unit and under load ......................................................... 86
Annex A......................................................................................................................................... 90
Annex B......................................................................................................................................... 94
Annex D......................................................................................................................................... 96
Annex E......................................................................................................................................... 98
Annex F ....................................................................................................................................... 101
Annex G ...................................................................................................................................... 104
Foreword
This standard provides basis for the installation, debugging and testing of
hydraulic turbine generator units and relevant auxiliary facilities and main content for
unit acceptance and examination. This standard is applicable to the installation of all
types of hydraulic turbine generator units and relevant auxiliary facilities.
This standard is the revision of GB 8564-1998 Specification for Installation of
Hydraulic Turbine Generator Units (hereinafter referred to as "the original standard").
The original standard summarizes technologies for installation of hydraulic turbine
generator units and relevant auxiliary facilities in and before 1988. On the basis of the
original standard, this standard contains supplements, deletions and amendments to
specifications for installation of large and medium hydraulic turbine generator units
and relevant auxiliary facilities including those imported since 1989, and makes
references of some relevant content in foreign standards.
Compared with GB 864-1988, the following changes are made herein:
-- The standard is clearly classified to be a piece of recommended standard;
-- Application scope of original standard is changed and "Scope" and
"Normative References" are stated separately herein;
-- The following contents are supplemented, such as installation of cylindrical
valve, aqueduct installation and bearing assembly of action turbine, assembly of
welded generator engine frame, assembly of generator stator base and iron core,
welding of disc-type rotor, installation of excitation system and commissioning of
reversible pump-storage unit.
-- Partial contents of installation of speed regulator, adjustment test of oil
charging for speed regulating system, technical requirements of pipeline welding and
quality inspection;
-- Installations of mechanical hydraulic speed regulator, initiator and
permanently-magnetic machine are deleted from the text of original standard, and
installation of mechanical hydraulic speed regulator and drying of stator winding are
stated in annex;
-- Indices and limit values of some articles are partially adjusted and increased.
Although stator windings of internal water cooling and evaporative cooling have
already been adopted in some units in China, experiences in design and construction
of these cooling types are immature and these cooling types may not be promoted in
the future. Therefore, these two cooling types are not covered herein.
This standard will replace GB 8564-1988 from the implementation date of this
standard.
Annexes B, C and G attached hereto are normative.
Annexes A, D, E and F attached hereto are informative.
This standard is proposed by and under the jurisdiction of China Electricity
Council Standardization Center.
Chief Development Department: China Gezhouba (Group) Corporation,
Sinohydro Corporation, China Gorges
Project Corporation and Harbin Electric
Machinery Co., Ltd.
Chief Drafting Staff: Fu Yuanchu, Zhang Hua, Wang Quanlong, Qin Xixiang,
Liu Yongdong, Zhao Shiru, Li Zheng'an, Zhang
Yaozhong, Du Qichen, Zhang Lianbin, Zhao Guishan,
Xu Guangtao, Gong Deping, Wang Tian, Yang Xiyin,
Huang Hongyong, Zhang Chengping, Liu Yanhua, Jiang
Xiaobing, Yin Longsheng, Liu Canxue and Tang
Wanbin.
China Electricity Council Standardization Center is responsible for interpretation
of this standard.
Specification for
Installation of Hydraulic Turbine Generator Units
1 Scope
This national standard regulates the installation, debugging of hydraulic turbine
generator units and the requirements of test. It is applicable to the installation and/or
acceptance of hydraulic turbine generator units in compliance with the following
conditions:
a) Unit capacity of 15MW and/or higher
b) Impulse hydraulic turbine with its nominal diameter of runner at 1.5m and/or
above
c) Radial-axial flow turbine with its nominal diameter of runner at 2.0 m and/or
above
d) Axial flow, mixed flow variable pitch turbine, and tubular turbine, with
nominal diameter of runner at 3.0m and/or above.
Hydraulic turbine generator units with unit capacity smaller than 15MW and units
with nominal diameter of turbine runner smaller than that specified in b), c), and d).
This national standard is applicable to the installation and/or acceptance of reversible
pump storage unit.
2 Normative standards
The following normative documents contain provisions, which, through reference
in this text, constitute provisions of this national standard. For dated reference,
subsequent amendments to, or revisions of, any of these publications do not apply.
However, it is recommended parties reaching agreement according to this national
standard carry out a study on if the most updated version of these documents may be
applied or not . For undated reference, the latest edition of the normative document
referred to applies.
GB3323 Methods for radiographic inspection and classification of radiographs for
fusion welded butt joints in steel
GB/T7409.3 Excitation system for synchronous electrical machines-Technical
requirements of excitation system for large and medium synchronousgenerators;
GB/T7894 Fundamental technical requirements for hydraulic turbine generators;
GB/T9652.1 Specifications of governors and Pressure oil supply units for
hydraulic turbines;
GB/T9652.2 Test acceptance codes of governors and pressure oil supply units for
hydro-turbines;
GB/T10969 Specifications for water passage components of hydraulic turbines;
GB/T11120L-TSA Turbine Oil;
GB11345 Method for manual ultrasonic testing and classification of testing results
for ferritic steel welds;
GB/T18482 Start - up test code for reversible pump - storage units;
GB50150 Emending explanation of Standard for hand-over test of electric
equipment electric equipment;
GB50168 Code for construction and acceptance of cable levels electric equipment
installation engineering;
GB50171 Acceptance of switchboard outfit complete cubicle and secondary
Circuit Electric Machine;
DL/T507 Start-up test code for hydraulic-turbine and generator units;
DL/T679 Code for welder technical qualification;
DL/T827 Start-up test code for bulb tubular hydraulic-turbine and generator units;
JB/T4709 Welding specification for steel pressure vessels;
JB/T6204 Specification for withstand voltage test on stator coil and winding
insulation of high voltage AC machines;
JB/T8439Technical requirements on suppress corona of high-tension machines
used in high altitude areas
JB/T8660 Standard for hydroelectric set packing, transportation and preservation
3 General principles
3.1 Installation of water-turbine generator set shall proceed according to this
national standard in compliance with the installation drawing approved by design
organization and manufacturer as well as related technical documents. Special
requirements raised by the manufacturer shall be satisfied according to related technical
documents. Supplementary provisions for requirements not listed in this standard and
technical documents of manufacturer shall be specified additionally. In case of a
conflict between the technical requirements from the manufacturer and this standard,
generally, the requirements of the manufacturer shall proceed. Otherwise, consult with
the manufacturer for a settlement.
3.2 Other than this national standard, installation of unit and its auxiliary facilities
shall also comply with current related specifications on safety, environmental
protection, fire control, and so on issued by the state or related authorities.
3.3 Equipment for water-turbine generator units shall be in accordance with the
regulations of current national standard and purchase contract. After the equipment
arrives at the acceptance spot, the installation party may participate in unpacking,
counting, checking the supply list and random packing list, and then operate according
to JB/T8660.
The following documents shall be taken as important evidence for acceptance of
both unit and it auxiliary equipment as well as quality acceptance.
a) Equipment installation, operation, instruction on operation and maintenance and
technical documentation;
b) All random drawing materials (including equipment installation drawing and
structure drawing of spare parts);
c) Certificate of analysis, inspection and test records;
d) Material quality and performance certificate of vital parts.
3.4 Before the installation, read design drawing, factory inspection record and
related technical documents carefully and be familiar with them, and then make out a
logical construction design in compliance with the actual conditions.
3.5 Before the installation, read related civil design drawing and participate in the
acceptance of the delivered civil construction parts. For places with flaws, the
installation must be carried out after treatment.
3.6 All materials used in the installation of water-turbine generator unit shall be in
accordance with design requirements. Primary materials must possess inspection
certificate and certificate of analysis.
3.7 Plan the installation field integrated. The following requirements shall be met:
a) Installation field shall be windproof, rainproof and dustproof. Unit installation
must proceed after the completion of the factory building roofs of this unit and adjacent
units are sealed.
b) Generally, the temperature shall not be lower than 5°C. Relative humidity of air
shall not be higher than 85%. For other equipments and parts that have requirements
over temperature, humidity and other special conditions, the installations shall be
implemented according to the design specifications.
c) Enough illumination shall be provided on the construction field;
d) Safety facilities for construction in compliance with requirements must be
equipped on site. Places to put flammable, high explosive items must have
corresponding safety provisions;
e) Civilize production. Installation equipment, construction tools and materials
shall be placed in order. The construction site shall keep clean. Passage remains to be
smooth. Clear the site on the completion of work.
3.8 After the completion of the installation of water-turbine generator set, proceed
the test run according to this national standard and DL/T507. Comprehensively check
the quality of design, fabrication and installation. After the test run is proved qualified,
proceed the acceptance of the unloading phase of this unit. Hand over related materials
according to the requirements of Annex A.
4 General regulations
4.1 Before installation, clear and inspect the equipment overall. Check the main
dimensions and/or tolerance of primary parts according to the drawing requirements as
well as ex-factory records.
Equipment inspection and flaw treatment shall have records and licenses.
Packed equipment under warranty may not have to be dis-integrated.
4.2 Generally, deviation of the elevation of entombment of equipment foundation
bedplate shall not exceed - 5mm ~ 0mm. Deviation of the center and azimuth
distribution shall not be greater than 10mm. Horizontal deviation is no greater than
1mm/m.
4.3 After fitting entombment part, reinforce it. Foundation bolt, lifting jack,
fastener, wedge, and floor plate shall all be spot-welded and fixed. The built-in fitting
and the concrete binding surface shall be free of oil sludge and serious rustiness.
4.4 Installation of the anchor bolt shall comply with the following requirements:
a) Check if the anchor bolt hole is in the right position. The inner wall of the hole
shall be roughened and cleaned. Deviation of the screw center line and base center line
shall not be greater than 10mm; the elevation and depth of the bolt shall be in
compliance with the design requirement; squareness deviation of bolt hole wall shall
not be greater than L/200 (L refers to the length of anchor bolt mm, the same for the
following context) and shall be smaller than 10mm.
b) Centre of second phase concrete direct burial and casing flush type anchor bolt
shall comply with design requirement. The deviation of center shall not be greater than
2mm. The discrepancy in elevation shall not be greater than 0mm ~ +3mm. Squareness
deviation shall be smaller than L/450.
c) Anchor bolt adopts embedded bar. Welding of screw on it shall conform to the
following requirement:
1) Material quality of embedded bar shall agree with the material quality of anchor
bolt basically;
2) Cross-sectional area of embedded bar shall be greater than that of bolt, and the
embedded bar shall be upright;
3) When the bolt and embedded bar adopts double side welding, the weld length
shall not be smaller than 5 times the diameter of the anchor bolt. When single side
welding is adopted, the weld length shall not be smaller than 10 times the diameter of
anchor bolt.
4.5 Use wedge plate pairs and the overlapping length shall be 2/3 upwards. For the
wedge plate that bears important parts, inspect the contact situation with 0.05mm feeler
gauge. The contact length of each side shall be greater than 70%.
4.6 Install the equipment after the substructure concrete intensity reaches 70% of
the design value. Second term concrete on the floor plate shall be poured and
compacted.
4.7 The coupling surfaces of equipment shall be smooth and burr free. For joint
close clearance, measure with 0.05mm feeler gauge and the gauge shall not pass
through. Partial clearance is allowed. Check with 0.10mm feeler gauge and the depth
shall not exceed 1/3 the width of plane of composition. The total length shall not
exceed 20% of the perimeter. No clearance shall exist around the assembling bolt and
pin bolt.
Generally, fitting surface at the combination slot staggering shall not exceed 0.10
mm.
4.8 Match marks shall be considered during component installation. When a lot of
machines are installed together, each machine shall be assembled with the part marked
with the same series design.
The serial numbering in the installation record of same kind of installation or
survey points for fixed parts shall begin from +Y and be numbered clockwise (begin
from generator end, same for the following context); for rotating installation, begin
from the position of No.1 polar of rotor. Except that the survey point on the jigger is
numbered counterclockwise, others are all numbered clockwise. Attention shall be paid
to the above numbering regulations of the manufacturer.
4.9 For connecting bolt with pre-tightening force requirement, the pre-tightening
force deviation shall not exceed the 10% of the set value. If not specified by the
manufacturer, preliminary tension shall not be smaller than twice the design work
stress and shall not exceed 3/4 of the yield strength of materials.
During the installation of closely-pitched connecting bolt, the screw thread shall
be applied with lubricant. Connecting bolt shall be fastened evenly by many times.
Adopt thermal state screwed bolt. After fastening, spot check the pretension of around
20% bolt.
After each part is installed, drill hinge pin tack hole and fit pin bolt according to
design requirement.
Lock and fasten the bolt, bolt cap, and pin bolt according to design requirements.
4.10 Universality measurement of the unit shall conform to the following
requirements:
a) Check and adjust all measuring tools in the qualified metrological examination
departments.
b) Deviation of X, Y datum line and height point used in the installation of unit
against the data mark of factory building shall not exceed±1mm.
c) Measuring error of the height deviation of each part shall not exceed±0.5mm.
d) Horizontal survey deviation shall not exceed 0.02mm/m.
e) Generally, diameter of the steel wire used by the center is 0.3mm ~ 0.4mm. Its
tension stress shall not be smaller than 1200MPa.
f) No matter which method to take in measuring the center or roundness of the
unit, the measuring error shall not be greater than 0.05mm;
g) Pay attention to the impact on the surveying accuracy by temperature
fluctuation. Amend the measured number according to the changes of temperature
during the measuring.
4.11 In the intensity waterproof test for field manufactured bearing equipment and
bridge pieces, the test pressure is 1.5 times the nominal operating pressure, but the
minimal pressure shall not be smaller than 0.4MPa. Sustain for 10 minutes, no leakage
or crackles, and so on.
During the tightness compression test of equipment and its bridge pieces, the test
pressure is 1.25 times the actual working pressure. Sustain for 30 minutes, no leakage
phenomena. During the leakage test, the test pressure is actual working pressure,
sustain for 8 hours, no leakage phenomena.
Carry out the waterproof test of single cooler according to design requirement. If
not regulated, the test pressure shall be twice the working pressure, but no lower than
0.4Mpa. Sustain for 30min, no leakage phenomena.
4.12 In the kerosene leakage test of vessel, sustain at least 4h. If no leakage
phenomena, do not dismantle the vessel after finishing the leakage test.
4.13 Single keystroke shall coordinate with keystroke for the examination. The
tolerance shall comply with design specification. Keystrokes in-pair shall be checked in
pair. The parallelism shall meet the design requirements.
4.14 Welding of assembling unit and its auxiliary facilities shall comply with the
following requirements:
a) Welders of assembling unit and its auxiliary facilities shall attend special item
training and examination regularly as required by the manufacturer. They must hold
certificate to take the position after they pass examinations and are licensed.
b) All the length and height of the welding seams shall meet the drawing
requirements. Welding quality shall be checked as required by the design drawing.
c) For important components, welding shall proceed according to the welding
process or welding procedure specification specified by the manufacturer after the
qualification of welding procedure.
4.15 Trademark of turbine lubricating used by assembling unit and
speed-regulating system shall comply with the design regulations. See Annex F.
4.16 All monitoring equipment and automation components of the assembling unit
shall be check and qualified according to the ex-factory specifications.
4.17 Assembling and general installation of the water-turbine generator as well as
installation shall all be kept clean. After the installation of assembling unit, clean and
check carefully both inside and outside the unit. No impurities or nastiness shall exist.
4.18 Antisepsis painting of each part of the water-turbine generator set shall
satisfy the following requirements:
a) Each part of the assembling unit shall be pre-treated and painted in the
manufacturing factory according to the design drawing.
b) Installation (including site-welding seams) needs to be painted with final
coating on site shall proceed according to the design requirements. If the color and
factory building ornament do not agree, except for the tube color, colors of other parts
are changeable.
c) During the installation process, if the finish coat is damaged partially, fix it
according to the requirements of original coating.
d) Coating of the site operation shall be homogeneous, bubble free, wrinkle free
and with the same color.
e) Installation that needs to be varnished on site according to contract or required
specially shall comply with regulations.
Table 2 Permissible deviation for Runner chamber, foundation ring, and the stand ring
installation
Unit: in millimeter.
300
No 600
Item 0
. 0≤D 8000≤
≤D D≥10
D < 3000 < D<
< 000
800 10000
600
0
0
Measure
the
distance
between
X and Y
marks on
1 Center and azimuth 2 3 4 5 6 the
built-in
fitting
and X, Y
datum
line of
unit
2 Elevation ±3
0.05 mm/m,
Flatne No
maximal no
ss of machinework
greater than Elevation difference of the
flange Radial survey at the site
0.60 highest point and the lowest
face to
Site point
install 0.25
3 machinework
coping
No 0.
and 0. 0.6
machinework 3
base Circumferential 40 0
at the site 0
ring survey
Site
0.35
machinework
Difference between each radius Measure the three upper,
and the average radius shall not middle and lower sections
Roundness of runner
4 exceed ±10% of the design with axial flow; measure
chamber
average clearance of the paddle upper spigot and lower
and runner chamber spigot with mixed flow
variable pitch turbine;
evenly divide it into 8 ~ 64
measuring points
Evenly divides it into 8 ~ 32
Foundation ring, measuring points. For mixed
socket ring roundness flow unit, the lower fixed
5 and/or its right 1.0 1.5 2.0 2.5 3.0 sealing ring hub is taken as
alignment with the reference, and for axial
runner chamber flow unit, runner chamber
hub is taken as the reference
5.1.4 Split runner chamber, foundation ring, socket ring plane of composition of screw-in
structure shall be applied with sealant, and the combination slot clearance shall be in
compliance with the requirements of Article 4.7. To prevent leakage, combination slot of
waterway surface may be sealed and welded. Weld surface shall be burnished and polished.
Combination if throating ring, foundation ring and socket ring of group weld shall meet the
design requirements.
5.1.5 During the installation of the upper ring of pillar socket ring and fixed guide vane,
direction of the azimuth deviation of socket ring and foundation ring shall be identical. To
guarantee end clearance of the guide blade is in accordance with the design requirements,
height from the foundation ring surface to the socket ring surface shall be controlled critically.
The distortion of socket ring caused by concrete pouring, deviation of measuring tool, as well
as the decreasing value of the end surface clearance caused by the tectorial distortion in service.
To reduce the distortion in the process of concreting, socket ring shall have reliable
reinforcement measures.
5.1.6 Permissible deviation for spiral casing erecting shall conform to the requirements of
Table 3.
5 D ± 0.002 D
6 Pipe orifice 3 Combination on the steel
flatness platform or guy wire inspection
tube mouth shall be on the same
surface (belonging to the
inspection project).
5.1.7 Permissible deviation for spiral casing assemble shall conform to the requirements
of Table 4.
5.1.8 The following requirements shall be met for spiral casing weld:
a) Weld shall conform to the regulations of Article 4.14;
b) Generally, clearance between internodes, spiral cases and butt welds connected to the
socket ring is 2mm ~ 4mm. Unevenness of the waterway surface shall not be greater than 10%
of the slab thickness, but the maximal unevenness of longitudinal seam shall not be greater
than 2mm and the maximal unevenness of circumferential seam shall not be greater than 3mm;
c) If local clearance of groove is over 5mm, its length shall not exceed 10% of the weld
length. It is permitted to make overlay welding treatment at the groove.
5.1.9 Spiral case welding seam shall accept visual examination and non-destructive
examination. If not regulated by the manufacturer, the following requirements shall be met:
a) Weld appearance inspection shall conform to the regulations of Table 5;
Table 8 Distance from spherical surface center to the gravity center of runner
Quality of the runner - t Maximal distance (mm) Minimal distance (mm)
(Kg)
t<5000 40 20
5000≤t<10000 50 30
10000≤t<50000 60 40
50000≤t<100000 80 50
100000≤t<200000 100 70
t≥200000 120 90
c) .During the adoption of surveying rod strain method or static pressure ball-bearing
method, proceed according to the requirements and process as required by manufacturer.
d) Residual unbalanced moment shall be in compliance with the design requirements. If
no requirements are raised, requirements of Table 9 shall be met:
5.2.6 Operational test of runner blade of Kaplan turbine and tightness compression test
shall meet the following requirements:
a) Oiliness of test purpose oil shall be qualified and the oil temperature shall not be lower
than 5 °C;
b) Maintain 16h under the maximum test pressure;
c) During the test, during the test, switch on and off the paddle two or three times per
hour.
d) No leakage phenomena are allowed for each combination seam. oil leakage limit for
each single paddle package under or without test pressure shall not exceed the limit regulated
in Table 10, and be no greater than fuel oil leakage quantity during the ex-factory test;
Table 10 Oil leakage limit of each single paddle package per hour
Runner
diameter D D<3000 3000≤D<6000 6000≤D<8000 8000≤D<10000 D≥10000
(mm)
Oil
leakage
limit of the
each single
5 7 10 12 15
paddle
package
per hour
mL/h
e) Runner servomotor shall move steadily. Generally, minimal oil pressure to turn on and
turn off shall not be greater than 15% of the nominal operating pressure;
f) Plot the relation curve of runner servomotor stroke and paddle rotor angle.
5.2.7 Joint of principal axes and runner shall be in compliance with the following
requirements:
a) Flange plane of composition shall be free of clearance. Check with 0.03mm clearance
gage and it shall not fill in;
b) Drop pit of screw bolt of flange shield shall be filled and leveled up.
c) Runner boss screw bolt shall be spot welded and fastened. Frame cover weld shall
adopt measures to prevent distortion. Welding seam shall be planished.
5.2.8 Right alignment and/or roundness of each part of the runner shall be examined with
principal axes as the center. The difference between each radius and average radius shall meet
the requirements of Table 11.
Table 11 Permissible variation of right alignment and/or roundness of each part of the
runner
Permissible
No. Item Notes
deviation
1) Seal ring ±10% design Tip of blade is
2) Fitting clearance measured only
surface of seal when it is
ring necessary, and
3) Tip of blade when the
quantity flow is
0
Nominal head <
1 4) Wearing ring ±15% design
200 m
of diversion clearance
board
5) Flange
protection cover
also serves as
sealing cover
during overhaul
Nominal 1) Exterior ±5% design Corresponding
2
head≥200 m margin of upper clearance fixed parts are
canopy coping and/or
2) Exterior base ring
margin of lower
ring
3) Seal ring of ±0.10 mm
upper claw tooth
4) Runner band
seal
Table 12 permissible variation for the right alignment of sealing socket and flange
spigot of bearing block Unit: in millimeter
Runner D<300 3000≤D<600 6000≤D<800 8000≤D<1000 D Notes
diameter D 0 0 0 0 ≥1000
0
Permissibl 0.25 0.50 0.75 1.00 Evenly
e variation distribut
e 8~24
points
c) Upper spigot centre of deriaz turbine and runner chamber shall be taken as the unit
fiducial center;
d) Preassembling quantity of guide blade shall not be less than 1/3 of total;
e) After the adjustment of base ring and top cover, the quantity of symmetric, screwed
fitting-up bolts shall not be less than 50% and shall meet the requirements of Table 13. Check
the clearance of guide blade sections. Clearance left on both sides of the header and end of
each guide blade shall identical. No regular inclinations are permitted. The maximal total
clearance shall not exceed the design clearance. Deformation value of the bearing rear head
cover shall be taken into account.
Table 13 Permissible variation of base ring and top cover Unit: in millimeter
Runner diameter D
Project D<3000 3000≤D 6000≤D 8000≤D D Notes
<6000 <8000 <10000 ≥10000
Roundness of 5% design clearance of runner sealing ring Evenly
the wearing distribute 8~24
ring measuring
points
Concentricity 0.15 0.20 Evenly
of seal ring distribute 8~24
measuring
points
Check the 0.35 0.45 0.60 The number of
surface level circumferential
of base ring measuring
points shall not
be less than the
number of
guide vanes.
Adopt the
difference of
elevation
between the
culmination and
nadir point
Right In compliance with the design requirements
alignment of
wicket gate
housing
5.3.4 Guide apparatus without preassembling but directly installed formally shall also
meet related requirements of 5.3.1 ~ 5.3.3.
5.3.5 Installation of cylindrical valve shall meet the following requirements:
a) After the group welding of tunnel body, roundness of tunnel body under free condition
shall meet the design requirements;
b) Installation and adjustment of servomotor and pipeline shall meet the design
requirements. Consistency of the actuation time of each servomotor shall be guaranteed;
c) Welding of tunnel body shall meet the provisions of JB/T4709 and 4.14;
d) Installation of synchronizing mechanism and stroke indicator shall meet the design
requirements. Movement during the total excursion shall be stable.
5.4 Emplacement and installation of rotatable parts
5.4.1 Placement elevation of the principal axes and runner after being suspended into unit
pit shall be slightly lower than the design elevation. Between the flange face on the upper part
of principal axes and the subface of lower flange spigot of the generator shaft, 2mm ~ 6mm
clearance shall be left. For unit with bearing collar installed on the water turbine, the
placement elevation after the principal axes and runner are suspended into unit pit shall be
slightly higher than the design elevation to leave a 2mm ~ 5mm clearance between the bearing
collar and rotating plate after the installation of bearing collar. Deviation of the principal axes
squareness shall not be greater than 0.05mm/m.
When the water turbine or generator are centered according to objective, adjust the centre
and/or principal axes plumbness of runner to make the wearing ring clearance in compliance
with the requirements of Article 5.4.2. Squareness deviation of principal axes shall not be
greater than 0.02mm/m.
5.4.2 Permissible variation for the ultimate elevation of the installation of runner, each
wearing ring clearance or clearance between paddle and runner chamber shall meet the
requirements of Table 14 if no requirements are given by the manufacturer.
5.4.3 Zero clearance between the combination seams of two flanges after the coupling of
the unit. Check with 0.03mm clearance gage, and the gage shall not fill in. 5.4.4 Installation of
oil supply line and oil-supply head shall meet the following requirements.
a) Oil supply line shall be rinsed critically. Joints shall be secure, with no leakage.
Screwing oil supply line shall have locking measures.
b) Generally, for fixed tile structure, swing of oil supply line shall not be greater than
0.20mm; for floating tile structure, it shall not be greater than 0.30mm.
c) Horizontal deviation of oil-supply head shall not be greater than 0.05mm/m if
measured on the surface of oil receiver holder.
d) Oil deflector ring clearance between the rotating sump and oil receiver holder shall be
even and shall not be smaller than 70% of the design value.
e) Grounding insulation resistance of oil receiver shall not be smaller than 0.5MW during
the measuring when draft pipe is anhydrous.
5.5 Installation and adjustment of guide blade and/or servomotor
5.5.1 End clearance of guide blade shall meet the design requirements. Axial clearance of
guide blade thrust ring shall not be greater than 50% of the gap width on the upper part of the
guide blade. The guide blade shall be able to rotate flexibly.
5.5. 2 At the maximum opening position, the distance between the guide blade and
bearing plate shall meet the design requirements. When there is no regulation, 5 mm ~ 10 mm
shall be left.
Link rod shall be linked and adjusted on occasions that the guide blade and control loop
are located in a small opening position. Vertical plane clearance inspection of guide blade shall
proceed under complete shutdown position. The connection of link rods shall proceed when
the guide blades are fastened by steel wires or control loop is completely shut down. Deviation
of the circle of gate closure shall meet the design requirements. The link rod shall be leveling
off and the difference of height of both ends shall not be greater than 1mm. Measure and
record the distance between the two axial holes.
5.5.3 The clearance of vertical plane of guide blade shall be checked with 0.05mm
clearance gage when it is tightened by rope coil and the gage shall not pass through. Partial
clearance shall not exceed the limit required by Table 15. Total length of its clearance shall not
exceed 25% of the height of guide blade. When the design has a special requirement, it shall
meet the design requirements.
e) Position of orifice set and opening dimension shall meet the design requirements;
f) Servomotor piston shift shall be calm and flexible. The piston stroke shall meet the
design requirements. Deviation of the two piston strokes of linear type servomotor shall not be
greater than 1mm;
g) Behind the oil separator tubing of wobble servomotor, servomotor movement shall be
flexible.
5.6 Installation of water conduit and main shaft seal
5.6.1 Bearing shell shall meet the following requirements:
a) Rubber bearing shell surface shall be leveling off, flawless and/or no peel-back. Babbitt
metal bushing shall be free of flaws like concentrated porosity, crackle, hardpoint and/or
peel-back. Tiling roughness shall be smaller than 0.8mm;
b) Try the assembling of rubber tile and spool tile with axle. Total clearance shall meet
the design requirements. The difference between the maximal and minimal total clearance at
each side and the difference of the total clearance of the upper and lower ends in the same
azimuth shall both be no greater than 10% of the average total clearance according to the
actual survey.
c) When spool tile conforms to the two requirements of a) and b), it does not have to be
grounded and scraped any more. The grounding and scraping of sectional type tile shall be
determined according to design requirement;
d) After the grounding and scraping of bearing shell, the tiling osculation shall be even.
At least one contact point shall be set on per square centimeter; each of the partial non-contact
area of each piece of tile shall not be greater than 5%. The sum shall not be greater than 15%
of the total area of bearing shell.
5.6.2 Installation of guide-block shall conform to the following requirements:
a) Guide-block shall be installed under the conditions that the unit axial line and stress
over thrust pad is adjusted to be eligible and the wearing ring clearance of water turbine and air
interstice of generator meet the requirements. To facilitate the countercheck of the central
position of rotor shaft, establish central measuring point at proper parts of the fixed section of
bearing. Measure and record related data;
b) Generally, during the installation of guide-block, gap adjustment shall be made
according to the spindle center; also, the swing, direction and dimension of jigger shall be
taken into account. The total installation clearance shall meet the design requirements. For
units with only two guide bearings, swing may be neglected during the gap adjustment;
c) Permissible variation of sectional type guide-block clearance shall not exceed±
0.02mm; permissible variation of sausage type guide-block clearance shall not be greater
than±20% of the assigned clearance value. Tiling surface shall be kept vertical.
5.6.3 Bearing installation shall meet the following requirements:
a) Oil leakage is not permitted for thin oil bearing tank. Generally kerosene leakage test is
required in accordance with Article 4.12;
b) Bearing cooler shall have tightness compression test as required by Article 4.11.
c) Oil quality shall be eligible. The oil level shall meet the design requirements. Generally,
the deviation shall not exceed± 10mm.
5.6.4 The overhauling and installation of principal axes shall meet the following
requirements:
a) Before the assembling of the air lashing strip, 0.05MPa compressed air shall be filled in.
In the air leakage test in the water, no air leakage phenomena shall exist.
b) After the installation, diametral clearance shall meet the design requirements. The
deviation shall not exceed 20% of the design gap width.
c) After the installation, air charging test, air discharge test and pressure maintaining test
shall be carried out. The pressure drop shall meet requirements. Generally, under 1.5 times
working pressure, the pressure shall be maintained for 1h. The pressure drop should not exceed
10% of the nominal working pressure.
5.6.5 The working, pressurizing and installation of principal axes shall meet the following
requirements:
a) Axial and radial clearance of the working pressurized installation shall meet the design
requirements. Permissible variation shall not exceed±20% of the actual average gap width;
b) The sealing element shall be able to shift up and down freely. The contact with swivel
sealing surface shall be good. Drainage system shall go smoothly.
5.7 Installation of fittings
5.7.1 Vacuum breaking valve and gulp valve shall have actuation test and leakage test and
its initial actuating pressure and maximum opening shall meet the design requirements.
5.7.2 Spiral case and drainage gate valve of draft pipe or servomotor of disk valve shall
all have tightness compression test as required by Article 4.11.
5.7.3 For installation of the valve base of disk valve, horizontal deviation shall not be
greater than 0.20mm/m.
After the installation of disk valve, check the sealing surface, which shall be free of clearance.
The actuation of valve box shall be flexible and the pressurizing of valve stem shall be
secure.
5.7.4 Device installation for the admission of air of spindle center hole shall meet the
design requirements. If required by the design, the spindle center aeration pipe shall attend the
jigger checking. The swing value shall not exceed 20% of the actual average value of sealing
clearance. The maximal value shall not exceed 0.30mm. Connecting bolt shall be secured.
After the installation of fulcrum bearing, grounding insulation resistance shall be measured.
Generally, it shall not be smaller than 0.5MW. Exposed pipeline shall have moisture
condensation resistant facilities.
Table 17 Permissible variation for the installation of tubular turbine draft pipe Unit as
millimeter
Runner diameter D
No. Item Notes
D< 3000 3000≤D<6000 6000≤D<8000
Difference Structure
between the with
maximal and foundation
1 the minimal 3.0 4.0 5.0 ring refers to
diameters at the flange on
the pipe foundation
orifice ring
Left-right
deviation of
elevation at
Centre and
2 ±1.5 ±1.5 ±2.5 the pipe
elevation
orifice level
and its
vertical label
Distance (1) If stay
between the ring is
3 ±2.0 ±2.5 ±3.0
flange face installed
and runner first, then its
centerline downstream
side flange is
taken as
reference;
(2) Measure
four points:
up and down,
right and left
Measure the
Vertical squareness of
4 plane of 0.8 1.0 1.2 flange face to
flange face the unit
center line
6.1.2 For the installation of tubular turbine stay ring, the permissible variation shall meet
the requirements of Table 18.
Table 18 Permissible variation for the installation of tubular turbine stay ring
Unit: in millimeter
Runner diameter D Notes
No. Item
D< 3000 3000≤D<6000 6000≤D<8000
(1) Marked
elevation of the
upper lower
stream flange
level
Azimuth and
1 ±2.0 ±3.0 ±4.0 (2) Distance
elevation
between X and
Y marks on the
installation and
corresponding
datalines
(1) If the
draught tube is
installed first,
Distance
flange shall be
from flange
taken as
2 face to ±2.0 ±2.5 ±3.0
reference; (2)
runner
Measure the
centerline
four points up
and down, right
and left
Maximum Plumbness and
3 0.8 1.0 1.2
size for plane of other
vertical plane flange faces
of flange shall be
face converted
based on this
deviation
4 Roundness 1.0 1.5 2.0
Distance
between the
inner and
outward
5 0.6 1.0 1.2
flange faces
at the
downstream
side
6.1.3 For the installation of cover board of flow channel, permissible variation shall meet
the requirements of Table 19.
Table 19 Permissible variation for the installation of cover board of tubular turbine
flow channel Unit as millimeter
Runner diameter D
No. Item Notes
D< 3000 3000≤D<6000 6000≤D<8000
Centre and
Deviation
position of
of frame
flow
1 ±2 ±3 ±4 center line
channel
and design
cover board
center line
shaft hole
Elevation of
the
2 ±5
foundation
frame
Height
difference of
the four
3 4.0 5.0 6.0
corners of
foundation
frame
Level
degree of
4 0.8
the flange of
flow
channel
cover board
shaft mm/m
6.1.4 For the installation of tubular turbine servomotor, the permissible variation shall
meet the requirements of Table 7.
6.1.5 After the installation and acceptance of stay ring, pour the concrete according to
Article 5.1.11 and 5.1.12.
6.2 Installation of principal axes
6.2.1 Generally, installation of principal axes shall be carried out in the clipping room.
Place the principal axes on the bracing frame used for installation. Adjust the degree of level.
Generally, it shall not be greater than 0.5mm/m.
6.2.2 Oil supply line shall be rinsed rigorously. No oil leakage. Make sure the exactitude
sliding of inner oil supply line inside the outer oil supply line.
6.2.3 The examination of water guide-block before its installation shall comply with the
requirements of Article 5.6.1. When it is fitted into the principal axes, the bearing shell
clearance shall comply with the design requirements. Sealing on both ends of the bearing shell
shall be in good condition. Return oil shall go smoothly.6.2.4 Coupling of water guide-block
and shell bearing shall comply with requirements of Article 10.4.4. Clearance of the plane of
composition between the shell bearing, supporting ring and hub cap shall conform to the
requirements of Article 4.7.
6.2.5 Installation of main guide bearing shall consider the variance generated by the
deflection of rotation parts.
6.2.6 For bearing with grounding insulation requirements, before oil charge, check its
insulation with 1000V megohm meter, and it shall not be lower than 1MW.
6.3 Installation of guide apparatus
6.3.1 Split of outer and inner cone and control loop composition plane shall be spread
with sealant or fitted with stamping steel ribbon according to the design requirements. The
combination seam shall conform to the requirements of Article 4.7. Fitting of stamping steel
ribbon shall leave 1mm ~ 2mm space on both sides.
6.3.2Installation of guide apparatus shall meet the following requirements:
a) Right alignment of outer and inner cone shall be adjusted. The deviation shall not be
greater than 0.5mm;
b) On the upper stream, distance between the inner and outer flange shall meet the design
requirements. The deviation shall not be greater than 0.4mm;
c) Adjustment of guide blade end clearance shall be measured in a closed position.
Clearance distribution of inside end surface and outer end surface shall meet the design
requirements. End clearance at both the head and end of guide blade shall be basically the
same. The rotation shall be flexible;
d) Maximal allowable partial vertical plane clearance of guide blade shall not be greater
than 0.25mm and the length shall not exceed 25% of the gate height.
6.4 Installation of guide apparatus
6.4.1 When inner cone, outer cone and gate vane are entirely suspended into unit pit,
adjust the right alignment of inner cone and hub cap as well as stay ring to no greater than
0.5mm.
6.4.2 After the control loop and outer cone are suspended into unit pit, measure or adjust
the clearance between control loop and outer cone to make it meet the design requirements.
6.5 Installation of the principal axes, runner and runner chamber
6.5.1 After the installation of runner, carry out the tightness compression test and
actuation test, which shall meet the requirements of 5.2.6.
6.5.2 During the axial line adjustment, axial variance generated by operation shall be
taken into account, as well as the actual inclination value of stay ring flange face, which shall
meet the design requirements.
6.5.3 After the connection of runner and principal axes, check the plane of composition
with 0.03mm clearance gage, which shall not pass through.
6.5.4 Oil supply line of oil receiver shall take the jigger examination. Its swing value shall
not be greater than 0.10mm. Right alignment of tilting fillet of oil receiver and the operational
oil tube shall not be greater than 0.15mm for fixed tile; for floating tile, it shall not be greater
than 0.20mm.
6.5.5 Adjust and install runner chamber centering runner. The runner chamber value and
impeller clearance value shall meet the design requirements.
6.5.6 Installation of main shaftseal shall meet the requirements of Article 5.6.4 and 5.6.5.
6.5.7 After the installation of telescopic joint, clearance left in advance for collapsing
shall meet the design requirements. The deviation shall not be greater than± 3mm.
6.6 Waterway surface and plane of composition shall be fitted with sealing element and spread
with sealant according to the design requirements. Tightness examination shall be carried out,
and no leakage is permitted.
6.7 For guide apparatus with heavy punch, after completing the installation of water turbine
and formation of operating system of guide apparatus, carry out the heavy punch turnoff test
under anhydrous or still water conditions. Record the closing time.
Table 20 Permissible variation for the installation of scavenge box (oil tank of speed
governor) and overhead tank
Permissible
No. Item Notes
deviation
Distance from the
marks on measuring
1 Center (mm) 5
equipment to X and
Y fiducial point
2 Elevation (mm) ±5
Measure the
elevations of four
3 Planeness (mm/m) 1 corners of scavenge
box (speed governor
oil tank)
Plumbness of Drainage thread
4 overhead tank 1 measurement in X
(mm/m) and Y directions
8.1.3 Before the application of overhead tank, oil pipeline and bearing components, they
shall take tightness compression test as required by Article 4.11 using qualified turbine oil.
8.1.4 Decentralization and inclination for the installation and centering of horizontal type
oil pump and electromotor elastic coupling shall not be greater than 0.08mm. If axial
movement of oil pump shaft towards motor side is zero, 1mm ~ 3mm clearance shall exist
between coupling joints. After all plugs are filled in, coupling joints may be allowed to rotate
slightly. The body of oil pump chamber shall be infused with qualified turbine oil.
8.1.5 Each oil level of oil pressure installation shall meet the design requirements.
8.1.6 Test run of oil pump and electromotor shall meet the following requirements:
a) Examination and test of electromotor shall be in compliance with the related
requirements of GB 50150;
b) Generally, oil pump operate with no load for 1h and operate for 15min respectively
under 25%, 50%, 75% and 100% of the nominal pressures, no abnormal phenomena shall
exist.
c) During the operation, vibration of oil pump case shall not be greater than 0.05mm.
Temperature of bearing shell shall not be greater than 60°C;
d) Under nominal pressure, the measured oil delivery rate of oil pump shall not be smaller
than design value.
8.1.7 The adjustment of each component of oil pressure installation shall be in
compliance with the following requirements:
a) Examine the relation curve of pressure, output voltage (electric current) of fuel level
gauge and oil pressure, as well as oil level. Within the variable scope, it shall be linear. Its
characteristics shall be in compliance with the design requirements.
b) Adjustment of safety valve, signal indicator of working pressure of oil pump and
annunciator of emergency bearing oil pump shall be in compliance with requirements in Table
21 if no design requirements are given. The actuating mechanism deviation of pressure signal
shall not go beyond ±1% of the setting value. The return value shall not exceed the design
requirements.
c) For oil pump under continuous operation, if the actuating pressure of overflow cock
has no design requirements, requirements on the setting value of working oil pump in Table 21
shall be met.
Table 21 Setting value of the safety valve and signal indicator of oil pump
Unit: in megapascal
Setting value
Emergency bearing
Nominal Safety valve Working oil bump
oil pump
oil
Initial oil Full Full Starting Reverter Starting Reverter
pressure
drainage opening shutoff pressure pressure pressure pressure
pressure pressure pressure
2.50 ≥2.55 ≤2.90 ≥2.30 2.20~2.30 2.50 2.05~2.15 2.50
4.00 ≥4.08 ≤4.64 ≥3.80 3.70~3.80 4.00 3.55~3.65 4.00
6.30 ≥6.43 ≤7.30 ≥6.10 6.00~6.10 6.30 5.85~5.95 6.30
d) Actuating mechanism of safety valve shall yield no fierce vibration and noise;
e) Setting value of slip low oil pressure shall meet the design requirements. The actuating
mechanism deviation shall not be greater than ±2% of the setting value;
f) Self-acting air supply device of overhead tank and actuating mechanism of oil level
dispatching device of scavenge box shall be accurate and secure.
g) Start-up and closedown action of pressure oil pump and oil leakage pump shall be
accurate and secure. No reversal phenomenon shall exist.
8.1.8 Under the work pressure of overhead tank, when the oil level is in normal position,
shut down all communicating valve gate and sustain for 8h. The drop-out value of oil pressure
shall not be greater than 4% of the nominal operating pressure. Record the drop-out value of
oil level.
8.2 Installation of speed governor
8.2.1 Installation of engine tank of speed governor, regulator cubicle, and accident
regulation valve shall meet the following requirements:
a) Deviation for the installation of electro-hydraulic governor cabinet, regulator cubicle,
accident regulation valve shall meet the requirements of Table 22:
b) Installation of combined type electro-hydraulic governor shall take the speed regulation
axle mechanism bracket as reference and its deviation shall meet the design requirements.
c) See Annex C for the installation of mechanic hydraulic pressure speed governor.
8.2.2 As for mechanic hydraulic pressure pieces that must be disorganized, the rinsing,
packing and adjustment of the component shall meet the drawing requirement of manufacturer.
8.2.3 Indicator and lever inside the cabinet of speed governor shall be adjusted according
to the drawing dimension. Generally, the position deviation of each mechanism shall not be
greater than 1mm.
8.2.4 When guide blade and runner blade servomotor are in the middle position
(equivalent to 50% opening), position of each oscillating arm and link rod of reversion
mechanism shall meet the design requirements. The plumbness or horizontal deviation shall
not be greater than 1mm/m; joint of reversion mechanism shall be secure. Carry out the load
test according to the design requirements.
8.2.5 Examine the return circuit connection of each system of electric part, and all shall
meet the design requirements. Determination of its insulation resistance and voltage withstand
test shall proceed according to related requirements on commissioning test of electric
installation in GB50150.
8.2.6 Output voltage of the regulated power supply device in electric part shall meet the
design requirements. The output voltage variance shall not exceed ±1% of the design value.
8.2.7 Examine the characteristic and adjustable parameter of each return circuit of electric
part: regulating range including steady state speed droop bp (slip ratio ep), proportional gain
Kp, integral gain Ki, incremental gain Kd (or temporary droop bt, damping time constant Td,
acceleration time constant Tn) etc. shall meet the design requirements.
8.2.8 Check the adjustment range of opening assignment, frequency setting, horsepower
assignment, all of which shall meet the design requirements.
8.2.9 Record relation curve of input and output signals (electric current and electric
pressure) of speed detector. Within the scope of ±10% nominal speed, static characteristic
curve shall be rounded as straight line and its speed dead band shall meet the design set value.
Within the scope of ±2% of nominal speed, deviation of the measured amplification coefficient
shall not be greater than ±5% of design value.
8.3 Oil filling adjustment test of speed regulating system
8.3.1 Switch on oscillating current. Examine the oscillating quantity of electrohydraulic
conversion device, which shall meet the design requirements.
8.3.2 Examine the zero deflection and null shift of pressure of electrohydraulic
conversion device. Generally, its zero deflection shall not be greater than 5% of nominal value
of output quantity (electric current, electric pressure); within the working oil pressure scope,
the pressure null shift shall not create overt shift of servomotor.
8.3.3 Record the relationship transfer curve of incoming frequency and the
electricity-liquid or electricity- machine conversion device output. Dead volume and
amplification coefficient shall meet the design requirements.
8.3.4 Determine the relation curve between the output voltage (electric current) of
feedback transducer and servomotor stroke. Within the total excursion range of servomotor, it
shall be linear and its characteristics shall meet the design requirements.
8.3.5 The first oil charge of speed regulating system shall proceed slowly. Generally, oil
charge pressure shall not exceed 50% of the nominal pressure. Servomotor actuates several
times the entire stroke. No abnormal phenomena shall exist.
Operation switching of speed governor between manually, automatically or different
kinds of control modes shall be tested. The actuating mechanism shall be normal. Servomotor
has no evident swing.
Oil pipeline and bearing components shall take proof test as required by 4.11.
8.3.6 Manually operate the opening restriction of wicket gate servomotor; check the
indicated value on the indicator of mechanic cabinet. The indicated value shall be in
compliance with the stroke of wicket gate servomotor and servomotor of runner blade.
Deviation shall not be greater than 1% of the entire stroke of plunger for the former and for the
latter the deviation shall not be greater than 0.5°.
8.3.7 Time for emergency shutdown and opening of guide blade and runner blade as well
as step closure stroke, time and design value of guide blade shall not exceed±5% of the design
value, but ultimately it shall satisfy the requirements of calculation of guaranteed regulation.
Generally, time of shutdown and starting shall adopt twice the needed time for 75% ~ 25%
opening.
8.3.8 Deviation of time and design value of the shutdown of guide blade by accident
regulation valve shall not exceed ±5% of the design value, but ultimately it shall satisfy the
requirements of calculation of guaranteed regulation.
8.3.9 Examine the dead-stroke of reversion mechanism. Generally, the value shall not be
greater than 0.2% of the entire stroke of servomotor.
8.3.10 Plot the relation curve of wicket gate servomotor stroke and guide vane opening
from starting and closing directions. Measure 4~8 guide vane openings for each point. Adopt
the average value. When the guide blade is wide open, measure the opening of all the guide
blades. Generally, the deviation shall not exceed ±2% of the design value.
8.3.11 Plot the relation curve and switch rule of wicket gate servomotor stroke and runner
blade servomotor stroke under different water head on-cam relationship from the starting and
closing directions. It shall meet the design requirements. The inaccuracy of its runner blade
servosystem shall be smaller than 1.5% of the entire stroke.
8.3.12 Setting of the practical open-loop gain of servosystem: time for the switch-on and
closure of servomotor has been adjusted and meet the design requirements. Set amplification
coefficient and lever ratio as the maximum design value. Input step-function signal into
servosystem equivalent to 10% of the entire stroke of servomotor. Observe the movement of
servomotor; the maximal amplification coefficient and lever ratio that can keep the
servosystem stable and not over control are the practical open-loop gain.
8.3.13 Record the static characteristic curve of speed regulating system when permanent
speed droop bp = 6%, static characteristic curve shall be approximated as straight line. Speed
dead band is no greater than 0.04%. For speed regulating system of Kaplan turbine, inaccuracy
of its runner blade servosystem shall not be greater than 1.5%.
8.3.14 When the spiral case is anhydrous, record the pressure of overhead tank of low oil
pressure closedown and drop-out value of oil level.
8.3.15 When the spiral case is anhydrous, measure the minimal operation oil pressure of
guide blade and runner blade operating mechanism. Generally, it shall not be greater than 16%
of the nominal oil pressure.
8.3.16 Speed regulating system of impulse turbine shall take oil charge adjusting test
according to related test items and standards in Article 8.3.
8.4 Simulation test of speed regulating system
8.4.1 Simulate all kinds of malfunctions of speed regulating system. Protective devices
shall be secure. The actuating mechanism and alarm signals are correct.
8.4.2 Carry out the starting, shutting down, and emergency stop simulation test by
manually operation and in automatic mode. The actuating mechanism of speed regulating
system shall be normal. Alarm signal shall be correct.
Table 23 Deviation for the average value of absolute radius of inner circle of each
circumferential lamellae of butt welded structure sub-frame and the design value
Unit: in millimeter
Number of the
paddles of 3 4 5 6 8
sub-frame
Deviation for
the absolute
radius of each +1.0~+2.0 +1.5~+2.5 +2.0~+3.0 +2.5~+3.5 +3.0~+4.0
circumferential
lamellae
Table 24 Deviation for the average value of absolute radius of each circumferential
lamellae inner circle on butt welded structure sub-frame and the design value
Unit: in millimeter
Number of the paddles of
≤5 ≥6
sub-frame
Deviation for the absolute
radius of each +0.5~+1.5 +1.0~+2.0
circumferential lamellae
Table 25 Permissible deviation for the height of each measuring point of the stator core
Unit: in millimeter
Height of the 1000 < h < 1500 ≤h<
h < 1000 2000≤A<2500 h≥2500
iron core h 1500 2000
Deviation -2~+4 -2~+5 -2 ~ |6 -2~+7 -2~+8
c) Waveness of the rabbet tooth tip at the upper end of iron core shall not be greater than
the value regulated in Table 26;
Table 26 Allowable value for the waveness of the upper end of iron core
Unit: in millimeter
Length of the 1000 < l < 1500 ≤ l <
l < 1000 2000≤ l <2500 l≥2500
iron core l 1500 2000
Deviation 6 7 9 10 11
d) Examination over the iron-cored flute profiles with continuous manger rod shall all
pass through. Groove depth and slot width match the design value.
9.3.11 Installation of supporting ring shall proceed. Joint weld of metal supporting ring
shall adopt non-magnetic material. Connection of insulated supporting ring shall meet the
requirements of manufacturer. The insulation wrapping shall be tight. The lap joints between
the original insulation and new insulation shall be machined into slope. Generally, the lap
length shall not be smaller than that specified in Table 27.
9.4.7 Installation of brake hoop plate shall conform to the following requirements:
a) Brake hoop plate shall be assembled according to serial number. Assemble according
to symmetric mass principle.
b) For brake hoop plate with welded structure, planeness of brake surface of brake hoop
plate shall be smaller than 2.5mm. No downbulge is permitted for longitudinal ream and the
allowable fovea superior value shall not be greater than 0.5mm;
c) Brake hoop plate of fabricated structure:
1) Radial direction of the circumferential lamellae shall be horizontal and the deviation
shall be within 0.5mm. Waveness around the entire circumference shall not be greater than
2mm;
2) Seam crossing shall have clearances above 2mm. Examine the flashboard juncture
along the rotation direction of unit. The piece after shall not bulge out of the previous piece.
3) Screw bolt at the circumferential lamellae part shall yield to the friction surface by
over 2mm.
9.4.8 Stack-up of yoke punching shall meet the following requirements:
a) Try stacking 100mm of yoke punching first. Examine and make sure dimension of
each part meets the requirements, and then formally stack up;
b) Generally, punching shall be located by yoke key and dowel. Yoke without
localization structure can be evenly penetrated by over 20% permanent screws in the
localization, and each punching shall have at least 3 yokes; Yoke without localization
structure can be evenly penetrated by over 20% permanent screw stems in the localization,
and each punching shall have at least 3 screw stems;
c) Temporary guidance key will serve as a structure for tangential grinder and radial
location. Proceed the installation of guidance key as regulated by the manufacturer;
d) During the lamination procedure, clearance between the punching and stud excircle
of rotor field spider shall be even. Front and back side of punching shall be identical.
Lamination mode and stacking height shall meet the design requirements;
e) Impaction of the yoke shall be made by moment spanner symmetrically and orderly.
Increase the packing force bit by bit until it reaches the required pretightening force. At least
10 screw stems should be spot tested in the peripheral direction for the prolongation value to
check the pretightening force. Stress and prolongation value of permanent screw stem shall
meet the regulations of manufacturer;
f) After the compaction of yoke, stacking factor of yoke calculated according to weight
method shall not be less than 0.99. Subsectional crush height shall meet the requirements of
manufacturer. If there are no definite requirements raised by manufacturer, generally, the
subsectional crush height shall not be greater than 800mm. But for punching of inferior
quality or yoke subsection with greater stacking pressure, the crush height shall be lowered.
g) During the procedure of yoke stack-up, check and adjust the roundness frequently.
h) As for brake plate laying at the lower part of yoke, adjustment of its radial level and
waveness shall proceed at the same time of impaction, and shall meet the requirements of
9.4.7c);
i) After the yoke is fully impacted, the average height of yoke shall not be lower than
the design height. Deviation in height at the same longitudinal section shall not be greater
than 5mm. Deviation of the height along circumferential direction and the design height shall
not go beyond the limit regulated in Table 29.
Table 25 Permissible deviation for the height of each measuring point along the
peripheral direction of the yoke
Unit: in millimeter
1000 ≤A < 1500 ≤A < 2000 ≤A <
Yoke height h < 1000 h≥2500
1500 2000 2500
Permissible
-1~+5 -1 ~ +7 -1~+8 0~+10 0~+11
deviation
j) Generally, zero clearance between yoke and the hookup of wheel arm. Very few that
have clearance shall not be greater than 0.5mm;
k) Dimension of air chute, dovetail slot, spring gutter and so on shall meet the design
requirements;
l) Press plate of yoke shall be weighed and shall be disposed with symmetric mass;
m) Contact surface of yoke and polar shall be examined with leveling rule no shorter
than 1m, which shall be straight; very few higher spots shall be planished;
n) Stack-up of subsectional yoke shall also meet the aforesaid regulations and the
requirements of drawing.
9.4.9 Installation of radial yoke key shall meet the following requirements:
a) Compact the yoke key under cold state. Relative displacement incurred in the radial
direction between the rotor spider and yoke during the cold key stroke shall meet the
commendatory value of manufacturer. If no definite provisions are given by the manufacturer,
generally, average value of relative displacement in the radial direction may be controlled at
0.08mm ~ 0.25mm according to the dimension of residual distortion of the rotor yoke;
b) For yoke with key stroke heating requirements, the length uncased on the top of the
yoke key must satisfy the requirements of hot key stroke;
c) During the warming up of the key stroke (or hot tray) of the yoke, yoke shall have
good insulation. Measures shall be taken to sustain a temperature difference between yoke
and bracket arm.
d) Pressing magnitude of the hot key stroke of (or hot tray) shall meet the design
requirements.
e) Cool the hot key stroke of yoke down to room temperature. Check the yoke
roundness to make sure it is eligible. The lower part of yoke key shall be cut flat and evenly
according to hookup of wheel arm. 150mm ~ 200mm shall be kept on the upper end, but an
adequate distance shall be maintained between it and upper framework or breastplate.
f) For rotor of non-shaft construction, after the heating of key stroke (or tray heating),
distortion at the upper and lower spigots of rotor center part shall be checked.
g) Installation of manifold key combination with yoke cross key, peripheral positioning
key, secondary positioning key and lamination key shall proceed according to the
requirements of manufacturer.
9.4.10 measure the yoke roundness. The difference between each radius and the design
radius shall not be greater than±3.5% of the design air interstice.
9.4.11 Before the installation of magnetic poles, the following examination shall be
taken:
a) When the pole coil is impacted, the height difference of press plate and iron core shall
meet the design requirements. When no regulation is given, the difference shall not go
beyond the range of -1mm ~ 0mm;
b) Before and after the suspension and installation of magnetic pole, check and test
according to regulations of Article 14.4;
c) Examine the polarity and installation mass according to magnetic pole number. Fit
the magnetic poles in order according to the manufacturer’s serial number. When no
regulation is given by manufacturer, It shall meet the requirement that the imbalance mass in
the symmetric direction shall not go beyond the requirements of Table 30 after the magnetic
pole is fitted within the scope of 22.5°~45° angles. Generally mass balance takes into account
the mass of leading wires and attachments.
Table 30 Permissible deviation for the mass imbalance of magnetic pole installation
Unit: in kilogram
Total mass of yoke Permissible deviation for the mass imbalance in the installation
and magnetic poles of magnetic poles under different rotation speed (r/min)
t < 200 ≥200~< 500 ≥500
t<200 6 3 2
200≤t<400 8 4 2
400≤t<600 10 5 3
600≤t<800 12 6 4
t ≥800 14 7 4
9.4.14 Connection of magnetic pole joint and installation of excitation leading wire shall
meet the following requirements:
a) Joint dislocation shall not exceed 10% of the joint width. Current density of contact
surface shall meet the design requirements:
b) Welding of soldered joint shall be replete, with luminescent and clean appearance and
shall possess certain elasticity.
Osculation and joints of bolting shall be rigorous and the connection shall be in
compliance with requirements of 9.3.17 a);
c) Wrapping of splice insulation shall meet the design requirements. A safety distance
no smaller than 8 mm shall be kept between the joints and grounding conductor. After the
tightening of the insulation clamping plate, 1mm~2mm clearance at both ends of the two
clamping plates;
d) Ranging of the Excitation Leading Wire of rotor shall be tight and the fastening shall
be secure. The joints at the terminals shall be connected according to design requirements.
The joints of the bolt connection shall be tin-coated or silver coated. The coated layer shall
be neat and clean and shall be made as required by 9.3.17a). The bolts shall be locked and
reliable.
9.4.15 The blower fan shall be free of flaws like cracks/ The installation shall be solid,
locked and reliable. It is strictly forbidden to adopt gas cutting or electric welding over the
blower fan. Generally, distance between its metal parts and magnetic poles as well as coils is
no smaller than 10mm.
9.4.16 Check the counterface of the damping ring joints with 0.05mm clearance gauge.
The inserting depth shall not be greater than 5mm. Connecting bolts of damping ring shall be
tightened according to the moment regulated by the manufacturer, locked and reliable.
9.4.17 Before the rotor is suspended into the unit pit, test according to Article 14.5 item
by item.
9.5 Overall installation
9.5.1 Installation of framework shall meet the following requirements:
a) Central deviation of the machine frame shall not be greater than 1mm. For units with
rotation speed higher than 200r/min, the excircle of oil deflector should be centered. The
central deviation value shall meet the manufacturer’s requirements. Roundness of the oil
deflector shall be in compliance with the design requirements;
b) Central deviation of thrust bearing base of the machine frame shall not be greater
than 1.5mm and its horizontal deviation shall not be greater than 0.04mm/m. For elastic oil
tank thrust bearing without support bolts and multi-spring support structure thrust bearing,
horizontal deviation of the machine frame shall not be greater than 0.02mm/m;
c) Elevation deviation of the machine frame installation shall not exceed ±1.5mm
generally;
d) Jack of the machine frame in radial direction should be flat and stress it bears shall be
even. Generally, its installation elevation deviation shall not be beyond the range of ±5mm.
9.5.2 Installation of the actuator shall meet the following requirements:
a) Tightness compression test on the actuator shall be carried out strictly according to
the design requirements. Sustain for 30min, and during the 30 minutes, the pressure drop
shall be within 3%. Piston of the spring-return actuator shall be able to reset automatically
after the pressure is removed;
b) Deviation for the installation elevation of the actuator top surface shall be within
±1mm. Gap deviation between actuator and rotor braking ring plate shall be within ±20% of
the design value;
c) Pipeline of the braking system shall take tightness compression test strictly according
to the design requirements;
d) Actuator shall take lowering and lifting test by having compressed in to check the
flexibility of the actuator’s mechanism and if the stroke of the actuator meet the
requirements.
9.5.3 Stator installation shall meet the following requirements:
a) Stator installation azimuth shall be in compliance with the position of the lead-out of
generator and ensure the normal connection of the generator lead-out.
b) During the alignment of stator according to the actual central line of water turbine,
for measurement at the same section during installation, difference of each radius and the
average radius shall not be greater than ±4% of the design air clearance. The alignment of
stator according to rotor shall meet the requirements of d) of this article.
c) Check the installation elevation of stator according to the elevation of main axle
flange of the water turbine and actually measured dimension of each part. Average central
elevation of the stator iron core and average central elevation of the rotor magnetic pole shall
be made identical and the deviation shall not exceed ±0.15% of the effective length of the
stator iron core, and the maximum shall not exceed ±4mm;
d) when the rotor is in the center of the unit, check the air clearance between the upper
and lower ends of rotor. Difference between each clearance and the average clearance shall
not be greater than ±8% of the average clearance.
9.5.4 Rotor installation shall meet the following requirements:
a) Adjust the elevation of the top surface of the actuator before the installation of stator
in suspension-type unit and sustain 4mm~8mm clearance between the stator and the carrier
plate during the coupling of thrust collar after the rotor is suspended.
b) For axleless umbrella type or half umbrella type hydraulic generator, adjustment of
surface elevation of its actuator only needs to consider the shaft coupling clearance between
water turbine and generator. During the suspension of rotor, drop the rotor directly onto the
thrust bearing through guide part;
c) During the suspension of rotor, clear the lower part of the rotor completely. Measure
the deflection of the rotor at the lower part of yoke;
d) When the stator of generator is aligned according to rotor, then the rotor shall be
aligned according to qualified water turbine shaft. Central deviation between the two flange
surfaces shall be smaller than 0.04mm and the parallelism between the flange surfaces shall
be smaller than 0.02mm. Check the uprightness of generator shaft or the flange surface level
on the central body of rotor;
e) If the stator center of generator has been aligned according to the fixed part of water
turbine, then adjust the center according to the air clearance after the rotor is suspended and
check and measure the air clearance between stator and the upper and lower ends of the rotor,
the difference between each clearance and the average clearance shall not exceed ±8% of the
average clearance value.
9.5.5 Installation of thrust collar shall meet the following requirements:
a) Before the coupling of thrust collar, adjust the elevation and level of the carrier plate.
Measuring with no lubricant applied on the surface of thrust bearing pads, its horizontal
deviation shall be within 0.02mm/m. Its elevation shall consider the deflection value of
bearing generator frame and compression value of the elastic thrust bearing;
b) Before the hot coupling of thrust collar, adjust its level under lifting and lowering
state. During the hot coupling of transitional fitting thrust collar, the heating temperature of
thrust collar should be better within 100°C;
c) After the heating up of thrust collar, the installation of clasp shall only proceed after
its temperature falls to ambient temperature. After clasp is stressed, check the clearance
between the upper and lower stressed surface of the clasp with 0.02mm gage, which shall not
be able to pass through. Otherwise, it shall be drawn out and disposed and shall not be
padded;
d) During the coupling of thrust collar and axial bolts, pretightening load to connect the
bolts shall meet the requirements of 4.9. No clearance shall exist between the coupling
interfaces. Check with 0.03mm gage, which shall not pass through. Central deviation of
thrust collar with guide spindle journal neck shall not exceed 0.03mm.
9.5.6 Adjustment of thrust bearing pad shall meet the following requirements:
a) Adjust the stress of thrust bearing pads when the shaft is upright, and the elevation
and level of carrier plate meet the requirements, and the rotor and runners are in the central
position;
b) Generally, adjust the stress of rigid support thrust bearing with the method of
measuring the distortion of bearing bush. Lifting and lowering the rotor, the difference
between the distortion value of each block plate and the average distortion value shall not
exceed ±10% of the average distortion value;
c) When the method of hammering load bearing bolt is adopted to adjust the stress on
rigid support thrust bearing, monitor the main shaft with a percentage meter at the water
turbine bearing. The hammering impact shall make the main shaft to have an
0.05mm~0.10mm inclination on average. Under equal hammering impact, the variance in the
inclination of main shaft and the average inclination value shall not exceed ±10% of the
average inclination value;
d) For hydraulic support thrust bearing, when the upper and lower parts of guide bearing
pads are cling to each other near the thrust bearing, lift and lower the rotor. When lowering
rotor and releasing the guide bearing pad, the deviation for the quantity of compression of
each elastic oil tank shall not be greater than 0.2mm;
e) For hydraulic thrust bearing without support bolt, the quantity of compression of each
elastic oil tank shall meet the design requirements.
f) For balance weight thrust bearing, under the condition that the balance weight is fixed,
lift and lower the rotor, measure the distortion of pillow or upper balance weight. The
distortion value shall meet the design requirements. When there is no design requirement, the
distortion value of each pillow or upper balance weight and the average distortion value shall
not exceed ±10% of the average distortion value;
g) For thrust bearing of elastic-girder double support-point structure, after carrier plate
is suspended onto thrust bearing pads, adjust the level of carrier plate, which shall not be
greater than 0.02mm/m. Check each side of oil outlet of thrust bearing pads and carrier plate,
between which there shall be no clearance. Difference between two angles of oil inlet sides
of each tile and the average clearance of carrier plate shall not be greater than ±20%;
h) Installation of multi-spring support structure thrust bearing shall proceed according to
the requirements of manufacturer;
i) After the final adjustment and location of thrust bearing pad, axial clearance,
tangential clearance of the press plate as well as the deflector of the thrust bearing pads and
the tiles, and radial relative position of thrust bearing pads and carrier plate, and axial
clearance between steel casing of hydraulic bearing and oil tank chassis shall all meet the
design requirements:
j) To facilitate the checking that if the elastic oil tank has leakage or not, when the thrust
bearing has been adjusted to be qualified and rotating part of the unit falls on the thrust
bearing, it is required to measure the distance from the upper surface of thrust bearing base to
carrier plate according to the crossing line direction and then record it;
9.5.7Check and adjust the axial line of the machine frame, which shall meet the
following requirements:
a) Generally, jiggering method is used to check and adjust the axle line. Before the
jiggering, the rotating part of generator unit is in central position and the main shaft is in
natural state and upright;
b) If pressurized oil jack is adopted in jiggering, thrust bearing pads and pressurized oil
jack system shall be cleaned up. When pressurized oil jack jigger is not adopted in jiggering,
surface of thrust bearing pads shall be coated with uncontaminated cleaned lubricating
granules.
c) For rigid jiggering of thrust bearing, stress over each tile shall be adjusted to be even.
Level of carrier plate shall meet the requirements of 9.5.5a). Adjust the single side clearance
of the guide bearing pad near thrust collar or temporary guide bearing pad, which is generally
0.03mm~0.05mm. On the completion of adjustment of axle line, the swing value of each part
of the generator unit shall not exceed requirements of Table 33.
If permitted by conditions, for elastic thrust bearing, swing in every squater of the unit
axial line shall also be checked according to rigid method jiggering. At the same time, carry
out elastic jiggering as required by Clause d of this article. Check the axial swing of the
carrier plate’s exterior margin;
d) Elastic jiggering of hydraulic prop thrust bearing shall proceed after the stress over
the toroidal membrane is adjusted to be qualified. Air clearance between the upper and lower
part of the guide bearing pad close to the thrust bearing shall be adjusted to 0.03mm~0.05mm.
During the jiggering, axial swing at the margin of carrier plate shall not go beyond the
requirements of Table 34.
After the axial line is checked and adjusted to be qualified, stress over the toroidal
membrane shall be counterchecked, which shall meet the requirements of 9.5.6 d);
Table 34 Allowable axle swing for carrier plate (End face run-out)
Diameter of the carrier plate (m) Axial Swing (mm)
<2.0 ≤0.10
2.0~3.5 ≤0.15
>3.5 ≤0.20
e) For multi-sectional axle construction unit, checking shall be made over the bending
conditions of each segment during the jiggering. Generally, the deviation shall not be greater
than 0.04mm / m. Check the in-plant operation record of axial line and the clearance
variations between the upper and lower shafts and the rotor after the thermal keying (thermal
padding) to check the axial changes during jiggering;
f) When the rotor is in central position, check the air interstice for every 90° rotation
with jiggering method and the value shall meet requirements of 9.5.3 d);
g) When the rotor is central position, air interstice monitoring plant should be used to
adapt to the jiggering method and check the stator roundness, rotor roundness, which shall
meet the requirements of 9.3.10 a) and 9.4.13 respectively;
h) Suspending steel wire at the cross direction or suspending steel wire in the center if
axle hole or other methods should be used in checking the folding and verticality of the
axials.
9.5.8 Installation of the high pressure oil lift device and external cycle cooling unit of
thrust bearing shall meet the following requirements:
a) Oil pipeline of the system shall be cleared clean. Pump oil into the oil system
continuously with oil pump until the oil quality reaches the standard. Carry out the oil
pressure test according to the design requirements;
b) Cracking pressure of overflow cock shall meet the design requirements. Each
non-return valve shall take tightness & oil-pressure resistance test when bearing reversed
compression. Sustain for 10min under 0.5, 0.75, 1.0 and 1.25 times of the working pressure.
No leakage shall happen under the aforesaid pressure conditions.
c) Adjust the oil mass of flow regulating valve of each tile under the working pressure to
make the grading tolerance of each tile's oil film thickness no greater than 0.02mm;
d) External cycle cooling unit and pipeline of thrust bearing shall be cleared clean and
water-pressure resistance test shall be carried out according to the design requirements.
9.5.9 Insulation resistance of each part of thrust bearing of the suspensory unit shall not
be smaller than the values regulated in Table 35.
Table 35 Insulation resistance of each part of thrust bearing of the suspensory unit
Electric voltage
Parts of the Insulation
No. of megohm Notes
thrust bearing resistance MΩ
meter (V)
Measure after
Base and
the installation
1 bracket of thrust 5 500
of base and
bearing
bracket
Before
connecting with
High pressure
the joint of
2 oil injecting oil 10 500
thrust bearing
pipeline
pads, test each
single one
On the
completion of
the bearing
installation, jack
Entire body of
up the rotor.
3 the thrust 1 500
Before infusing
bearing
lubricating oil,
the temperature
shall be 10 ~
30°C.
On the
completion of
the bearing
installation, jack
Entire body of
up the rotor.
4 the thrust 0.5 500
After infusing
bearing
lubricating oil,
the temperature
shall be 10 ~
30°C.
The rotor falls
on the thrust
bearing. The
Entire body of rotation part and
5 the thrust 0.02 500 all connectors
bearing on the fixed
parts shall be
dismantled
temporarily.
Before infusing
in lubricant oil,
measure the
Embedded insulation
6 temperature 50 250 resistance of
detector each
thermometer
core wire to
thrust bearing
pad
Table 36 Temperature and heat treatment conditions for hot bending of pipe in
common use
Materials Steel grade Hot bending Heat treatment conditions
temperature Heat treatment Constant Cooling
span ℃ temperature temperature method
hour
Carbon steel 10, 20 750~1050 Without Without Without
treatment treatment treatment
Stainless steel 1Cr18Ni9Ti 900~1200 (1050~1100)℃ 0.8min per Water
quenching millimeter quenching
wall
Non-ferrous Copper 500~600 Without treatment
metal copper Metallic 600~700
copper alloy
12.1.3 During the bending of slit tube, position of its longitudinal seam shall be located
at 45° point from the horizontal and perpendicular direction.
12.1.4 After the bending of the tube, the quality shall meet the following requirements:
a) Flawless, free from lamination and being overburnt, etc..
b) Diameter difference between the maximal pipe cross-section and the minimum
cross-section shall not exceed 8% of the pipe diameter.
c) Bending angle shall be in compliance with shaping plate.
d) Generally, height of fold of rippling inside the elbow shall not be greater than 3% of
the pipe diameter. Wave spacing shall not be shorter than four times the height of ripplings.
e) After the plying of annular tube, preassembling shall proceed. Generally, the radius
deviation shall not be greater than 2% of the design value. The pipe shall be at the same level
and the deviation shall not be greater than 40mm.
12.1.5 Incision quality of the pipe shall meet the following requirements:
a) Cut surface shall level off. Generally, partial convexo-concave shall not be greater
than 3mm.
b) Generally, vertical misalignment for the pipe end incision plane and the center line
shall not be greater than 2% of the external diameter of the pipe and shall not be greater than
3mm.
12.1.6 Generally, W-shape expansion joint is annealed with a pipe and shall be kept on
the same plane.
12.1.7 Generally, curvature radius of welded elbow shall not be shorter than 1.5 times of
the pipe diameter; the number of 90° elbow bend segments shall be at least 4. After the
welding, the axis angle of elbow bend shall be in compliance with the shaping plate.
12.1.8 Vertical misalignment of the branch pipe to weld T-joint generally shall not be
greater than 2% of its height.
12.1.9 For the fabrication of the conical tube, generally, the length shall not be shorter
than 3 times the difference of the exterior diameters of two tubes. The diameter and
roundness shall meet the design requirements. The deviation shall not exceed ±1% of the
design diameter and shall not exceed ±2mm.
12.1.10 The fabrication form, material quality, size and precision shall meet the
regulations of design drawing. Holes on the branch, supporting structure and hanger shall be
drilled by machine.
12.1.11 During the fabrication of flange gasket, the gasket material shall be adopted
according to the media and pressure of the pipe-line transportation. The gasket shall be
chopped into an entire circle to avoid interfacing. When concatenation is needed for large
caliber gasket, beveled edge lapping or labyrinth halving joint shall be adopted. It must not
be flush-jointed welded. Gasket size shall match the packing strip. The inner diameter is
permitted to be 2mm ~ 3mm larger and outer diameter is permitted to be 1.5mm ~ 2.5mm
shorter.
12.2 Pipeline welding
12.2.1 Proper groove type and size shall be adopted for pipe coupling according to the
pipe wall thickness. Generally, when the wall thickness shall not be larger than 4mm, I type
groove shall be adopted and the contra-aperture clearance is 1mm ~ 2mm; when wall
thickness is greater than 4mm, adopt 70° angle V-groove. contra-aperture clearance and
truncated edge shall both be 0mm ~ 2mm. Contra-aperture misalignment of pipe shall not
exceed 20% of the wall thickness, but at the most it shall not exceed 2mm.
12.2.2 For contra-aperture welding of steel tube of oil and gas system as well as water
system that has special purpose, welding technology of argon arc welding bottom closing and
arc welding capping shall be adopted. For butt welding of the pipe with outer diameter
D≤50mm , full argon arc welding should be adopted.
12.2.3Contra-aperture welding of copper pipe and welding of copper pipe and carbon
steel pipe joints shall adopt faucet insertion welding.
12.2.4 Technological requirements of pipeline welding
a) Adoption of welding rod shall be determined according to the chemical composition
and mechanical property of parent metal, crack resistance of soldered joint, working
conditions and execution conditions, and its welding process shall have a high performance.
b) During the tack weld, welding material and welding process shall be identical with
that adopted in root layer. Tack weld length, thickness and spacing shall ensure that welded
joint will not crack in the welding process;
c) Generating the arc and testing current on the parent metal surface other than the
groove, and parent metal damage from arcking shall be prevented.
d) When contra-aperture welding of stainless steel tube is precoated with argon arc
welding, the inside of welded joint shall be filled with argon gas or other protective gases or
other measures shall be adopted to prevent the inner side weld metal from being oxidized;
e) The welding shall adopt proper welding methods and welding order. During the
welding process, quality of arc starting and arc ending shall be guaranteed. During the arc
ending, the arc crater shall be filled in.
Interlayer joint of multi-layer welding shall be staggered;
f) Within the specified scope of welding operation guide book, with the guarantee that
through welding and fusion are in good conditions, adopt undercurrent, short arcking, fast
welding and multilayer multi-pass welding process and the temperature between layers shall
be controlled.
12.2.5 Weld quality examination
a) Reinforcement height of weld surface is 1mm ~ 2mm; cover surface width for I type
groove is 5mm ~ 6mm and for V-groove it shall be 2mm broader than each groove.
b) Weld surface shall be free of crack, slag inclusion and air cavity, etc.. undercut depth
shall be shorter than 0.5mm; length shall not exceed 10% of the welded joint length and shall
be shorter than 100mm;
c) Other than the conduit for natural flow discharge agent, the welded joint of pipe shall
all be checked in the intensity pressure test with water as the medium and no leakage and/or
seaminess shall happen.
Intensity pressure test shall proceed according to Article 4.11.
d) For conduit butt weld with nominal operating pressure greater than 8MPa, except that
intensity pressure test with water as media, sampling inspection of radiographic inspection
shall also proceed. Casual inspection proportion and quality grade meet the design
requirements. When there is no requirement, the casual inspection proportion shall not be
lower than 5% and the quality shall not be lower than Grade III.
12.3 Installation of pipeline
12.3.1 During the pipe laying, position of weld shall meet the following regulations:
a) Spacing between two circumferential seams of the ascending pipe shall not be shorter
than 100mm, and shall be twice longer than the outer diameter of pipe;
b) Distance from the butt weld to the bend starting point shall not be shorter than
100mm and shall not be shorter than the outer diameter of pipe;
c) Clear distance from circumferential weld to the support and hanger shall not be
shorter than 50mm. Pipeline drilling through partition wall and floor slab shall have no weld
junction in the partition wall and floor slab; d) No pore shall be opened on the pipeline
welded joint. If the pore must be drilled, the welded joint shall be examined to be qualified in
the non-destructive test.
12.3.2 Check the flatness of contra-aperture of pipe, if measuring at the point 200mm
from interfacing centre, the Permissible deviation is 1mm; the permissible variation of the
overall length shall not exceed 10mm.
12.3.3 Entombment of pipeline shall meet the following regulations:
a) Deviation of the exit position of pipeline shall not be greater than 10mm. Protrusion
of nozzle out of concrete surface shall not be shorter than 300mm in general. Distance from
the pipe to the concrete wall shall not be shorter than the installation dimension of flange in
general, and the nozzle shall be credibly blocked off.
b) Screw thread and flange are not suitable to be adopted in the connection of pipeline;
c) Pressure sensing tube shall have as few turns as possible. The curvature radius shall
be large. Evacuation shall also be taken into account. Pressure tapping hole shall meet the
design requirements:
d) Drainage pipeline and oil exit pipeline have corresponding gradient with the flow
direction. The gradient shall meet the design requirements.
IF there is no design requirement, generally, the construction shall proceed according to
2%~3% gradient;
e) Generally, the oil-piping adopts the method of burning tube casing;
f) When the pipeline passes through expansion joint of concrete, the passing measures
shall meet the design requirements.
12.3.4 Installation site of exposed pipe shall meet the following regulations:
a) Generally, deviation of pipe installation position (co-ordinate and height mark) shall
not be greater than 15mm outdoor and no greater than 10mm indoor;
b) Generally, the flection and horizontal deviation of horizontal pipe shall be within
0.15% and shall not be longer than 20mm. Squareness deviation of the riser shall not exceed
0.2% and shall not exceed 15mm;
c) Installation of racking pipe shall be at the same level. Deviation shall be within 5mm.
Pipe spacing deviation between pipes shall be within 0mm ~ +5mm;
d) Gradient of gravity drain pipe and oil exit pipe shall be identical with the direction of
liquid stream. Generally, the gradient shall range at 0.2%~ 0.3%.
12.3.5 Flanged connection shall meet the following regulations:
a) Packing strip and/or packing plate shall not have flaws that affect the sealing property.
As for gasket thickness, except that rubber plate for low-pressure water pipe is allowed to be
as thick as 4mm, generally, the thickness is 1mm ~ 2mm and the gasket shall not exceed two
layers.
b) After the screw-in of flanges, they shall parallel. The deviation shall be within 1.5 /
1000 of the outer diameter of flange and no greater than 2mm. Specification, dimension, and
installation direction of binding bolts shall be identical. The packing force of bolt shall be
homogeneous. The bolt shall be higher than the screw cap by 2~3 screw-pitches.
c) During the welding of pipe and flat flange, inside and outside welding shall be
adopted. The inside weld shall not tower above flange working face. After the welding, all
flange and pipe shall be perpendicular. Generally, the deviation shall be within 1%.
d) No flange shall be set up at the elbow bend of pressure piping;
e) Branch pipe welded on the main pipe shall have reinforcement flange or other
reinforcement measures over the part running through the main pipe.
12.3.6 Oil system pipeline shall not adopt welded elbow. When hot pressing elbow bend
is adopted, the wall thickness of elbow bend shall not be thinner than wall thickness of
ascending pipe.
12.3.7 Distance from the installation site of clamped-in style and cutting sleeve pipe
heads to the supporter and hanger shall meet the design requirements.
12.3.8 For pipeline with cutting sleeve pipe head, material quality, roundness, deviation
of outer diameter of the pipe as well as the length of the protruded cutting sleeve shall meet
the design requirements. After the fastening of compression nut, the top of the pipe shall not
touch the union body. Central deviation of the interlocking nozzle of double jointer shall not
be bigger than 2% of the pipe diameter.
12.3.9 Sealing materials of gas thread joints should adopt teflin tape or sealant. When
the screw thread is screwed down, sealing materials cannot be squeezed into the pipe.
12.3.10Before the installation of pipe, pipe fittings and valve, the interior of the pipe
shall be cleaned up. During the installation, impurities shall be ensured not to fall in.
12.3.11 During the installation of pipeline, fixing and adjustment of supporting structure
and hanger shall timely proceed. Position of supporting structure and hanger shall be correct.
The installation shall be neat and solid, and contact with the pipe shall be in good condition.
12.3.12 As for materials used for the heat insulation of pipeline, the intensity, unit
weight, coefficient of heat conductivity, resistance to heat, water content and specification of
species shall all meet the design requirements.
12.4 Treatment of the inner wall of pipeline
12.4.1 Before the installation of oil system conduit and speed regulating system conduit,
the inwalls may be pickled, neutralized and immunized.
When there is no design requirement, Annex D shall be referred to.
12.4.2 Before the use of oil system, water system, gas system and speed regulating
system, the inwalls shall be rinsed and checked according to the design requirements and
standard.
When there is no design requirement, Annex D shall be referred to.
12.5 Test of the conduit and pipe fittings
12.5.1 Bearing vessels machined at the construction site and pipe fittings with working
pressure as 1MPa or above, intensity compression test shall be carried out according to
requirements of Article 4.11
Atmospheric vessel machined at the construction site by themselves shall take leakage
test as required by Article 4.12.
12.5.2 For valve with working pressure as 1MPa or higher, or valves of important parts
under 1MPa shall take tightness compression test as required by Article 4.11.
12.5.3 Before concrete placement, the built-in pressure piping and pipe fittings shall
take tightness compression test as required by Article 4.11.
12.5.4 After the installation of conduits of oil, water and gas system, generally, oil
charge test, water passage or ventilation test shall be carried out. During the test, the pressure
is gradually raised to nominal operating pressure, no leakage phenomena shall happen.
Table 37 Standards for alternate current withstand voltage in the technical process of
stator coil (kV)
Nominal voltage, kV
Winding type Test stages 2≤UN≤6.3 6.3≤UN≤24
Test standard
1. Before the
setting-in;
2.75UN+1.0 2.75UN+2.5
Circle type 2. After
2.5UN+0.5 2.5UN+2.5
setting-in(after slot
wedge is drilled)
1. Before the
setting-in;
2.75UN+1.0 2.75UN+2.5
2. After setting-in of
Strip type 2.5UN+1.0 2.5UN+2.0
lower coil
2.5UN+0.5 2.5UN+1.0
3. After the setting-in
of upper coil (after
slot wedge is drilled)
Note: UN is the nominal line voltage of electric generator. The duration after the kV is raised
to the nominal testing voltage, if not specified specially, it shall all be 1min.
14.3 Test item and standard of stator shall meet the requirements of Table 38.
14.4 For rotor assembled on site, its single pole and slip ring, leading wire and brush
carrier shall all take voltage withstand test and insulation resistance test according to
regulations in Table 39.
Table 39 Voltage standard and insulation resistance of each single pole, slip ring,
leading wire and brush carrier
Name of components Voltage withstand Insulation
standard(V) resistance; MΩ
Each single magnetic Before the 10Uf+1500, but shall ≥5
polar suspension and not be lower than
installation, 3000
After the suspension 10Uf+1000, but shall
and installation not be lower than
2500
Slip ring, leading wire and brush carrier 10Uf+1000, but shall ≥5
not be lower than
3000
Note: Uf refers to the nominal excitation voltage of generator rotor, V
14.5 Test item and standard of rotor winding shall meet the requirements of Table 40.
Table 41 Allowable vibration value of water-turbine generator set for each part Unit as
millimeter
(Informative)
(Normative)
B.1.2 Rinsing, installation, and adjustment of the governor component shall meet the
following requirements:
a) Connection of governor driving motor and centrifugal flyweight shall be concentrical.
The rotation shall be flexible. Radial and axial swing of rhombohedral centrifugal pendulum
spring pedestal relative to the bearing at the upper end of steel band shall not be greater than
0.04mm.
b) When the buffering piston moves up and down and returns to the last 1mm middle
position, the time it takes shall meet the design requirements: Time difference for the two
rounds up and down shall not exceed 10% of the set time.
Measure the return interval of buffering bearing plate of speed regulator in the three
positions of middle and two terminals. There shall be no clearance between the support bolt
of buffer and bearing plate.
Actuation of buffer relay piston shall be stable. The deviation it returned to the middle
position shall not be greater than 1mm.
c) Each indicator and leverage in mechanism cabinet of speed regulator shall be
adjusted according to the drawing. Generally, the position deviation of mechanism shall not
be greater than 1mm.
d) When indication of steady state speed droop (residual degree of irregularity) is zero,
total stroke of return mechanism actuation and slippage mechanism shall be zero. The
maximum deviation shall not be greater than 0.05mm.
B.1.3 Others refer to related contents in Chapter 8.
Annex C
(Normative)
(Informative)
(Informative)
E.1.3.2 During the evaluation of round defects, the flaw size shall be converted into
number of imperfection points according to Table E2.
Table E.2 Conversion table for the number of points of imperfection Unit as point
Diameter of defects mm <1 > 1~2 > 2~3 > 3~4 > 4~6 >4~8 >8
Number of points 1 2 3 6 10 15 25
E.1.3.3 See Table E3 for size of the defects with points discounted
Table E4. Grading of round defects (according to the upper limit of the number of
imperfections)
Unit: in points
Evaluation area mm 10 X 10 10 X 20 10 X 30
Thickness of the
15 25 50 100
parental thickness T T < 10 T>100
≥T>10 ≥T>15 ≥T>25 ≥T>50
mm
I 1 2 3 4 5 6
Quality II 3 6 9 12 15 18
Grade III 6 12 18 24 30 36
IV Defect points grade greater than Grade III
E.1.4 Slag inclusion with length-width ratio of defect greater than 3 is streak slag
inclusion .
See Table E5 for the grading of streak slag inclusion.
E.1.5 Within the round assessment area, if both round defects and streak slag inclusion
(or incomplete penetration) exist, they shall be graded respectively and the total of the grade
minus 1 will be taken as the final grade.
E.2.GB11345-89 Abstract of Method for manual ultrasonic testing and classification of
testing results for ferritic steel welds
Classify the defects in compliance with the regulations of Table E6 according to the
flaw indication length.
(Informative)
Oxidation
stability e
a. Overall
oxidative
product, %:
GB
Precipitate, %: Report Report Report
8119
b. Acid value Report Report Report
SY
after 3000 2000 1500
2680
oxygenation
2.0
mgKOH/g, H
is not smaller
than:
Rust test in
liquid phase GB
Rustless Rustless Rustless
(synthetic sea 11143
water)
Copper strip
GB
test 1 1 1
5096
(100°C,3h)
Air release SY
5 6 5 6 -
valuef (50°C) 2693
Notes:
1. For steam turbine oil produced from intermediate base crude, viscosity index of L - TSA quality
products is permitted to be not lower than 70 and viscosity index of first grade products are allowed to be
not lower than 80. According to the production and practical application, after consultation with the user,
this standard may not be a limit.
2. Pour point index may not be limited by this standard according to the practice of production and
application after consultation with the user.
3. When the products are for the purpose of military, the demulsification value shall be negotiated by the
manufacturer and the army.
4. During the air bubble test, if the oil surface is not covered by bubbles, the report result is “0”.
5. Oxidation stability is a item that shall be guaranteed. It is spot checked once a year.
6. Air release value in the first grade products may not be limited by this standard according to the
practical production and application and after the negotiation with user.
Annex G
(Normative)
Wording Explanation:
G.11. Words used for different degrees of strictness are explained as follows in order to
mark the differences in executing the requirements in this code.
G.1.1 Words denoting a strict requirement under normal conditions:
“Shall” is used for affirmation; “shall not” for negation.
G.1.2 Words denoting an indication of the most suitable choice when conditions permit:
“Should” is used for affirmation; “should not” for negation.
G.1.3 Words denoting the option available, sometimes with the conditional permit.
“May” is used for affirmation; “may not” is used for negation;
G.1.4 Words denoting a causal possibility and capability
“Can” is used for affirmation; “can not” for negation.