E 2 01 Turbines and Governors

Gati Infrastructure Bhasmey Power Private Limited.
Bhasmey Hydroelectric Project Package 2 - Electro-Mechanical Equipment Particular Technical Specifications Turbines and Governors
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SECTIO 1:
TURBI ES A D GOVER ORS
TABLE OF CO TE TS
Pages
1 1.1 1.2 1.3 1.4
TECHNICAL REQUIREMENTS .........................................................................................4 SCOPE OF WORKS..............................................................................................................4 1.1.1 Turbine Components ..................................................................................................4 INTERFACES .......................................................................................................................7 SUPPLY BY THE EMPLOYER ...........................................................................................8 DESIGN CONDITIONS........................................................................................................8 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.4.10 Project Arrangement ................................................................................................10 Hydraulic Conditions ...............................................................................................11 Specified Conditions ................................................................................................14 Generator Characteristics .........................................................................................15 Transient Behaviour Data.........................................................................................16 Stability Of The System ...........................................................................................16 Noise.........................................................................................................................18 Vibration...................................................................................................................18 Sand Erosion Consideration .....................................................................................18 Safety Requirements ................................................................................................19
1.5
TECHNICAL PERFORMANCE AND OTHER GUARANTEES.....................................19 1.5.1 1.5.2 1.5.3 1.5.4 1.5.5 1.5.6 1.5.7 1.5.8 1.5.9 1.5.10 1.5.11 1.5.12 General .....................................................................................................................19 Guaranteed Power ....................................................................................................19 Guaranteed Minimum Discharge .............................................................................20 Guaranteed Efficiency With Respect To Guaranteed Annual Energy Production ................................................................................................................21 Guaranteed Maximal Momentary Pressure..............................................................23 Guaranteed Maximum Momentary Overspeed ........................................................23 Guaranteed Maximum Steady-State Runaway Speed..............................................23 Cavitation Guarantees ..............................................................................................23 Cavitation Pitting Guarantees...................................................................................24 Guaranteed Hydraulic Thrust ...................................................................................25 Guaranteed Maximum Weights And Dimensions ...................................................25 Other Technical Guarantees .....................................................................................26
1.6
MECHANICAL DESIGN CRITERIA ................................................................................27 1.6.1 Design Standards......................................................................................................27
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1.6.2 Stresses And Deflections..........................................................................................27 1.6.3 Special Design Considerations.................................................................................29 1.7 DESIGN DOCUMENTATION ...........................................................................................31 1.7.1 1.7.2 1.7.3 1.7.4 1.7.5 1.8 1.8.1 1.8.2 1.8.3 1.8.4 1.8.5 1.9 1.9.1 1.9.2 1.9.3 1.9.4 1.10 1.10.1 1.10.2 1.10.3 1.10.4 1.10.5 1.11 General .....................................................................................................................31 Data For The Employers Design Information To The Engineer .........................31 Requirements For Contractors Drawings, Technical Calculations And Data ........35 Contractors Review Of Employers Design ...........................................................35 Technical Reports By Contractor.............................................................................35 Scope ........................................................................................................................35 Materials Selection And Standards ..........................................................................37 Quality Assurance Procedures .................................................................................41 Shop Methods And Personnel ..................................................................................41 Corrosion Protection And Painting ..........................................................................41 General Requirements And Reports.........................................................................42 Material Tests And Certificates................................................................................42 Dimensional Checks.................................................................................................50 Shop Assembly And Tests .......................................................................................50 Spiral Case................................................................................................................53 Stayring ....................................................................................................................54 Bottom Ring .............................................................................................................55 Draft Tube ................................................................................................................56 Turbine Pit Liner And Coverings.............................................................................58
MATERIALS AND CONSTRUCTION .............................................................................35
SHOP INSPECTION AND TESTING................................................................................42
TECHNICAL SPECIFICATIONS FOR FIXED / EMBEDDED COMPONENTS ...........52
TECHNICAL SPECIFICATIONS FOR STATIONARY/ REMOVABLE COMPONENTS...................................................................................................................59 1.11.1 Headcover.................................................................................................................59 1.11.2 Guide Vanes .............................................................................................................61
1.12
TECHNICAL SPECIFICATIONS FOR GUIDE VANE REGULATING APPARATUS ......................................................................................................................62 1.12.1 Description And Requirements Of The Apparatus ..................................................62 1.12.2 Servomotors .............................................................................................................63 1.12.3 Locking Devices.......................................................................................................64
1.13
TECHNICAL SPECIFICATIONS FOR ROTATING PARTS, BEARINGS AND SEALS .................................................................................................................................64 1.13.1 1.13.2 1.13.3 1.13.4 Runner ......................................................................................................................64 Main Shaft ................................................................................................................65 Turbine Guide Bearing.............................................................................................67 Main Shaft Seal ........................................................................................................69
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1.13.5 Standstill (Maintenance) Seal...................................................................................70 1.14 1.15 TECHNICAL SPECIFICATION FOR THRUST BEARING ............................................70 TECHNICAL SPECIFICATIONS FOR MISCELLANEOUS COMPONENTS ...............71 1.15.1 1.15.2 1.15.3 1.15.4 1.15.5 1.16 1.16.1 1.16.2 1.16.3 1.16.4 1.16.5 1.16.6 1.16.7 1.17 Walkways, Acces Platforms And Stairs...................................................................71 Lifting Devices .........................................................................................................71 Special Tools ............................................................................................................71 Turbine Pit Hoist ......................................................................................................72 Nameplate.................................................................................................................72 Bearing Lubrication Systems ...................................................................................72 Runner Pressure Balancing And Pressure Relief Lines ...........................................72 Turbine Pit Drainage ................................................................................................73 Lubrication For Guide Vane Regulation System .....................................................73 Air Admission ..........................................................................................................73 Compressed Air System ...........................................................................................74 Governors .................................................................................................................76
TECHNICAL SPECIFICATION FOR AUXILIARY SYSTEMS .....................................72
TECHNICAL SPECIFICATION FOR INSTRUMENTATION ........................................85 1.17.1 General Requirements ..............................................................................................85 1.17.2 Control And Instruments For Turbine And Governor .............................................86 1.17.3 Contact Devices........................................................................................................90
1.18
SPARE PARTS....................................................................................................................92 1.18.1 General .....................................................................................................................92 1.18.2 Specified Spare Parts................................................................................................92 1.18.3 Recommended Spare Parts.......................................................................................93
1.19
MODEL ACCEPTANCE TESTS .......................................................................................93 1.19.1 1.19.2 1.19.3 1.19.4 1.19.5 1.19.6 General .....................................................................................................................93 Performance Of Model Tests ...................................................................................94 Model Performance Data .........................................................................................95 Acceptance Of Model Tests .....................................................................................96 Homology Model To Prototype ...............................................................................97 Test Report ...............................................................................................................97 General .....................................................................................................................98 Erection Procedures..................................................................................................99 Tests During Erection.............................................................................................102 Tests On Completion..............................................................................................102
1.20
ERECTION AND TESTS ON COMPLETION..................................................................98 1.20.1 1.20.2 1.20.3 1.20.4
The Copyright remains with AF Colenco Ltd.
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SECTIO 1:
TURBI ES A D GOVER ORS
TECH ICAL REQUIREME TS
1.1
SCOPE OF WORKS This Clause specifies only the principal plant to be provided and work to be done by the Contractor for the fulfilment of Section 1 of this Contract, covering the supply and services necessary for Two (2) vertical shaft Francis turbines with governors according to this Specification. Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Employers personnel, handing over to Employer and two years defect free operation and maintenance guarantee as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The Contractor is bound, however, to provide complete works, even if plant to be provided or work to be done are not mentioned specifically in the following description of the scope of works. The Contractor has to coordinate its work with other Contractors so as to guarantee a smooth connection at all Contract boundaries. This includes the exchanging of specialised knowledge, so that the plant forms a perfect functioning unit. This is especially the case for the control system, where the Contractor shall provide in good time the necessary operational description including function, Process and Instrumentation diagrams (PI-diagrams) together with the required regulating algorithms. The items enumerated under the following clauses refer to the minimum general requirements of one turbine, but these requirements shall apply to both the turbines to be provided as any interface plant deemed to be necessary except where stated otherwise.
1.1.1
Turbine Components Each of the Two (2) Francis turbines to be supplied under this Contract shall mainly comprise:
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1 Runner: The runner shall be a one-piece design, welded construction or cast steel alloy with a content of at least 13 % Chromium and 4 % Nickel. 1 Turbine Shaft of forged carbon or alloy steel having a coupling flange on the upper end at elevation 346.5 m.a.s.l. approx. for attachment to the generator shaft and one coupling flange on the lower end for attachment to the runner. 1 Turbine Guide Bearing of the oil- immersed segmental type, segments lined with antifriction metal and individually adjustable. The bearing shall be complete with bearing support, lubricating oil system with oil reservoir, cooling coils, oil and water piping, valves as well as oil fill and drain pipes. 1 Spiral Case with the upstream connection pipe of welded construction subdivided into suitable parts for transport complete with stay ring and stay vanes, the necessary foundation and lifting material, manhole, emptying valve and pipes for emptying spiral casing and filling penstock. 1 Pressure Testing Equipment for spiral casing consisting of test head cover, test ring, pump and piping arrangement, to be provided only once for both the units. 1 Head Cover of welded construction, split in halves if necessary to suit the conditions for erection at site. 1 Bottom Ring of welded construction, split in halves if necessary to suit the conditions for erection at site. 1 Discharge Ring (or foundation ring) of welded or cast steel (the discharge ring can be integral with the bottom ring). 1 Draft Tube Liner of elbow type and of welded construction, with removable cone in parts, with manhole in cone section, bottom discharge with isolating valve and the necessary connections for draft tube dewatering system, emptying valve and drain pipes to the main powerhouse drainage sump. 1 Inspection Platform for easy insertion into draft tube cone (one to be furnished for both the turbines). 1 Main Shaft Seal, complete with connections for the sealing water installation. 1 Complete Sealing Water Installation for the main shaft seal with the necessary pumps, piping, flow meter, manually and solenoid-operated isolating valves, water discharge and evacuation piping with appurtenances, including a suitable double filtering plant for the sealing water.
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1 Wicket Gate with 1 complete set of guide vanes including guide vane operating mechanism as well as guide vane bearings, operating ring, levers and links. 2 Servomotors pressure oil operated, double acting, of cast steel or fabricated construction for the control of the guide vane operating mechanism complete with the necessary fixations supports. 1 Turbine Pit Liner fabricated of welded steel plates to be welded or bolted to the stay ring with the necessary supports for the covers around the turbine pit. 1 Complete Set of Covers, Platforms, Stairways, Ladders, Guards, Hand railing, Walkways and Checkered Plates to obtain easy and save access to all plant provided under this Section 1 to be arranged inside and around the turbine pit. 1 Set Special Tools to be provided for both turbines in accordance with Clause 1.15.3 of this Section 1. 1 Compressed Air Supply System for draft tube air admission in accordance with Clause 1.16.5 of this Section 1. 1 Low Pressure Air Supply System for the generator braking and for service air, in accordance with Clause 1.16.6 of this Section 1. 1 High Pressure Air Supply System for the compressed air supply to the governor pressure oil accumulators of the turbine governors and main inlet valve, in accordance with Clause 1.16.6 of this Section 1. 1 Governor System to be provided for each turbine in accordance with Clause 1.16.7 of this Section. 1 Complete Set of Controls and Instruments to be provided for each turbine in accordance with Clause 1.17 of this Section. 1 Set of Spare Parts to be provided for both the turbines in accordance with Clause 1.18 of this Section including 100 % spare oil of the installed quantity for the bearings. Oil and Grease for first filling for the both turbine guide bearings and for the two governor systems, as well as sufficient grease and other lubrication oil necessary for all remaining lubricating requirements.
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1.2
I TERFACES Pos. 1 System Powerhouse Interfaces Section 1: Turbines and Governors All embedded parts delivered by the turbine manufacturer shall be positioned and leveled under his responsibility. Interfaces to the draft tube liner see Drawings. The Draft Tube Gates and the corresponding Gantry Crane are included in H&M Contract . 2 3 4 Main Inlet Valve Main Powerhouse Cranes Generator The spiral case is linked to dismantling pipe by a flange connection. Included in Section 24 of this Contract. Coupling between turbine and generator shaft. The coupling bolts, nuts and guards are included in this Section 1.
Auxiliary Systems included General interface: Turbine pit. Piping within the in turbine pit is included in this Section 1 and shall be provided by the turbine manufacturer. Section 20: Cooling Water System; Connections to the various auxiliary systems are included in this Section 1 and shall be provided Section 21: Drainage and by the turbine manufacturer (Interface: Turbine Dewatering System; pit). Section 27: Lub Purification system Oil Piping and isolating valves for the complete turbine dewatering system to the powerhouse sump as well as the pumps including pipes for dewatering the turbine pit shall be provided by the turbine manufacturer.
Auxiliary Power Systems
Supply General Interfaces are the terminal strips. Motor control centre (MCC) included in General Technical Specifications and LV- cabling are included in Section 15. General interfaces are the terminal strips in the different terminal boxes of the turbine. Control System cabling within limits of turbine supply is included in Section 1 only. The cabinet(s) for the turbine digital electronic controller, the speed measurement and the
Control System
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Pos.
System
Interfaces Section 1: Turbines and Governors vibration controller are included in this Section 1.
Monitoring and Protection All turbine mechanical protection sensors System instruments shall be included in this Section 1 (like vibration monitoring system, over speed device (hydraulic action), electronic speed sensing devices, temperature, pressure, governor feedback system, etc.). The unit control PLC and the master trip lockout relays are included in Section 12, SCADA System.
Cables
Power and control cables for turbine external connections are included in Section 15, Cables. However, cabling within limits of turbine supply is included in this Section 1. flow measuring The turbine discharge shall be measured in the penstock in front of each turbine by means of a high precision acoustic flow meter. Water flow measuring device required for index tests shall be provided during the commissioning tests only. Both shall be provided by the turbine manufacturer and shall be included in this Section 1. Water supply for the turbine shaft seal as well as for the labyrinths during dewatered operation, shall be provided in accordance with the Specification in Section 20 Cooling Water System
10
Water device
11
Cooling Water System
1.3
SUPPLY BY THE EMPLOYER The items and services which will be the responsibility of the Employer are listed in Project Description and General Information.
1.4
DESIG CO DITIO S The general design parameters of the turbines shall be as follows:
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Turbine Number of units Type of turbine Shaft position Rotational direction of generator rotor, viewed from above Rated turbine discharge Rated head (mode of operation Storage) Range of net head m3/s m m 2 Francis Vertical Clockwise 27.82 107.50 102.51 115.85 27.55 29.8 50 - 5% to + 3% 375 694 Approx. 1950 344.50 337.50 Approx 1 bar absolute / 12 / 18 35
Rated turbine output at rated head 107.5 m and rated MW discharge Maximum turbine output at net head 115.85 m and MW Rated discharge Rated frequency Permissible frequency operating range Rated speed (n) Runaway speed (nrun) Runner outlet diameter Elevation of spiral case center line Draft tube invert Hz Hz rpm rpm mm m.a.s.l m.a.s.l.
Minimum pressure in the draft tube cone below runner bar under most unfavorable transient conditions Maximum working pressure for all parts under water Kg pressure (design pressure) cm2 Test pressure for all parts under water pressure Kg cm2
Permissible pressure rise related to the pressure under % maximum flood level
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Permissible speed rise for turbine load rejection related % to the rated speed 1.4.1 Project Arrangement
50.0
The description of the project arrangement together with general arrangement drawings of the powerhouse, the layout of the electromechanical plant and the waterways at the high and the low pressure side is given in the various drawings and diagrams of General Project Information and Drawings & Construction time Schedule. The drawings are not considered as defining the design of the plant, but are intended to show the general layout and space requirements. Modifications may be made to suit the design of the plant provided by the Contractor, if the Engineer deems such modifications appropriate and acceptable. The two vertical shaft Francis turbines are located in a surface powerhouse at a proposed spiral casing centre line elevation of 344.5 m.a.s.l. The generating unit is of conventional design with a turbine guide bearing arranged in the head cover and a combined thrust and guide bearing on a bearing bracket just below the generator rotor and a guide bearing above the generator rotor. Water is guided through a vertical shaft and distributed to each turbine through a manifold of two branches. Butterfly valves are installed in each single penstock just upstream of spiral case inlet serving the purpose for carrying out repairs in turbine and also as emergency shut-off after governor failure. The turbine spiral case is completely embedded in concrete. Speed and output are controlled by the guide vane operating mechanism, which is regulated by two hydraulic servomotors actuated by the governor. The turbine discharges into the tailrace channel through an elbow type, partially steel lined draft tube, provided with draft tube gates allowing dewatering of the turbine for inspection and overhaul. Each turbine shall be controlled by an electronic governor and the pertaining electrohydraulic control system. The governor shall permit speed and power control of each unit individually. Joint control of both units in operation shall be provided by the control system. Synchronous condenser mode operation is not applicable to this plant.
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1.4.2
Hydraulic Conditions The hydraulic conditions under which to operate the units are presented in the following table: Storage reservoir water levels: Full supply water level FSL Minimum operating level MOL Active volume of reservoir Tailrace water levels for Turbine design: Maximum flood level (Qriver = PMF1)) m.a.s.l 356.0 348.99 348.39 Operating level at rated discharge 2x27.82 m.a.s.l m3/sec. Minimum operating (Qriver = Qunit = 40.25 m3/s) Turbine gross head: Maximum gross head (to be used for runaway m speed guarantee) Turbine net heads: Maximum net head Minimum net head Water temperatures: Maximum water temperature (to be used for C cavitation guarantee) Minimum water temperature (to be used for C determination of prototype performance with consideration of scale effects) Water quality analysis (chemical, corrosive nature, biological, suspended solids) Density of water to be taken (at 20 C) Acceleration due to gravity to be taken Range of ambient temperatures kg /m3 m/s2 C 25.0 15.0 m m 115.85 107.50 102.51 Rated net head (mode of operation STORAGE) m 117.8 level m.a.s.l m.a.s.l m.a.s.l million m
3
466.20 460.0 0.981
As per General Project Information 1000 9.81 50 400
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Range of ambient humidity

1.4.2.1
30 90 (tropical)
Guaranteed Turbine Operating Range

Guaranteed Turbine Operating range
35.00
30.00 Turbine Power Output (MW)
1MAX MW=27.64 at Q=29.17, H=102.51m, eff=94.2%
2MAX MW=28.98 at Q=29.17, H=107.5m, eff=94.2% RATED MW=27.64 at Q=27.82, H=107.5m, eff=94.2%
3MAX MW=29.80 at Q=27.82, H=115.85m, eff=94.2%
96.00%
94.00%
92.00%
20.00 90.00% 15.00 88.00% 10.00 1MIN MW=9.51 at Q=11.13, H=102.51, eff=85.0% 2MIN MW=11.91 at Q=11.13, H=115.85 eff=94.2%
5.00
86.00%
0.00 100 102 104 106 108 110 112 114 116 Turbine net Head (m) 118
84.00%
MW
Eff
The guaranteed turbine operating range for continuous operation (for each turbine) is: Operating Point omenclature Discharge (m3/s) et head (m) RATED 1MAX 2MAX 3MAX 1MI 2MI at Pmin at Hmax
Pmax at Pmax Qrated & Hmin Hrated 27.82 107.5 29.17 102.51 94.20% 27.64
at Pmax at Pmax at Pmin Hrated Hmax Hmin
29.17 107.50 94.20% 28.98
27.82 115.85 94.20% 29.78
11.13 102.51 85.00% 9.51
11.13 115.85 94.20% 11.91
Efficiency (%) 94.20% Power output 27.64 (MW)
Cavitation guarantee has to be fulfilled within the above range including temporary
1.4.2.2
Head Losses Head loss in high pressure part of the waterway (between upper reservoir and entry of spiral case) shall be taken to vary according to the following relationship:
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HLHP = KHP1 x Q2 HLHP = KHP2 x Q2
(when one unit in operation) (when two units in operation)
where: HLHP Q KHP1 = 2.51 * 10-3 KHP2 = 2.51 * 10-3
Head loss in high pressure part of the [m] waterway Flow rate in penstock [m3/s]
Head loss coefficient when one unit in [s2/m5] operation Head loss coefficient when two units in [s2/m5] operation
Head loss in low pressure part of the waterway (between exit of draft tube and tailrace outlet) shall be taken to vary according to the following relationship: HLLP = KLP1 x Q2 HLLP = KLP2 x Q2
where: HLLP Q KLP1 = 3.14*10-5 KLP2 = 2.15*10-5
Head loss in low pressure part of the waterway Flow rate in penstock Head loss coefficient when one unit in operation
[m] [m3/s] [s2/m5]
Head loss coefficient when two units in operation [s2/m5]
Turbine net head Hn becomes: Hn = HWL TWL HLHP HLLP where: Hn HWL TWL HLHP Turbine net head Head water level Tail water level Losses in the high pressure side [m] [m.a.s.l.] [m.a.s.l.] [m]
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HLLP
Losses in the low pressure side
[m]
The Contractor has to calculate the total annual energy production in accordance with the energy production table, using the formula mentioned above.
1.4.3
1.4.3.1
Specified Conditions Modes of Operation
1.4.3.1.1
Storage and run of river It is considered important to provide for the increasing of the energy produced during the dry season (base load) and reduction of spilling via the spillway rather than solely trying to maintain high heads to increase wet season energy at the expense of dry season energy. Therefore, the storage mode of operation by which an increase in the dry season energy can be achieved is the most beneficial mode of operation for the BHASMEY HEP. This mode also would avoid any spilling of water over the spillway in an average year. In the case that the energy generation situation in Sikkim would significantly improve it would be possible to change over to a run of river mode of operation without requiring any modification of the hydraulic plant. Therefore both modes of operation have to be taken into consideration. The Contractor shall calculate the yearly average energy production for the mode of operation storage as well as for run of river. Peak operation requirements: The BHASMEY HEP shall provide for the systems peak power demand, according to the daily load pattern. The anticipated number of start-stops per year and per unit can be assumed with 500.
1.4.3.1.2
Isolated and blackout-start operations Existing power system: The state of Sikkim, where Bhasmey is envisaged, is having only hydroelectric generation. Hydroelectric generation in Sikkim caters the requirement of power of the state as well as the adjoining states connected with Eastern grid. Northern grid can also be connected with other regional grids in view of the total revolution in transmission system of India. The generator is free to sell its power in any corner of the country. This power station is the constituent of the regional grid and there is no scope of power utilisation in local area, thus Bhasmey HEP is not likely to run in isolation. Power house will run in isolation only when there is grid failure and generator has to feed the auxiliaries of the power station.
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The power plant has been designed for running in peak hours for the time until power situation in the country improves significantly. Therefore, the machines and the systems shall be designed for black start by providing DG set of sufficient capacity to cater the load for black start. The plant should thus be capable to withstand the transient conditions associated with the regional grid system.
1.4.3.2
Penstock draining through Turbine Penstock draining through the turbine shall be enabled. The Contractor has to indicate the minimum permissible net head for draining through the turbine in the Technical Data Schedules.
1.4.4
Generator Characteristics (Refer also to Section 3 of Particular Technical Specifications) The principal characteristics of the generators to which the turbines will be coupled are as follows:
Rated power Max. continuous power output Rated speed Runaway speed ratio (RSR=nrun/n) Rated power factor cos overexcited Rated voltage Range of voltage variation Rated frequency Range of frequency variation Inertia constant of Generator & Turbine
MVA MVA rpm kV % Hz Hz kWs/ kVA
30 33 375 1.85 0.9 11.0 10 50 +3% to -5% 3.5 500 1 combined thrust and guide bearing below the (umbrella type).
Moment of inertia J (mass x square radius) tm2 of generator Preferred bearing arrangement -
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1.4.5
1.4.5.1
Transient Behaviour Data Speed Rise For sudden load rejection of the turbines from maximum load to no load under the most unfavourable head, the maximum speed rise shall not exceed the value indicated in the table design parameter of the turbines in Clause 1.4 of this Section. The value shall be guaranteed by the Contractor.
1.4.5.2
Pressure Rise In no case the pressure rise in the spiral case shall exceed the permitted pressure value indicated in the table design parameter of the turbines in Clause 1.4 of this Section. The maximum pressure rise shall be guaranteed by the Contractor. No dangerous pressure drop in the draft tube shall occur. The minimum level of absolute pressure within the draft tube shall be guaranteed by the Contractor.
1.4.5.3
Moment of Inertia The stability investigations of the regulating process shall be based on the assumption that the power plant will not only be operated in parallel with other power stations of the grid but also as sole power source for a supply area, i.e. isolated operation Isolated operation has to be taken into account for operation of all units under the maximum possible power range. Based on this, the necessary flywheel effect for the generating unit (especially for the generator) has to be determined by the Contractor, taking into account all boundary conditions i.e. total hydraulic system as well as the conditions in the grid. The value shall be indicated in the technical data schedules and shall be guaranteed by the Contractor.
1.4.6
Stability Of The System The Contractor shall carry out the stability study by mathematical simulation of the entire system penstock, generator, turbine, governor and power system in order to that system is stable under all load conditions. The hydraulic transient calculations shall be carried out by the Contractor with the basic assumptions and numerical data available: On drawings for the water conveyance system. The hydraulic characteristics of the turbine resulting from the model tests and scaled up to the prototype.
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The Contractor shall take into consideration the following assumptions, parameter values and their numerous combinations: Minimum and maximum net head with the discharge corresponding to full load under each respective net head. Various operations (start-up, normal shut-down, trip-off, wicket gate closure or failure to operate, etc.), within the normal and emergency operating mode changes. The Contractor shall submit the following results and justify that the most unfavourable though realistic conditions have been calculated and analysed: Maximum and minimum pressure in the spiral case. Maximum and minimum pressure below the runner and at the centre line of the draft tube outlet. Maximum transient rotational speed. Maximum and minimum water level in surge tanks for the most hazardous operation. Maximum and minimum pressure in the head race tunnel. Maximum and minimum pressure in the tailrace tunnel. Maximum and minimum pressure at the top of vertical pressure shaft (at the elbow elevation). Total momentum of inertia for the rotating parts. Optimized wicket gate motion for closure laws and emergency closing law of main inlet valves.
The Contractor shall supply a report describing the calculation method, a brief software description (including validation), computation assumptions, input data, results and analysis. Study shall be conducted for conditions including parallel operation with the infinitive network and isolated network conditions. The study shall indicate the setting range of the governor parameters for which the system is stable after any disturbance. As far as applicable, the governing system shall comply with IEC 61362 and IEC 60308. A preliminary transients report shall be submitted in advance to the Engineer for approval, four months before the expected date of the model acceptance tests. The definitive report shall be submitted, at the latest, one month after the end of the model acceptance tests.
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With reference to the Tender Drawings, all necessary information is available to predict possible resonance in the water conveyance system of the power plant.
1.4.6.1
Draft Tube Pressure Pulsation, Resonance Phenomena Amplitude and frequency of the draft tube pressure pulsation (DTPP), resulting from the turbine operation at partial load, shall be indicated in the technical data schedules. The value shall be guaranteed by the Contractor. The maximum amplitude of the DTPP shall not exceed 2% of the corresponding net head. The DTPP frequency shall be at least 20% lower or higher than the natural frequency of the penstock. The DTPP frequency shall be at least 20% less or more than the natural torsion frequency of the turbine / generator unit.
1.4.6.2
Power Fluctuations Guaranteed limits to power fluctuations are variation in power output measured at the generator terminal becoming 1.5 % of the rated power. The values shall be indicated in the technical data schedules and shall be guaranteed by the Contractor.
1.4.7
oise The noise level limits shall be in a distance from 1 m to the surface of the turbines or the auxiliary equipment less than 90 dB (A). Values up to 100 dB (A) are only acceptable during transient conditions.
1.4.8
Vibration The maximum shaft vibration as measured near the turbine and generator guide bearings shall be within ISO 7919-5, zone A (Mechanical vibration of non-reciprocating machines Measurements on rotating shafts and evaluation criteria), when operating at rated speed and any load.
1.4.9
Sand Erosion Consideration Due to the reservoir, the risk of sand erosion may be considered to be low. However due to the hydrological characteristic of the region, silt content rich in Quartz during high flow period, can be important.
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The Contractor shall critically study the impact of this type of silt on turbine parts and provide suitable special coating if necessary. HVOF Tungsten carbide protective coating on parts prone to abrasion i.e. runner, guide vanes, labyrinth and facing plates is to be provided. Suspended organic and inorganic matter will be expected in the storage reservoir and consequently in the available water for the turbines.
1.4.10
Safety Requirements The design of the plant shall provide all reasonable precautions for the safety of the personnel in charge of operation and maintenance and shall meet the relevant safety regulations and standards specified in the General Conditions of Contract.
1.5 1.5.1
TECH ICAL PERFORMA CE A D OTHER GUARA TEES General This Clause covers specific performance guarantees for the turbines. All guarantee values shall be indicated in Technical Data Sheets. For general conditions of guarantees, reference is made to Conditions of Contract. All guaranteed features, values, characteristics, etc. are required to be within the permissible tolerances. The Contractor is required to carry out modifications until all the permissible tolerances of the guaranteed features are met. If, however, in spite of all measures taken, these permissible tolerances cannot be met, than the Employer provided that this is not regulated by penalties, as per Special Conditions of Contract, may stipulate a suitable compensation sum which will be deducted from the purchase price.
1.5.2
Guaranteed Power The Contractor guarantees the power output at the turbine shaft, according to Section 1.4.2.1, as follows: Maximum power P1TU,MAX Maximum power P2TU,MAX output output 27.5 MW at min. net head 102.51 m, H1TU 29.7 MW at rated head 107.5 m, H2TU
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Maximum power P3TU,MAX
output
29.7 MW at maximum 115.85m, head H3TU
Moreover, the turbine output for continuous operation shall be guaranteed at rated head for: Rated power output at rated head and rated discharge At 75% of rated power output.
Refer to Turbine Technical Data Sheets. The guaranteed turbine output (P) shall be demonstrated by model tests (output at turbine runner coupling PM) and by calculating turbine bearing losses and thrust bearing losses PLM (P = PM PLM as specified in IEC 60193 and IEC 60041). Should the Contractor fail to achieve the output guarantee with a tolerance of 0.5%, then the Contractor shall correct the design to achieve the guaranteed output within 6 months in order to fulfil the guarantee. The Contractor shall be responsible for all costs associated with any necessary modification and retesting of the machine. If the guaranteed output cannot be achieved by means of a modification or if by mutual agreement such modifications are omitted, the Contractor shall pay to the Employer penalties as specified in Particular Conditions of Contract. No bonus will be given for exceeding the guaranteed values. The maximum turbine output shall be verified by field tests according to IEC 60041. Should the Contractor again fail to achieve the maximum turbine output guarantee with a total tolerance of 1.5 %, then the Contractor shall pay to the Employer penalties as specified in Particular Conditions of Contract. Penalties shall be paid only once based on model measurements or on the field measurements depending on which one is the higher value. No bonus will be given for exceeding the guaranteed value.
1.5.2.1
Power Fluctuations Guaranteed limits of power fluctuations (variation in power output measured at the generator terminal) shall not exceed + 1.5 % of the rated power.
1.5.3
Guaranteed Minimum Discharge The Contractor has to guarantee a minimal turbine discharge of 11.13 m3/s (equivalent to 40% of rated load which is supposed to be the minimum safe load for Francis turbine) between a net head of 102.50 m and 115.85 m for a period of approximately 30 days per year. During this operation all requirements mentioned in this Specification shall be fulfilled completely.
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1.5.4
Guaranteed Efficiency With Respect To Guaranteed Annual Energy Production The weighted average efficiency will be computed using the following grid of weighting coefficients Wi and formula: Units in operation et head (m) Maximum output Rated output 75% of rated output Min output 2 107.5 12 45 15 10 1 115.85 10 8 Total 22 45 15 18 100
The weighted average efficiency to be guaranteed by the Contractor is defined as follows:
W *
i
weigthed =
100
i being the individual efficiency and Wi the corresponding weighting coefficient

according to the above chart. The Contractor has to calculate and guarantee the, to be expected, weighted yearly energy production, taking into account losses in the waterway defined in Clause 1.4.2.2 of this Section 1. Verification will be established by means of model acceptance tests in the Contractors laboratory or in another laboratory acceptable to both parties, using test results with the step-up formula according to IEC 60193. The calculation of the medium average, weighted yearly energy production is in accordance with the criteria set out in the energy production tables. The turbine efficiency for the prototype is to be guaranteed for the respective operating levels and the corresponding discharges. A constant generator efficiency of 97.5 % is assumed when calculating the yearly energy production at the generator terminals. The turbine manufacturer has to establish the optimum switching levels (start up respectively shut off the second generating unit).
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Bhasmey HEP will generate 142.48 GWh during 112 days of monsoon period and 98.72 GWh shall be generated during rest 253 days in a year. These figures are related to 90% dependable year. The power plant is designed for operation as a peaking power plant. The storage capacity of reservoir is less than 8 hours for all the two machines on full load. The plant will run as peak plant for most of the part of the year giving rated power during peak hours ranging 3 to 17 hours a day except during monsoon period of 70 days giving rated power round the clock. The plant may run on run of river mode barring the period when river discharge is not equivalent to safe run of one unit. All efficiencies for the turbine prototype indicated in the energy production table by the Contractor will be verified by model tests in accordance with IEC 60193. Should the Contractor fail to achieve the guaranteed weighted efficiency with a tolerance of 0.3% of rated power, then the Contractor shall modify the turbine design in order to attain the guaranteed value at the Contractors expense. If the guaranteed value cannot be achieved by means of modifications or if by mutual agreement such modification is omitted, the Contractor shall pay to the Employer penalties as specified in Particular Conditions of Contract. Should the Contractor fail to meet the guaranteed weighted efficiency by more than 2.0% (measuring tolerance included), then the Employer has the right to reject the turbine. No bonus will be given for exceeding the guaranteed values. The efficiencies guarantees shall be verified by field tests according to IEC 60041. Should the contractor fail to achieve the efficiency guarantees, then the Contractor shall pay to the Employer penalties as specified in Particular Conditions of Contract. At the option of the Employer, full scale field efficiency tests shall be performed on at least one unit. The Contractor shall indicate the method to be used for such tests in his Tender and shall specify corresponding costs in the Price Schedules (price for one unit and for the second and third together). Curves of turbine efficiency, output and discharge against net head of 107.50, 102.51 and 115.85 m for outputs of 100%, 90%, 80%, 70%, 60% 50% and 40% of maximum output shall be submitted with the Tender. These curves shall be consistent with the guarantees relating to the efficiency and output.
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1.5.5
Guaranteed Maximal Momentary Pressure

The maximum momentary pressure at the turbine inlet respectively spiral case due to sudden load rejection under most unfavourable operating conditions (during operation at the maximum reservoir level of 466.20 m.a.s.l with maximum power output), shall be guaranteed as stated in the Technical Data Sheets. Compliance with the guaranteed maximum momentary pressure rise values shall be proved by respective calculations and verified by model tests.
1.5.5.1
Pressure Fluctuations
Limits to pressure fluctuations are pressure amplitudes of 2 % of the corresponding net head measured at the draft tube wall below the turbine runner.
1.5.6
Guaranteed Maximum Momentary Overspeed

The maximum momentary overspeed is the overspeed attained under the most unfavourable transient conditions. Under certain conditions, it may exceed maximum steady state runaway speed. The maximum momentary overspeed ( 150% of rated speed) shall be guaranteed by the Contractor. Compliance with the guaranteed speed rise values shall be proved by respective calculations and verified by field tests.
1.5.7
Guaranteed Maximum Steady-State Runaway Speed

The maximum runaway speed as stated in the Data Sheets for the most unfavourable conditions (maximal gross head, fully open wicket gates, considering variation in the plant cavitation factor) has to be guaranteed. Compliance with the guarantee shall be proved by model tests.
1.5.8
Cavitation Guarantees
The Contractor shall guarantee cavitation-free operation in the whole turbine operating range defined in section 1.4.2.1. In accordance with IEC 60193, the Incipient Thoma Number (i) and the Plant Thoma Number (PL) shall be used. Basically, a safety margin in terms of a safety factor (k) between the Incipient Thoma Number (i) and the Plant Thoma Number (PL) have to be guaranteed, where PL = k * i.
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The safety margin shall be at the highest possible level, k > 1.0. When operating under temporary conditions, (about 100 hours per year, at loads outside the continuous operating range), only the Plant Thoma Number (PL) shall be higher than the model test o (called Thoma number zero and defined in IEC 60193), based on maximum water temperature stated in Clause 1.4.2, Hydraulic conditions of this Section 1.
1.5.8.1
Cavitation Guarantees Verified on the Turbine Model Test

The verification of the cavitation guarantees is performed with a model acceptance test in the laboratory of the supplier or in another independent laboratory accepted by the employer. Without any restriction, the model acceptance test is subject to international standard IEC 60193 and it shall fulfil completely the cavitation guarantees. For the following operating points the supplier has to specify the Incipient Thoma Number (i) and to guarantee the safety factor k: Maximum power output P1TU, MAX at minimum net head H1TU=102.51 m, Maximum power output P2TU, MAX at rated head H2TU=107.50 m, Maximum power output P3TU, MAX at maximum head H3TU=115.85 Minimum power output P1TU, MIN at minimum net head H1TU=102.51 m, Minimum power output P2TU, MIN at maximum net head H3TU=115.85 If based on the results of model acceptance tests, the Contractor fails to achieve this cavitation performance guarantees, the Contractor shall modify the turbine design in order to attain the guaranteed values at the Contractors expense. If the guaranteed value cannot be achieved by means of modifications within 6 months, the Employer has the right to reject the turbine design.
1.5.9
Cavitation Pitting Guarantees

The Contractor shall guarantee the runner, discharge ring and draft tube liner free from excessive cavitation pitting for 8000 hours of operation in generating mode, starting on the date of Taking Over, or a period of 2 years after the date of Taking Over, whichever shall occur first.
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If within the Defects Liability Period stated above and under the operating conditions, the turbine runner or other parts become excessively pitted, the Contractor shall repair the pitted places and rectify the runner profile in a manner satisfactory to the Engineer by stainless steel welding. Excessive pitting of the turbine runner caused by cavitation is defined as that which entails the removal of 0.3 x D2/8000 kg of metal per operating hour, where D is the outlet diameter of the runner in meter, or pitting depth exceeding 5 mm after 8000 hours of operation in generating mode, regardless of the area. The amount of pitting shall be determined in accordance with IEC 60609. Metal removal exceeding either criterion shall constitute failure to meet the cavitation pitting guarantee. During the cavitation Defects Liability Period, the Contractor shall be permitted to inspect the turbine. The first inspection of the runner and other parts subject to cavitation shall be carried out at the end of the trial operation. Further inspection will be decided by the Employer if deemed necessary. During the cavitation Defects Liability Period, the Contractor is not entitled to carry out any rectification on the runner profile unless permitted by the Engineer. The Employer will have the right to reject a runner if the cavitation guarantee is not fulfilled, or if more than three rectifications, done by the Contractor at his expense have not brought sufficient improvement. For erosion or damage caused by suspended matter in water the cavitation guarantee does not apply.
1.5.10
Guaranteed Hydraulic Thrust

The maximum hydraulic thrust in both directions occurring under the most unfavourable transient conditions shall be guaranteed as indicated by the Contractor in the Technical Data Sheets. Compliance with the guarantee shall be proved by model tests.
1.5.11
Guaranteed Maximum Weights And Dimensions

The maximum permissible transport and assembly weights, as well as the maximum transport dimensions, are based strictly on existing facilities (powerhouse crane capacity, access roads) and in accordance with the General Technical Specification. Should the Contractor be unable to meet these guaranteed requirements, then he shall be liable for the ensuing damage costs.
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1.5.12
1.5.12.1
Other Technical Guarantees Wicket Gate Torque

The maximum wicket gate torque (caused by hydro-dynamic forces) shall be indicated in closing and opening sense, preferably for two opposite gates, under the most unfavourable transient conditions. The wicket gate torque shall have the closing tendency for all openings down to an opening which keeps the turbine at no-load speed below the synchronous speed. Compliance with the guarantee shall be proved by model tests.
1.5.12.2
Mechanical Behavior
The guarantee concerning mechanical behaviour shall cover a period of 2 years from the date of Taking Over. During this period, all main steel parts especially those in contact with the water flow or in the turbine pit will be inspected at the end of the trial operation, and then every 2000 hours of operation until expiry of the above-mentioned Defects Liability Period. The inspection shall be performed in compliance with the inspection of the finishmachined runner for defect on the surface, and the same limits of acceptability shall apply as specified under Clause 1.9, Shop inspection and testing, of this Section 1. Such inspections shall basically be carried out by the Contractor, together with the Employer. For each inspection carried out, the Contractor has to issue a report to be submitted to the Employer and the Engineer. If the inspections carried out during the Defects Liability period as mentioned above should reveal the appearance of cracks in any portion of the turbine, the Employer reserves the right to apply one of the following procedures: If the cracks or other defects do not demonstrate any systematic character, the Contractor shall eliminate or repair said defects at his own cost according to an approved and recognised method. If the cracks or other defects demonstrate any systematic character all over the runner, the Contractor shall propose a general repair procedure followed by a heat treatment. All repairs are subject to the Engineers prior review and acceptance of the repair procedure. The repairs shall be made at no cost to the Employer and will be considered final and successful, if they allow operation for a minimum of 8,000 hours without the appearance of new cracks or other defects.
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If after repeated repair or at the expiration of the runners Defects Liability Period new cracks should continue to appear, the Employer reserves the right to reject the defective parts. During the Defects Liability period specified for the Francis runners, all necessary repairs on the runners shall be carried out by the Contractor at his own cost. This refers in particular to the following: Anomalies of metallurgical origin, such as casting defects or cracks. Rectifications due to incorrect shape and surface quality of the runner blades in order to eliminate cavitation and improve hydraulic performance. Normal uniform wear due to erosion will not be considered as a fault to be covered by this specific guarantee.
1.6 1.6.1
MECHA ICAL DESIG CRITERIA Design Standards

Unless specified otherwise in the Particulars Technical Specifications, design, materials, manufacture, and testing of all works under this Contract shall comply with an approved standard in accordance with General Technical Specifications, Clause 2.2.
1.6.2
Stresses And Deflections

All parts of plant shall be designed and manufactured in the best and fully suitable manner with materials best suited to their purpose and in accordance with recognised standards of good practice and latest technology. Also transient and abnormal conditions, such as overload, alternator short-circuit, runaway speed of at least 5 minutes duration shall be withstood without detrimental vibrations or distortions. In view of the disastrous consequences which may result from failure of even minor parts carrying water under pressure, the Contractor shall design and manufacture all such parts on a highly conservative basis. Liberal safety factors shall be applied throughout the design, particularly for parts subject to alternating stress, vibration, impact or shock.
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The following design requirements to working stresses shall be applied:
Pos. Working conditions
Maximum unit stress in % of yield point ultimate stress
1 2 3 4
1)
Turbine parts under normal load conditions 1):

2)
50
36 45 45
Turbine parts under extraordinary load conditions 66.7 : Turbine parts under emergency load conditions 3) Prestressed turbine part (screws, bolts, etc.) 66.7 66 - 90
Normal load conditions applied for the following parts and conditions: All possible conditions between synchronization up to full load. Full load rejection with the wicket gates timed to move a full closing stroke within minimum closing time. For constructions under water pressure, such as e.g. the spiral casing under design pressure. Blade servomotor cylinder or piston cap (pipe head) fastenings, as applicable, when torqued or preloaded to meet the design elongation requirements. Quick shutdowns (QSD I and QSD II) and emergency shutdown under full load as specified in Clause 1.16.7, Governor, of this Section 1.
2)
Extraordinary load conditions applied for the following parts and conditions: For all affected parts of the turbine when operating at maximum runaway speed under conditions of maximum head with the wicket gates at the maximum runaway position and no load on the generator. For the wicket gates, gate stems, gate levers, shear levers, friction device, gate links, and pins at the breaking points of the shear pins. For all affected parts of the turbine under hydrostatic test pressure.
3)
Emergency load conditions applied for the following parts and conditions: For all affected parts of the turbine when operating under earthquake acceleration stipulated in Clause 1.6.3.2 of this Section 1.
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In addition to verifying stress levels in all the components of the turbines, the Contractor shall perform finite element analyses of the critical components to verify that stiffness and structural integrity of such components satisfies the requirements of these specifications and the unit will perform satisfactorily under any specified loading condition, including maximum runaway speed. Upon the engineers requirement, the Contractor shall present full information on the admitted stresses in any part of the equipment. All parts of the turbines have to be designed in such a manner, that a service life of more than 40 years can be expected.
1.6.3
1.6.3.1
Special Design Considerations General

The Contractor is responsible for the design of the dynamic behaviour of the combined generator and turbine with respect to critical speed calculations and shaft alignment criteria. Dismantling of the runner, assembly shall take place from bottom, i.e. after removal of extended draft tube cone. However, dismantling of top cover (head cover), guide vane, bottom ring and guide bearing is foreseen through stator bore (top). Special attention shall be paid to quiet and vibration free operation of the turbines and all auxiliary equipment.
1.6.3.2
Earthquake
Refer to General Technical Specification, Clause 2.19.
1.6.3.3
Calculation of Critical Bending and Torsion Vibration Speeds of the Shaft

Both, the turbine and the generator manufacturer are together responsible for the calculation of the critical speeds of the shaft. Therefore, each manufacturer has to calculate the critical speeds for the complete shaft arrangement. The critical bending speeds as well as the critical torsion vibration speeds and the corresponding Eigen shapes have to be calculated by using a computer program which is proved and tested by the turbine and generator manufacturer respectively. Assumption and approximations:
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The combined shaft has to be considered as a continuous beam with sectional constant bending resistance, own mass, continuous distributed additional load, additional concentrated mass and elastic foundations. The stiffness of the rotor, the turbine and generator guide bearing design, the stiffness of the bearing support and the bearing bracket respectively, the stiffness of the foundation itself as well as the rotor weight have to be taken into account. Linear behaviour of all stiffnesses that means no damping influences have to be taken into account The oil film can be assumed as absolutely rigid (due to extremely high bearing forces) Radial bearing can be assumed as isotropic Shearing deformation, rotational inertia and gyrostatic effect have to be taken into account. The magnetic pull has to be taken into account, although while the machine is running at a high speed, the magnetic pull should be de-excited. According to these assumptions the first critical bending speed of the rotor has to be at least 20 % higher than the specified runaway speed of the generator (off-cam runaway speed of the turbine). The safety margin to the torsion vibration speeds has to be a minimum of 20% to the stimulated frequencies. The influence for the first critical bending speed to the stiffness of generator and turbine guide bearing has to be shown in a figure (speed versus flexibility). In this figure, the nominal point as well as the zone of tolerances for the Bhasmey generating unit has to be indicated. The Contractor shall carry out the thorough check of all relevant Eigen frequencies. The compliance to all requirements shall be demonstrated in a technical report. This has to be submitted for approbation of the Engineer before manufacture.
1.6.3.4
Shaft Stability
The Contractor shall carry out a detailed mathematical analysis of the rotating parts of the turbine and generator as a whole and of the bearings and their support system to ensure stability, taking into account amplitudes and frequencies or transient axial and lateral thrusts and torsional vibration together with steady-state loads emanating from the generator, and the turbine. These calculations shall be submitted in accordance with Clause 1.7 of this Section 1.
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1.7 1.7.1
DESIG DOCUME TATIO General

Reference is made to Clause 2.5, General Technical Specifications.
1.7.2
Data For The Employers Design Information To The Engineer

In addition to the requirements in General Technical Specifications, Clause 2.5, the following information shall be provided in accordance with the dates and deadlines indicated therein. Basically, the documents submitted by the Contractor for the Engineers review are required to be delivered punctually so as to avoid delays in manufacture, assembly and commissioning. The period of time available for review is in accordance with Clause 2.5.4, General Technical Specifications, and is required to be adhered to. The necessary details for the planning of the entire plant such as foundation plans, weights of the components to be concreted, plan and form of cavities or recesses, as well as functional descriptions, electrical user, signal and alarm lists, etc., are also to be submitted for review accordingly and punctually. Selection of the documents to be submitted is not conclusive and can be extended at any time by the Engineer, as required. The Contractor is liable for the ensuing costs. The review does not relieve the Contractor of any of his obligations under the Contract.
1.7.2.1
Drawings
Layout drawings of the turbine and auxiliary plant. Detailed manufacturing drawings of runner, turbine shaft, main shaft seal, guide bearing, spiral casing, head cover, bottom ring, discharge ring, draft tube liner, wicket gate including guide vane operating mechanism, governor system, oil and water piping arrangement, turbine auxiliary components, tools and the whole instrumentation. Detailed transport drawings indicating all items of the supply to be transported with designation, total amount of items, total amount of items per box, dimensions and net and gross weight. Detailed erection sequence drawings, indicating progressive steps of erection work on site.
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1.7.2.2
Design Calculations
Stress calculation of the turbine including turbine shaft and runner, head cover and spiral casing. Design calculation of the turbine guide bearing under normal and any conceivable abnormal or transient operating conditions. Calculation of all foundation loadings of turbine under normal and any conceivable abnormal or transient operating condition including maximum overspeed and maximum pressure. Among the design calculations required to be made by the turbine manufacturer, the following ones are explicitly asked for to be carried out in collaboration with other manufacturers: Calculation of the critical speed of the generator / turbine combined shaft system in accordance with the requirements mentioned in Clause 1.6.3.3 of this Section 1. Water hammer computation of all transient cases occurring under the various hydraulic and electrical conditions of operation, including overspeed, permissible minimum closing and opening times of turbine wicket gates and main inlet valve, fly-wheel effect and conditions of stability of regulation. Mechanical / electrical calculation of stability of operation, damping and avoidance of any resonance between exciting torque variations originated by hydraulic forces from penstock, turbine draft tube and the unit own frequency of rotation in consideration of masses and flywheel effect provided, including final optimisation of the flywheel-effect to be installed.
1.7.2.3
Operation and Maintenance Manuals:

(Reference is made to Clause 2.5.2.8 of the General Technical Specifications) The Operation and Maintenance Manuals shall describe the erection procedure and the use of all erection equipment and measurement devices. The procedure for assembling, adjusting, operating and dismantling of each component shall be described, including the recommended frequency of inspections and lubrication. Said document shall include a separable and complete section describing the normal and emergency operation procedure of the plant supplied and shall include easily readable diagrammatic drawings of the plant to facilitate understanding of the descriptive information.
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The Contractors documents shall include the following data, some of which may be amended according to experience gathered during commissioning. Normal operating range and setting of alarms and trip contacts of all sensing elements of turbine supervision. The detailed description shall include nominal figures and permissible tolerance for measurement to be made as for instance shaft run out tolerance, bearing clearance, etc. Diagrams, including a hill diagram, relating heads, tail water elevations, flow and output, servomotor stroke and operating limits. Turbine governor and servomotor characteristics. Adjustment of overspeed protection devices. Type and grade of fluid for servo systems, and filter specifications. Maximum steady-state runaway speed and maximum momentary speed and pressure variations at various operating heads. Minimum steady speed for initial run (depending on design of turbine guide or other bearings). Description of lubrication system, lubrication volumes, grade and intervals. Intermediate oil levels and pressure at which pumps and compressors should be started or alarms given, data for automatic signalisation and emergency devices. Maximum and minimum temperatures in bearings, seals and in the pressure oil or fluid circuits (alarm and trip values). Maximum and minimum pressures and flows or levels in oil or fluid pressure systems and bearings, according to control system (alarm and trip values) Maximum and minimum pressures and flows in coolers (alarm and trip values) Data for electric motors, pumps, and other accessories. Security instructions for testing and operating. Other data of importance for the safety of the plant, including all deemed necessary for instruction of personnel.
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The instructions shall include a complete list of all reviewed drawings prepared for this Contract, the agreed spare part list, and a complete parts list for each component or item of plant. The part list shall be detailed and for the exact type of plant supplied and shall not contain general comparable type but varying in detail.
1.7.2.4
Material Tests
To be performed by the Contractor in accordance with Clause 1.9 of this Section 1.
1.7.2.5
Workshop Assembly and Workshop Tests

To be carried out by the Contractor under the supervision of the Employer/Engineer in accordance with Clause 1.9 of this Section 1.
1.7.2.6
Seaworthy Packing, Dispatch and Transport

To be carried out by the Contractor, in accordance with Clause 2.4 of the General Technical Specifications, and transport to and at site in accordance with Clause 6.3 of the General Technical Specifications.
1.7.2.7
Insurances
To be effected by the Contractor according to the General Conditions of Contract.
1.7.2.8
Erection, Commissioning and Trial Operation

To be carried out by the Contractors qualified staff in accordance with the General Conditions of Contract, Clause 6 of the General Technical Specifications, and Clause 1.20 of this Section 1.
1.7.2.9
Training and Instructions of Employers Personnel

At the Contractors works and during erection on site in accordance with the General Conditions of Contract and Clause 7 of the General Technical Specifications.
1.7.2.10
Model Tests
In accordance with Clause 1.19 of this Section 1 and under particular considerations of the specific guarantees as per Clause 1.5 of this Section 1.
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1.7.2.11
Tests on Completion
In accordance with the requirements Clause 1.20.4 of this Section 1 and under particular consideration of the specific guarantees as per Clause 1.5 of this Section.
1.7.2.12
Photographs
As per Clause 2.16 of the General Technical Specifications.
1.7.3
Requirements For Contractors Drawings, Technical Calculations And Data

As per Clause 2.5 of the General Technical Specifications.
1.7.4
Contractors Review Of Employers Design

The Contractor will receive from Employer / Engineer drawings for checking with regard to compatibility with his plant design in particular as related to box-outs, foundation provisions and built in parts. The Contractor is obliged to notify any modifications or problem areas. If he fails to notify such he is responsible for modifying his plant to suit the as-built civil works or for any remedial measures required.
1.7.5
Technical Reports By Contractor

The technical reports to be submitted are defined in Clause 2.17, General Technical Specification. No standards are required for the preparation of the reports. Progress reports are to be made out in accordance with Clause 2.17.1, General Technical Specifications. The reports are to be supplemented by photographs. These photos are to be integrated at a later date into the Operation and Maintenance Manuals as per Clause 1.7.2.12 of this Section 1.
1.8 1.8.1
MATERIALS A D CO STRUCTIO Scope

Wherever practicable, the design and shaping of important components shall be such as to facilitate full non-destructive examination.
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The Contractor shall provide proper preparations of all faces for field welded and bolted connections. All connecting parts are to be match marked, shop assembled, and doweled. Welding seams shall be ground flush on all surfaces in contact with water. The Contractor shall furnish the necessary bracing and/or tightening devices to maintain true shape of pats during shipment, unloading, assembly and erection. Partition of components shall be selected in consideration of transport limitations, easy erection and maintenance, and are subject to the Engineers review. Any water and air traps in plant shall be avoided. All bolts and nuts which are not accessible or are liable to loosen in operation shall be secured in a proper manner (i.e. Loctite), excluding spot welding. Shut-off valves which would endanger the plant, if operated inadvertently, shall be supplied with secure locking means. All valves shall be installed so that in event of plug or stem failure, valve will not slam close. Cast iron valves will not be accepted. All pumps and compressors supplied shall be of recognised make and of adequate type and size to meet their functions. They are to be supplied with all accessories and with electric motors suitable to allow continuous and safe operation under all conditions of the respective system. Each pump and compressor shall be supplied with and mounted on a common base plate for pump and motor or compressor and motor respectively. All elements subject to appreciable wear by water erosion shall be provided with easily removable and accessible wearing parts, permitting rapid and economical repair. Cubicles, boards and other enclosed compartments forming part of the plant supplied shall be adequately ventilated and equipped to minimise condensation. If necessary, additional heaters shall be supplied for this purpose. All ventilation openings shall be provided with louvers of corrosion-resistant metal. All components of the Francis turbines shall be subject to the tolerances prescribed in the ISO standards specified under Clause 2.2 of the General Technical Specifications.
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1.8.1.1
Surface Finish of Water Passages

Dimensions, dimensional tolerances, profile deviations such as waivers and surface roughness of all turbine parts, which will be in contact with water shall be similar to the model turbine as indicated by IEC 60193.
1.8.2
Materials Selection And Standards

All materials shall comply with an approved standard. Reference is made to Clause 2.2 of the General Technical Specifications. All materials selected shall be most suitable for the intended use and shall be of a grade or class having guaranteed composition and properties according to the applicable standard. Generally, the Contractor is entirely free to use a better quality or more stringent standard of acceptability for certain items, if he deems this necessary. Lower grades and less stringent prescriptions are not acceptable.
1.8.2.1
Basic Requirements for Steel Plates for Fabricated Steel Structures:

For fabricated structures exposed to water pressure, only fully normalised materials or of quenched and tempered quality, of high resilience with low temperature ductility, and age-resistant shall be used. The material shall be of a grade or class having guaranteed composition, properties and weld ability and shall be ultrasonic-tested at the steel mill according to Class 3 of the Steel/Iron Terms of Delivery 072 77 (German heading: Stahl/Eisen Lieferbedingungen 072 77 ) of the Verein Deutscher Eisenhttenleute Table 2, Class 3 and Table3, Class 3 or equivalent. The finished plates shall be free from cracks, injurious surface flaws, laminations and any other defects. They shall have a workmanlike finish and shall not have been hammer-dressed. Remedying of plate defects by welding is not acceptable. Plates shall not be under their normal thickness at any point. Plate material is subject to acceptance tests in the steel mill according to DIN 50 049 3.1 B or equivalent. For mixed constructions (cast steel and plate steel), the Contractor shall examine the conditions of weldability and shall be responsible for transmitting to the steel foundry all instructions required for the selection of a compatible grade of cast steel.
1.8.2.2
Basic Requirements for Steel Castings

Steel castings of importance, in particular for constructions exposed to water pressure, shall be of a grade or class of an approved standard having guaranteed composition and properties, including low temperature ductility. The cast, cleaned, heat-treated and ready pre-machined casting shall be material-tested as specified in Clause 1.9 of this Section 1. The test results shall comply with specified composition and properties. Steel castings shall be completely free of cracks, shrink holes, hot tears, and shall not contain sand
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spots and inclusions, segregation, gas and blow holes, unfused chaplets and internal chills to a degree affecting their strength and durability. Repair welding of any kind may not be made without the consent of both the Contractor and the foundry; in case of doubt, the Engineers review shall also be obtained. Appropriate heat treatment shall be repeated after such major repairs. An accumulation of minor defects shall be considered as a major defect. Regarding standard of acceptability of steel castings, reference is made to ASTM-E-71 and E-186 standards. The castings shall comply with Class 2. Indications of imperfections derived from other methods of non-destructive testing shall also be considered. Such imperfections exceeding the nature of a local and tolerable imperfection may constitute a reason for rejection depending on careful investigation in conjunction with and on the basis of the respective design. Such indications are the following: All indications of linear or square dimension and local concentrations of several imperfections regardless of their individual size. All imperfections near surfaces, especially those to be machined or near highly stressed areas. Ultrasonic indications larger than 6 mm diameter substitute fault size (6 mm diameter AVG diagram) and indications of more than 50 % back-wall-echo reduction. A complete descriptive report of major faults, supplement by sketches, photos and radiographs, surface prints and metallurgical test reports as the case may warrant, and the proposed repair procedure shall be submitted to the Engineer for review. The casting shall be clearly stamped with the heat number in such location as to be readily observed when the casting is assembled in a completed unit. The extent of basic material tests required for steel casting is listed under Clause 1.9 of this Section I. For special requirements for the stainless steel casting for the turbine runner, refer to Clause 1.9 of this Section I.
1.8.2.3
Basic Requirements for Cast Iron

Cast iron will only be accepted for secondary parts, such as counterweights, supports, small bearings, etc.
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1.8.2.4
Basic Requirements for Forgings

Forgings of importance (e.g. shafts) shall be made of vacuum- degassed steel and shall be forged thoroughly and throughout. Forging to shape, heat treatment (quenched and tempered, annealed or normalised as required) and rough machining shall be completed previous to material testing; results thereof must comply with specified compositions and properties. Forgings must be flawless, completely free form cracks and flakes, and shall not contain any other imperfection such as porosity, non-metallic inclusions, segregations, hard spots and residual tensions to a degree affecting their strength and durability. In accordance to the standards of acceptability of forgings, cracks, flakes and excessive hydrogen content as well as noncompliance with specified compositions and properties constitute reasons for rejection. Further, all imperfections as detected by non-destructive testing (dye check, radiographic or ultrasonic inspection, etc.) exceeding the nature of al local and tolerable imperfection may constitute a reason for rejection depending upon careful investigation in conjunction with and on the basis of the respective design. Such indications are the following: All indications of linear or square dimension and local concentrations of several imperfections regardless of their individual size. All imperfections near surfaces, especially axial bores. Ultrasonic indications larger than 5 mm diameter substitute fault size (5 mm diameter AVG diagram) and indications of more than 10 % back-wall-echo. Further, all indications of imperfection larger than 2.5 mm diameter substitute fault size (2.5 mm diameter AVG diagram) of ultrasonic inspection or similar indications of other methods are to be recorded for judgement. The largest fillets compatible with the design shall be incorporated wherever a change in sections occurs. All finished surfaces of forgings shall be smooth and free from tool marks. The forging shall be clearly stamped with the heat number in such location as to be readily observed when the forging is assembled in a completed unit.
1.8.2.5
Basic Requirements for Welding of Structures under Water Pressure

(For requirements on general steel structures refer to Clause 4.3 of the General Technical Specifications).
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Minimum requirements for important weldings (i.e. rotor / spiral casing / head cover): International Institute of Welding collection of Reference Radiographs, compliance with classes black or blue, not inferior or equivalent. All welding shall be performed by processes and procedures producing welds whose properties match those of the steel being joined as closely as practicable. Butt welds shall be performed by processes and procedures producing welds whose properties match those of the steel being joined as closely as practicable. All butt welds of the spiral case shall be ground flush. Flush shall mean not below and not more than 1 mm above the plane joining adjacent plate surfaces. Fillet welds shall be performed with low carbon electrodes or wires and by a procedure designed to provide maximum ductility and freedom from cracking in the weld and heat-affected zones. The surface finish of the fillet welds shall be reasonably smooth and free from irregularities, grooves or depressions; weld beads shall be narrow, shallow, regular and symmetrical in shape. Weld metal of the spiral casing and the draft tube shall be ground off up to 1 mm over the inside surfaces. Butt welds and tee joint welds shall be full penetration welds developing the strength of the plates being joined and designed to provide maximum ductility and freedom from cracking in the weld and heat affected zones. Butt welds an tee joints welds shall further be welded from both sides, expect when otherwise shown on the reviewed drawings. Weld metal originally deposited at the bottom of the weld groove shall be chipped or gouged to sound material prior to depositing the first bead from the opposite side of the joint. The sequence of welding and tack welding shall be clearly indicated on the Contractors drawings prior to submitting them to the Engineer for review. Tack welds shall be chipped or gouged before welding. Preheating shall be performed prior to and during tack welding and shall be maintained as a minimum temperature during welding. Run-on and run-off plates shall be provided for all butt welds, expect when reviewed otherwise by the Engineer. Striking of the arc on the penstock, scroll case or pressurized piping will not be permitted in any event.
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All welding materials including electrodes used for the work shall be of the highest quality and, with the proper procedure, shall be capable of producing weldings to the requirements of the Specifications. Electrodes for manual welding shall be of the low hydrogen type. All welding shall be performed by skilled welders possessing satisfactory experience and qualified in the particular welding procedure, welding position and steel being used. Welders will be considered qualified for a particular welding procedure, welding position and steel if they satisfactorily pass the qualification tests.
1.8.3
Quality Assurance Procedures

Reference is made to Clause 1.8.2 of this Section 1.
1.8.4
Shop Methods And Personnel

Reference is made to Clause 1.8.2 of this Section 1.
1.8.5
Corrosion Protection And Painting

For executing corrosion protection of plant included in this Section 1, the general requirements as set forth in Clause 4.1 of the General Technical Specifications shall apply. All priming and painting material shall fulfil the requirements imposed by the site conditions, as well as the stresses to which the respective material is subjected during operation. At the request of the engineer, painting samples for the different coats and colours shall be provided. Plant ready fabricated and machined in the Contractors workshop shall be completely shop painted. For components with considerable field welding (stay ring, spiral case, draft tube), the contractor shall supply details regarding the extent to which sandblasting and painting will be carried out in his workshop and at site after erection. A properly equipped paint shop shall be set up at the site using specialist personnel, experienced and skilled in the preparation and application of protective coating under the conditions prevailing at site.
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The colours of the external surfaces, water and oil pipes as well as the auxiliary components exposed to atmosphere (pumps, compressors, air vessels, hoists, drives, etc.) will be specified by the Employer in a later stage of the project.
1.9 1.9.1
SHOP I SPECTIO A D TESTI G General Requirements And Reports

The extent of material tests, the relevant test procedures and limits of acceptance are listed hereafter. Based on these minimal requirements, the Contractor shall prepare an Inspection and Test Plan (ITP) enumerating all components of the supply to be tested and the corresponding test to be carried out. The Employer, however, reserves the right to request further tests, if he deems such tests are necessary. The ITP shall be clarified and reviewed before manufacture commences. The Contractor has to provide the required type and number of test certificates. All turbine parts, subassemblies, component equipment and material shall be tested with due regard to the stipulations of Clause 1.8 and as described below. The individual tests are marked with letters having the following significance:
A B C D E F G
Raw material tests verified by steel work / Contractors certificates A witnessed by the Contractors representative Manufacturing tests verified by Contractors certificates A respectively C witnessed by the Employer and / or Engineer Workshop acceptance tests verified by the Contractors certificates E witnessed by Employer and / or Engineer Field tests witnessed by the Employer and / or Engineer
1.9.2
1.9.2.1
Material Tests And Certificates Raw Material Tests

The Contractor shall define and list in the ITP and shall perform all required material tests and deliver the required type and number of test certificates. The raw material,
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from which the test specimens shall be obtained, must be provided by the Contractor and be marked for identification and use under this Contract in a permanent manner. For tests marked (B) the piece must be left in an integral state, and the specimens shall be cut off only in the presence of the Contractors representative who shall mark them with a control stamp. When machining the test specimens, care shall be taken not do damage the control marks. A chemical analysis shall be performed for each material for important highly-stressed parts of the turbine (A) i.e. rotor / spiral casing / head cover. On each piece being tested at least one tensile test and three notched bar impact tests shall be performed. For highly stressed or very important parts i.e. rotor / spiral casing and head cover, at least two tensile tests and six notched bar impact tests shall be performed on opposite sides of the piece to be tested. The yield point, tensile strength, elongation and traverse contraction shall be obtained from the tensile test. For the notched bar impact test, the impact value shall be obtained at + 20 C ambient temperature on ISO-V test specimens if it is not otherwise specified. Minimum requirements for ultrasonic testing of important forged and cast steel pieces: Tolerable may be ultrasonic indications smaller than 5 mm diameter substitute fault sizes (5 mm diameter AVG diagram) which have all to be recorded. However, those bigger than 5 mm diameter substitute fault size and indications of more than 10 % back wall echo reduction (30% for cast steel) may be a reason for rejection.
1.9.2.2
Welding
(Welding on fabricated structures exposed to water pressure or mixed constructions steel plates/cast steel under water pressure.) Welders Tests: The following describes the tests prior to manufacture (refers to both shop welding and field welding): Prior to commencing production welding, all welders shall have, to the satisfaction of the Engineer, completed test plates in the welding processes, welding positions, of joint types and steels corresponding to the production welding type they will be performing.
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The test plates shall be cut out of the thickest normalized steel plate to be used on the pipe shell constructions. Welders who will be engaged in welding quenched and tempered steel shall be qualified on test weldings of this steel quality. All welders engaged with the welding of the stainless steel turbine parts respectively pipe work shall be qualified on test weldings of this steel quality. All welders engaged to perform welding for the Bhasmey HEP project shall pass the welders qualification tests according to AWS 460 (American Welding Society). The welder qualification certificates shall be forwarded for review to the Engineer together with the welding drawings. The Contractor shall submit a description of the proposed weld procedures for review by the Engineer one month prior to commencing the welding tests and the production welding. The test plates required for the welders qualification may also serve for the qualification of the proposed welding procedure.
1.9.2.3
Welding tests during manufacture

The following describes the tests during manufacture (refers both to shop welding and field welding). During production, tests on welded joints will be required. They may be on run-on or run-off plates or on test plates which meet as closely as practicable the production weld being checked and shall be performed in accordance with the welding procedure of the production weld. On each test plate shall be performed (for important parts i.e. runner if not cast steel, spiral casing and head cover: (C, D)): Radiographic check of the welds. 2 bend tests (one transverse face and one transverse root test). 2 tensile tests with parallel bars. 3 Charpy V notch tests in the heat transition zone at -20C. 3 Charpy V-notch tests in the cover layer at -20C. The frequency and location of the required testing will be determined by the Engineer. The average frequency will be one test plate every 10 m of welded joints for longitudinal joints such as on pressure pipeline and spiral casing.
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Required minimum test values: Tensile strength Conforming to guaranteed values of the steel quality.
Charpy V-notch impact test 50 Joules Bend test

1.9.2.4
Conforming to guaranteed values of the steel quality
Ultrasonic Tests
General Longitudinal and circumferential butt joints shall be ultrasonically examined. The extent of ultrasonic examination shall be agreed between the Contractor and the Engineer, but for welding joints subject to head pressure, 100% ultrasonic tests shall be carried out. Methods The Contractor shall be free to employ any recognized ultrasonic method, such as DGS (Distance Grain Size Methods) provided that discontinuities can be accurately detected and located. The Contractor is required to use reviewed procedures for ultrasonic examination. When the Engineer questions the adequacy of the Contractors method, the Contractor shall be required to demonstrate to the satisfaction of the Engineer that the method is capable of detecting and locating discontinuities in butt joints. Independent of the result of the radiographic examination, all welds shall be repaired if the echo joints of ultrasonic testing are determined as cracks, lack of fusion or root failures, or if the echo heights reach or exceed the reference level. Calibration If the DGS method is used calibration shall be by a flat bottom hole reflector. Test Preparation of Seam For satisfactory execution of the test, the work piece shall be cleaned by means of rotating wire brushes on the left and on the right side of the seam along a width of at least 200mm from loose scale, rust and other contaminations, weld spatters shall be removed by grinding or with chisel.
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Evaluation and Judgement All indications which are below 20% of the reference line will be ignored and shall not be recorded. Indications which are at the 20% line or higher are examined so far that the shape, kind, and position shall be determined and judged exactly. Discontinuities are unacceptable if the amplitude exceeds the reference level, and discontinuities having lengths which exceed: 6 mm for t up to 19 mm, inclusive 1/3 t for t from 19 mm to 55 mm, inclusive 19 mm for t over 55 mm, where t is the thickness of the weld being examined. If the weld joining two members has different thickness at the weld, t shall be the thinner of these two members. Where discontinuities are interpreted to be cracks or incomplete penetration, they are unacceptable regardless of discontinuity or signal amplitude. Any group of indications in line that have an aggregate length greater than t in a length of 12 t except where the distance between the successive indication exceeds 6L, where L is the longest indication in the group. When the DGS method is used the following acceptance criteria shall apply: Longitudinal Indications
Nominal wall thickness Reportable reference Max. permissible reference (t) in mm defect echo size defect echo size 10 20 20 60 60 1.5 2.0 3.0 3.0 5.0 8.0
Transversal Indications Reference defects of equal or no greater than 1.5 shall be acceptable.
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1.9.2.5
Radiographic Examination
In addition to the ultrasonic testing, radiographic examination on 10% of the welding joints subject to head pressure shall be carried out (on shop welding as on field welding). Particularly, T-joints (joints between longitudinal and circumferential welds) shall be subject to radiography. Also all repaired portions of welding joints shall be re-examined with radiography conform to ASTM E 94. Preferably X-rays should be used; Gamma rays with Iridium 192 are allowed in special case for larger thickness. Interpretation of radiographs: Radiographs will be classified in accordance with the reference radiographs of the International Institute of Welding. Welds of the classes specified as black or blue colours shall be acceptable. Welds of the class specified as green, brown or red colours shall be rejected. The Engineer reserves the right to demand additional radiography at the expense of the Contractor, if in his opinion serious doubts exist regarding the quality of the execution of the welds. The films shall be submitted to the Engineer for review and will become property of the Employer.
1.9.2.6
Tests of other parts

The inspection and test plan to be issued by the Contractor shall reflect all necessary other examinations and tests on all components which the Contractor intends to apply. However, the Engineer reserves the right to demand and apply other examinations and tests if he deems such to be necessary.
1.9.2.7
Shaft forgings
The following tests shall be carried out (A, B, D): Chemical analysis. On test specimens each taken from both ends of the shaft: each 1 tensile test (axial and tangential) 3 impact tests (charpy V-notch at 0 degree Celsius).
Ultrasonic inspection.
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Radiographic inspection (in case of doubt). Magnetic particles inspection (preferably) or liquid penetrant inspection of the ready machined work piece. With respect to the standards of acceptability, judgement shall be made on basis of acknowledged good practice taking into consideration all regulations of standards, or the Specification of the Contractor.
1.9.2.8
Francis Runner
Inspection at the steel foundry (for cast runner): Immediately after casting and heat treatment of the turbine runner or turbine runner components a careful examination at the steel foundry shall be carried out comprising the following material tests (A, B, D): Magnaflux examination of the whole casting. Ultrasonic examination where practicable. Radiographic examination of the highly stressed parts. Mechanical material tests. The mechanical properties of the runner material shall be verified by mean of test samples taken from test material cast to the runner. Such test material shall be sufficient for at least three complete sets of test specimens to allow for the possibility of making good and subsequent reheat treatment, or reheat treatment to obtain the required mechanical properties. All test specimens shall undergo the same heat treatment as the component they represent. The mechanical material tests shall consist of (A, B, D): Chemical analysis. 2 tensile tests. 3 charpy V-notch impact tests at 0 degree Celsius. 3 charpy V-notch impact tests at 20 degrees Celsius (for information). Required test values conforming to guaranteed values of the specified steel quality. After preparation for repair, the Engineer has to be invited to inspect the runner. No repair to the runner casting shall be made unless reviewed by the Engineer.
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1.9.2.9
Inspections of the ready machined runner (at the Contractors workshop):

The ready machined Francis runner shall be subject to the following final inspections: Roughness tests of all ground surfaces of the runner blades. The roughness shall be as recommended in IEC 60139 within 250 mm from the inlet and outlet edges (C, D). Waviness checks of the runner blades as recommended in IEC 60193 (C, D). Inspection for defects on the surface, to be detected by the dye penetrant method. As result of this inspection the following limits of acceptability shall apply: Cracks: No superficial crack whatsoever will be tolerated. Porosities: On both sides of all blades. No circular indications exceeding or equal to dia. 4mm shall be indicated. No linear indications will be accepted. No linear indications with circular spots will be accepted.
Unfused chaplets, sand spots, and inclusions will not be tolerated on the ground surfaces of the blades. Note: The Contractor shall indicate the acceptance criteria according to the specification for inspection of steel casting for hydraulic machines CCH 70-3, by filling in the corresponding quality sheet, attached to the Technical Data Sheets. Inspection for invisible defects, to be detected by non-destructive test methods, such as ultrasonic or radiographic examination, whichever is practicable. Cracks: No cracks (or defects having the aspect of a crack) will be tolerated. Gas and blow holes: For the whole of the plates, the acceptable limit is represented by plate A3 of the ASTM Radiographic Standards for Steel Castings. Internal shrinkage: For the whole of the plates the acceptable limit is represented by plate C3 of the ASTM Radiographic Standards for Steel Castings. Cast Steel (Other than Francis Runners) Steel castings of importance, in particular for constructions under water pressure, shall be carefully examined immediately after casting, and the following material test shall be carried out at the steel foundry: Magnaflux examination of the whole casting (guide vanes: A, B, D). Ultrasonic examination where practicable (guide vanes: A, B, D).
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Mechanical material tests (guide vanes: A, B, D). The mechanical properties of the casting shall be verified by means of test samples taken from test material cast to the component. Such test material shall be sufficient for at least three complete sets of test specimens to allow for the possibility of making good and subsequent reheat treatment or reheat treatment to obtain the required mechanical properties. All test specimens shall undergo the same heat treatment as the component they represent. The mechanical material tests shall consist of: Chemical analysis (guide vanes: A, B, D). 1 tensile test (guide vanes: A, B, D). 2 x 3 charpy V-notch impact test at 0 degree Celsius (guide vanes: A, B, D). After machining of the cast steel components, a final inspection shall be carried out at the Contractors workshop, comprising: Ultrasonic examination of the whole casting (guide vanes: C, D). Dye penetrant examination of all machined surfaces (guide vanes: C, D). With respect to the standards of acceptability, judgement shall be made on basis of acknowledged good practice taking into consideration all regulations of standards, or the Specification of the Contractor, if approved. Roughness test and waviness checks for guide vanes shall be similar to those for the runner described in Clause 1.8.1.1.
1.9.3
Dimensional Checks
Critical dimensions shall be checked by the Contractor prior to shipment of the components to the job site. The test shall be indicated in the ITP.
1.9.4
Shop Assembly And Tests

The turbines and governors are intended to be assembled in the Contractors workshop. Special attention shall be given to a good supervision and checking of all parts with regard to dimension, fits of fitting parts, surfaces, corrosion protection, etc. Respective reports (A), (B), (C), and (E) shall regularly be submitted to the Employer / Engineer. They may be verified by random tests (D), (F) during occasional visits of the Employer/ Engineer.
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The following tests shall be performed: Pressure test of all oil coolers and air and oil pressure receiver, and strainers (B) and (E). Roughness of guide bearing journals not to exceed N6 (0.8m), (E, F). Run out measurement of turbine shaft if possible combined with the generator shaft according to NEMA MG5.1 3.04A (E), (F). All parts of the supply shall generally be assembled at the Contractors works to the extent necessary for the purpose of inspections, testing and otherwise ensuring that they will function satisfactorily. Exceptions to this rule may be permitted, if agreed by the Engineer. All parts shall be correctly dowelled and match marked to facilitate assembly at site. At least the following parts of the turbines shall be assembled at the Contractors workshop and be presented to the Engineer for inspection: Assembly of turbine draft tube liner. The bars which are provided for welding at site shall be tack-welded in the workshop. Assembly of turbine spiral casing with stay ring and check of perfect alignment of the various parts. The parts which are provided for welding at site shall be tackwelded in the workshop. Complete assembly of internal parts of turbine, such as bottom ring, turbine cover, all guide vanes, operating mechanism with servomotor (if possible), turbine guide bearing, and main shaft seal. Notes: In accordance with the general construction schedule the erection of the draft tube assembly and spiral casing will take place well ahead of other parts of the turbine, and it may become difficult to pre-assemble the complete turbine in the workshop. For this reason, provisions shall be made that also the turbine cover will match perfectly with the stay ring on the occasion of erection at site, for fabrication of a special template for the drilling of the fixation holes of stay ring and turbine cover would become necessary. The following is required for the assembly of each turbine/governor: Static balancing of the runner and run out test according to the latest edition of the appropriate NEMA Standards. Complete assembly of governor cabinet, including pressure oil supply unit. Complete assembly of electronic governor panel.
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In the assembled condition, the following shop tests shall be performed by the Contractor, and witnessed by the Engineer (E, F): Dimensional test of all water passages, in order to verify similarity between model and prototype, according to IEC 60193 The guide vanes shall be operated through their full movement as may be required to demonstrate that the vanes and operating mechanism function properly. To demonstrate that the guide vane shear pins will break at the design breaking load, a break test shall be performed in the shop using adequate equipment to simulate the actual operating conditions. Pressure test of the pressure oil system of governor, including servomotor. The system shall be tested for one hour at double the normal operating pressure. Complete trial run and acceptance test of the electronic governor in conjunction with the pressure oil supply system and regulating mechanism in order to verify as far as practicable the performance indicated in this Specification. For these tests, the IEC 60308 International Code for Testing of Speed Governing Systems for Hydraulic Turbines shall be applied. Complete electrical functioning test for pressure oil supply units as far as practicable. Trial operation of all compressed air supply units.
1.10
TECH ICAL SPECIFICATIO S FOR FIXED / EMBEDDED COMPO E TS

All parts embedded in concrete shall be provided with necessary structural members for secure anchorage to concrete. The necessary major foundation materials and devices shall be completely furnished in time to adjust and hold turbine parts in position during the placing of concrete, including jacks, levelling screws, base plates, anchor loops, tie rods, and turnbuckles, etc. All major parts shall be provided with eye bolts, lugs, or lifting devices to facilitate handling with crane. All embedded parts shall be provided with grout and vent holes which shall be plugged after grouting. The grout pressure shall be specified by the Contractor and reviewed by the Engineer. The maximal concrete embedment rates have to be mutually agreed together with the Civil Contractor.
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1.10.1
Spiral Case
The spiral case and the main inlet valve shall be linked by a flanged connection to the dismantling pipe. The dismantling pipe is equipped with an expansion joint, which is connected to the spiral case inlet flange. The distance from the unit centre line to the welding joint with the penstock shall be approx. 12 m which will include spiral inlet edge, dismantling piece, main inlet valve, make-up piece and taper piece. The spiral case inlet axis will be parallel to the turbine transverse axis. Furthermore, the spiral case inlet shall have a nominal inside diameter of approx. 2160 mm. The spiral case shall be designed for a maximum working pressure (including pressure rise) stipulated in Clause 1.4 of this Section 1 without any support from the surrounding concrete. Any bending effects due to eccentricity of load shall be taken into account. The spiral case shall be of steel plates. The joining together of the adjacent sections of the spiral case and of the spiral case sections to the stay ring shall be carried out at site by welding. Spiral case, stay ring and upstream connection pipe shall be fabricated in a minimum number of sections practicable for shipment and handling, to suit the conditions for access, transportation and erection indicated under Clause 6.3, General Technical Specifications. The spiral case shall be provided with stiffeners and sufficient anchorage to ensure that no deformation will occur during welding and concreting. If necessary, the stay ring shall be provided for this purpose with two sets of rigid spider braces with adjustable arms for maintaining circularity. The spiral case shall further be provided with a sufficient number of levelling screws or jacks, lugs and tie rods for supporting and holding the case during concreting. After the spiral case has been assembled on permanent foundations at site, it shall be filled with water and subjected to an internal hydrostatic test pressure of 150% of the design pressure during at least one hour. The necessary test ring for closing the stay ring openings, as well as the pressure test cover for the spiral casing inlet and other blank flanges and taps necessary to close the various openings on the spiral case for pressure test, shall be provided by the Contractor once for all three turbines and be delivered to the site with the first turbine. The necessary pumps, valves, gauges, piping and water to carry out the hydrostatic pressure test shall also be provided by the Contractor.
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The design stresses during hydrostatic test pressure shall remain within the limits referred to under Clause 1.6.2 of this Section 1. The supplier has to supply all equipment, in order to maintain the pressure of 50% of the design pressure during concrete curing.
1.10.1.1
Connections and Auxiliaries

The spiral case shall be provided with one access opening not less than 600 mm diameter. The location where the manhole is welded in position shall be suitably strengthened in order to avoid stress peaks. The circular shaped manhole cover shall be hinged and shall be fixed to the flange with stainless steel bolts, nuts and washers. A bent water guiding shield shall be welded to the manhole cover. Suitable means shall be provided on the pipe and cover to open and close the heavy cover in an easy and safe manner. For each turbine a set of minimum 4 stainless steel tappings shall be provided for head measurement. These tappings shall be connected by pipe work to isolating valves or cocks at a convenient location. Embedded piping shall be of stainless steel, supplied with redundancy and equipped with a suitable vent valve. One or more suitable piezometer together with all piping and fittings for connection to the tappings shall be provided by the Contractor. Tappings will be used for monitoring turbine head together with the tapping at draft tube outlet. The spiral case shall be drained through the dismantling pipe. For each turbine a set of minimum 4 stainless steel tappings shall be provided for connection to the turbine flow meter and for index tests (Winter Kennedy Method). Design and location of the piezometer taps shall be in accordance with the model tests and the tappings for head measurement and have to be reviewed by the Engineer. One suitable portable differential pressure measuring device together with all piping and fittings for connection to the tappings shall be provided by the Contractor. All embedded pipes shall be equipped with an elastic layer (approx. 500 mm). Discharge measurement by ultrasonic shall be provided by the Contractor. The suitable location of this equipment has to be determined by the Contractor (if possible in the upstream connection pipe or otherwise in the penstock).
1.10.2
Stayring
Reference is made to Clause 1.10.1, spiral case, of this Section 1.
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The stay ring shall be designed for a maximum working pressure (including pressure rise) stipulated in Clause 1.4 of this Section 1 without any support from the surrounding concrete. In addition the stay ring shall be designed to accept all loads transmitted from the generator, including turbine hydraulic thrust through the generator support structure which is of the reinforced concrete type. The stay ring, as an integral part of the spiral case, shall be of welded plate construction. The stay ring shall be supplied fully machined and its sections prepared for bolting together at site. The stay ring shall be provided with uniformly spaced vanes, positioned to best meet efficiency requirements, machined flange connections to receive pit liner, head cover, and bottom ring, grout and vent holes in lower portion to facilitate concrete placement. Tap holes for pipe connections and furnish pipe lugs with exterior surface flush with stay ring. The design of the stay ring shall pay particular attention to avoidance of stay vane vibration resulting from vortex excitation. To this end the natural frequency of the stay vanes shall be at least 50 % above the frequencies of vortex shedding ascertained from the model tests or field tests on turbines of similar specific speed. The water passages of the stay ring shall be smooth and free of irregularities. The internal surface finish of the stay ring, including any welds shall be 6.3 microns (N9) or finer. A sufficient number of pads on the stay ring for jacks and fasteners for tie rods, and a corresponding number of jacks and tie rods shall be provided for levelling the stay ring during erection and for holding in proper position during concreting.
1.10.2.1

Two drain pipes shall be provided through the stay vanes, for connection to the embedded drain piping, in order to drain the stay ring collection area (outside the head cover) to the Draft Tube Floor drain system in case of failure of the two head cover drainage pumps. All embedded pipes shall be equipped with an elastic layer (approx. 500 mm).
1.10.3
Bottom Ring
The bottom ring shall be made of welded steel equal to those provided for the head cover, may be delivered in sections and shall be bolted to the stay ring.
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The bottom ring shall contain the replaceable maintenance free lower wicket gate bearing bushes. The runner shall be removed from runner chamber through removable draft tube cone (dismantling from the bottom). The bottom ring shall be fitted with stationary seal rings for the runner and facing plates for the guide vanes. The bottom ring shall be integral with the discharge ring respectively foundation ring. A shoulder shall be provided on the discharge ring or draft tube liner for supporting the turbine runner and shaft for erection purposes. In accordance with the specification of the draft tube liner, a stainless steel liner shall be fitted to the bottom ring (or draft tube cone) below the runner outlet. With respect to damage caused by cavitation erosion, the provisions of Clause 1.5.8 of this Section shall apply to the stainless steel surfaces of the guide vanes, head covers and bottom rings. Cooling water connections for labyrinth seals needs to be included in the bottom ring. Holes for measuring the labyrinth gap shall be provided.
1.10.4
Draft Tube
The draft tube shall be of the elbow type constructed in concrete with steel lining extending to a section where the average velocity at maximum discharge has reduced to less than 3.5 m per second. In any case, the draft tube liner shall include the draft tube elbow, and thus allows a suitable connection of the draft tube dewatering pipes referred to in drawing no. 71.1164.08.921 The Contractor shall be responsible for the design of the complete draft tube, both the concrete and steel lined sections. The guarantees of performance an efficiency of the turbine shall include any effects of the entire draft tube. When designing the hydraulic form of the draft tube, consideration shall be given to minimising draft tube pressure fluctuations and the impact of draft tube pressure fluctuation on the civil structure at part load operation. The draft tube liner shall be fabricated in a minimum number of sections practicable for shipment and handling, to suit the conditions for access, transportation and erection indicated under Clause 6.3 of the General Technical Specifications. The complete painting of the draft tube shall be carried out at site.
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The draft tube liner shall be of fabricated steel plates. The Contractor will be responsible for selecting the most suitable plate thickness, to be indicated in the data schedules. The upper part shall be from stainless steel or shall have a stainless steel overlay of a minimum thickness of 5 mm over a length of at least 600mm. The interior of the draft tube liner shall be smooth and the exterior ribbed and provided with anchors for securing the liner to the concrete against the most severe operating condition of draft tube vortices and cavitation. The ribbing and anchorage shall be designed for a full hydrostatic pressure on the outside due to a maximum tail water level stipulated in Clause 1.4.2, hydraulic conditions, of this Section 1. A watertight and airtight manhole having a clear opening of 600(W) x 900 (H) mm, with hinged door, bolts with water level test cock shall be provided in the draft tube liner (removable cone section) and shall be located in the draft tube access for runner removal from bottom. The draft tube shall be so designed as to support a scaffold for inspection of runner. One scaffold shall be provided for use in the three turbines. A sufficient number of levelling screws or jacks, anchors, and anchor rods with turnbuckles shall be provided for centering, levelling and securely holding the liner in correct position, during assembly and placing of concrete. The draft tube liner will directly serve as shuttering during concreting and therefore has to be provided with sufficient internal stiffeners to be included in the supply; stiffeners to be removed after concreting and grouting.
1.10.4.1

Reference is made to the flow diagram of the dewatering system: At the draft tube invert a connection with a nominal diameter of 200 mm shall be provided for emptying the draft tube. The appropriate drain valve and the hot dip galvanized drain pipe, which shall extend down to the drainage channel and the main dewatering sump of the power station, shall also form part of the Contractors supply. A tap for a draft tube pressure and vacuum gauge connection shall be provided. The gauge shall be provided with associating valve and a damping device. Pressure balance pipes between head cover and draft tube shall be included. The Contractor shall furnish 4 stainless steel plates and anchorage for embedment in concrete with suitable stainless steel tapping for the measurement of turbine net head. The location of the tappings shall be geometrically similar to that used during the Contractors model test. These tappings shall be connected by pipe work to isolating valves or cocks at a convenient location. Embedded piping shall be of stainless steel and
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supplied with redundancy. One or more suitable piezometer together with all piping and fittings for connection to the tappings shall be provided by the Contractor. Tappings will be used for monitoring turbine head together with the tapping in the spiral casing. The Contractor shall provide a system of pipe work and tappings to enable the measurement and recording of any pressure fluctuations that may be present in the draft tube. Embedded pipe work shall be of stainless steel and supplied with redundancy. The location of the tappings shall be geometrically similar to that used during the Contractors model tests. All embedded pipes shall be equipped with an elastic layer (approx. 500 mm).
1.10.5
Turbine Pit Liner And Coverings

A welded steel liner extending the full height from the stay ring to the lower bracket of the guide bearing of the generator shall be supplied with each turbine. The turbine pit liner shall be of rigid construction with external ribs and anchors for embedment in the surrounding concrete, fabricated in sections for delivery with flanged joints to suit the conditions for access and transportation indicated under Clause 6.3 of the General Technical Specifications, and designed to support and accommodate the guide vane servomotors. With the exception of the site weld zones, the complete painting of the liner shall be carried out in the Contractors workshop. The liner shall have adequate openings for the necessary cooling and oil piping. The turbine pit liner shall have suitable supports for the placement of easily removable coverings arranged around the turbine pit. These coverings belonging to the Contractors supply shall preferably be of the grated type, allowing a perfect inspection of the turbine operating mechanism, main shaft sealing and guide bearing.
1.10.5.1

The Contractor shall furnish in addition to the pit liner, all walkways, stairways, floor plates, and handrails and lifting devices inside the pit liner for easy access to all turbine components. Suitable penetrations and openings shall be provided to permit passage of piping of the lubricating oil, governor oil, drainage water, seal water and compressed air. Openings shall be provided in the pit liner to permit entrance to the pit. All removable equipment shall be easily removable for dismantling the turbine from top except bottom ring and runner.
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The liner shall be provided with a seepage water collection system to channel seepage to the drainage sump system. Two portable chain hoists with a capacity of not less than 5 tons each and trolleys shall be provided in the turbine pit for maintenance of components in the pit and disassembly of the turbines. Moreover the Contractor shall provide 1 circular I-beam inside turbine pit carrying one electric hoist to be provided, for lifting heaviest single item within turbine pit. Suitable ventilation equipment shall be provided for the turbine pit in order to maintain an acceptable working environment for the maintenance staff.
1.11
TECH ICAL SPECIFICATIO S COMPO E TS Headcover
FOR
STATIO ARY/
REMOVABLE
1.11.1
Reference is made to Clause 1.10.3, bottom ring, of this Section 1. The head cover shall be of steel plates and sufficient rigid so that deflections under service conditions have no adverse effect on the performance of the turbine and designed in a number of sections practicable for handling, shipment, and erection at site. The head cover shall contain the upper wicket gate bearing bushes to support the wicket gate stem seals and the wicket gate operating mechanism. It shall be designed to serve as support for the turbine guide bearings, the shaft seal, maintenance seal and the head cover drain pumps. Access space shall be provided to areas which require adjustment and maintenance. The head covers shall be fitted with stationary seal rings for the runner and facing plates for the guide vanes. The under sides of the head cover shall be designed to minimise friction and eddy losses in the space between the runner and the head cover, and the space shall be adequately drained to prevent excess water pressure under the head cover or excessive thrust on the top of the runner. Therefore, a system shall be provided to keep the hydraulic thrust to a minimum. A provision acceptable in principle for this purpose would include pressure balance pipes connecting the head cover runner crown to the draft tube. With reference to Clause 1.10.2.1 of this Section 1, drains for head cover top surface preferably by gravity through stay ring shall be provided.
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With respect to damage caused by cavitation erosion, the provisions of Clause 1.5.8 of this Section shall apply to the stainless steel surfaces of the guide vanes, head covers and bottom rings. Holes for measurement of the labyrinth gap in dewatered conditions shall be supplied. Cooling water connections for labyrinth seals needs to be included in the head cover.
1.11.1.1
Facing Plates
The guide vane facing plates shall be of stainless steel and fitted with seals to seal against the upper and lower faces of the guide vanes in the closed position. These seals shall be replaceable without dismantling the covers or guide vanes. The contact faces shall preferably be of rubber. The Contractor shall guarantee the maximum leakage rate through the closed guide vanes under maximum static head with the runner dewatered.
1.11.1.2
Runner Labyrinth Seal

Stationary Wearing Rings At areas of small clearance between runner and stationary parts of the turbine (head cover/runner crown and bottom ring/runner band) easily removable and renewable stainless steel wearing rings shall be provided and fastened by screws secured by means other than tack welding (i.e. Loctite). Stainless steel selected for the wearing rings shall be of a different hardness from that of the runner in order to prevent galling or tearing of the metal in case of friction. Therefore the stationary seal rings shall be not less than 50 Brinell points lower in hardness than the rotating seal rings of the runner. The labyrinth seal rings shall permit a vertical movement of the turbine runner adequately enough for the flange coupling of the turbine shaft to be disengaged from the generator shaft. So-called clearance measuring holes shall be provided so that the concentric setting of the runner in the head cover and bottom/discharge ring can be checked by suitable tools without dismantling the head cover or bottom/discharge ring. Provision shall be made to enable renewal of the stationary labyrinth seal rings without dismantling of the generator rotor.
1.11.1.2.1
1.11.1.2.2
Rotating Wearing Rings The rotating wearing rings shall be fixed to the runner.
1.11.1.2.3
Labyrinth Seal Water Supply
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Suitable connections shall be provided for cooling water, required by the labyrinth seal rings during dewatered operation e.g. synchronous condenser operation. Therefore, suitable connections for water supply shall be provided by the Contractor on both head cover and discharge ring, enabling safe labyrinth flush.
1.11.1.3
Guide Bearing Support

The head cover shall be designed to serve as support for the turbine guide bearing. The estimated stiffness of this bearing support has to be indicated in the Technical Data Sheets by the Contractor.
1.11.1.4
Wicket Gate Bearing Housing and Bushings

The head cover shall contain the upper wicket gate bearing houses and bushes to support the wicket gate stems seal. The bottom ring shall contain the lower wicket gate bearing houses and bushes to support the wicket gate stems seal. The bearing bushes have to be replaceable and maintenance free that means made of bronze or other suitable antifriction metal respectively synthetic material.
1.11.2
1.11.2.1
Guide Vanes Design Data

The hydraulic design of the wicket gate shall be such that upon loss of governor oil pressure, the hydrodynamic forces will move the blades to a position which keeps the no-load speed below the synchronous speed. The wicket gate and the gate stems shall be made of one-piece stainless steel castings. The closing edges shall be thoroughly machined to reduce clearance of the closed gates. Suitable gaps between head cover and in the bottom ring shall be designed to minimize leakage. The peaking mode of turbine operation and the required long life of the turbine shall be considered in the design of all components. Sealing surfaces of guide vanes shall be of stainless steel material. Each guide vane shall be provided with a bronze thrust collar or other suitable material designed to carry the wicket gate weight and resist upward thrust.
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With respect to damage caused by cavitation erosion, the provisions of Clause 1.5.8 of this Section shall apply to the stainless steel surfaces of the guide vanes, head covers and bottom rings.
1.11.2.2
Guide Vane Stems

The wicket gate and gate stems shall be made of one piece stainless steel castings. The gate stems shall be provided with upper and lower maintenance free self lubricating bearings and gate stems seals located above and below the water passage.
1.12
TECH ICAL APPARATUS
SPECIFICATIO S
FOR
GUIDE
VA E
REGULATI G
1.12.1
Description And Requirements Of The Apparatus

The gate mechanism shall have ample strength to withstand maximum load imposed by most severe transient operating conditions. Suitable protection devices shall be incorporated in the wicket gate adjusting mechanism to prevent damage in the event of wicket gate blockage. A replaceable shear pin breaking element and frictional restriction device shall be provided on all gates. These elements shall withstand the maximum operating force, but shall break or yield from extraordinary forces acting in either the opening or closing direction. These elements shall protect the rest of the mechanism from injury in case of most of the gates become blocked by an obstruction. Breakage of each shear pin shall release an alarm signal. If an individual guide vane becomes disconnected from the gate mechanism, no part of gate shall come in contact with the turbine runner. The design of the gate mechanism shall allow independent adjustment of any individual gates position. This independent adjustment will allow each gate to make contact with adjacent gates in the closed position and all gates will have equal and simultaneous openings. Means shall also be provided to adjust each separate gate in the mid- position between head cover and bottom ring. The mechanism shall be readily accessible for inspection, adjustment and repair. All parts having relative motion in contact shall be provided with maintenance free self lubrication bearings (i.e. Deva or other suitable materials).
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Rugged gate stops designed for the maximum hydraulic moment and impact that can be exerted on the stops under the most unfavourable operating conditions shall be provided for each gate. The stops shall be provided between the gate lever and head cover and shall limit the angulation provided movement of a gate in the event of breaking of a shear pin to prevent interference of a loose gate with operation of other gates. Gate stops that protrude into the water passages will not be accepted. These gates shall be provided with shock absorbent pads. All guide vanes shall be interchangeable and independently adjustable. The gate mechanism shall be provided with a plate and a pointer for indicating the wicket gate position and shall be calibrated in the field.
1.12.2
Servomotors
The turbines shall be provided with two oil pressure operated, double acting servomotors, located in the turbine pit, to operate the wicket gates. The servomotors shall be supported on suitable machined pads forming integral parts of the turbine pit liner and shall be designed to withstand the maximum reactions in both directions with the aid of foundation bolts or other devices supported from the building concrete. Each servomotor shall be provided with an adjustable plate or plates for proper alignment of the servomotor during erection. If machining of these plates is required during erection to obtain proper alignment, the Contractor has to pay the cost of machining. The servomotor shall have a combined capacity sufficient to supply the maximum force necessary for moving the wicket gates a full opening or closing stroke in the shortest time required, with a minimum operating oil pressure and close the wicket gates even when one or more of the gates become blocked. This shall be verified by test results and calculations submitted to the Engineer, and during commissioning testing. The servomotor shall be equipped if required with separate openings for retarding the rate of closure, slightly below the speed-no-load position to the fully closed position to minimize pressure rise in the water passage. Materials: Servomotors cylinders of cast or fabricated steel, rings and foundation parts of cast steel, or welded steel plate; pistons cast steel or iron rings per piston to prevent leakage of oil along piston. Provide adjustable mechanical, electrical or electronic connection to governor restoring mechanism at one servomotor cylinder. The servomotor shall be controlled by an actuator type governor. The normal working pressure in the governor oil pressure tank shall be of the order of 60 bars.
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1.12.3
Locking Devices
An automatically operated gate locking mechanism for locking the turbine gates in the fully closed position shall be provided. The gate lock shall be controlled by a solenoid operated valve. A manual locking gate limiting device shall be provided which can lock the wicket gates in the open or closed position or limit the opening position to any intermediate position A manually operated lock shall be provided for blocking the guide vanes in the closed position during maintenance or repair. Provide limit switch to act when gate lock is in unlocked position.
1.13
TECH ICAL SPECIFICATIO S FOR ROTATI G PARTS, BEARI GS A D SEALS Runner

The runner and the runner cone shall be of the Francis type and shall be of stainless steel type 13 /4 (13% chromium, 4 % nickel). The runner will be welded or cast as one piece. A flange connection shall be provided for bolting the runner to the lower end of the turbine shaft. The runner shall be capable of supporting its own weight, together with the weight of the turbine shaft, when the runner shaft assembly is uncoupled from the generator shaft and lowered to rest on the discharge or bottom ring. The torque transmission from the runner to the turbine shaft shall be by friction. In this case, for the attachment of the runner to the shaft, special coupling bolts shall be provided. Removal of the runner shall be made from below. The coupling bolts shall therefore be designed in a manner allowing an easy removal of the runner. Ample vent holes through the runner crown shall be provided to reduce pressure under the head cover. The design and construction of the runner shall provide sufficient clearance for adjustment and, in case of necessity, replacement of the thrust bearing segments (part of the generator supply).
1.13.1
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The runner nose cone fixing bolts, nuts and washers shall be of stainless steel of the same grade as the runner. Each finished runner (with wearing rings attached) shall be carefully statically balanced at the manufacturers workshop. All runners in the power station shall be interchangeable without any adjustment.
1.13.1.1
Runner Water Passage Shape and Surface Finish

Dimensions, dimensional tolerances, profile deviations such as waivers and surface roughness of the runner part, which will be in contact with water shall be similar to the model turbine as indicated by IEC 60193. The surface of the runner shall be free of any manufacturing imperfections which might cause pitting due to cavitation.
1.13.1.2
Rotating Seal Rings

The runner shall not be provided with wearing rings; however the runner shall be designed for easy attachment of replaceable wearing rings if the seal parts of the runner would have worn away. Reference is made to Clause 1.11.1.2, Runner seal stationary wearing rings, of this Section 1.
1.13.2
Main Shaft
The Contractor shall supply for each turbine a turbine shaft for connecting to the lower generator shaft. The shaft shall be an integral carbon or alloy steel forging properly heat treated, with the centre machined out to allow examination of the full length of the bore. The size of the main turbine shaft and all rotating parts shall be ample to operate at any speed up to full runaway speed without vibration or objectionable distortion. Upper and lower coupling flanges shall be integrally forged with the turbine shaft. If a radial shaft seal is provided then the turbine shaft shall be fitted with a removable and renewable stainless steel sleeve. The upper coupling flange shall be at elevation 1043 m.a.s.l. approx. and shall be complete with a removable protection cover for the coupling bolts which shall be provided by the turbine manufacturer. The shaft shall be accurately machined throughout its length and polished where it passes through the guide bearings. A hole not less than 150 mm diameter shall be bored
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through the centre of the shaft and finished to facilitate a thorough visual inspection of the shaft. After the inspection, the hole shall be plugged at the lower end. For the shutdown of the unit in case of overspeed, the necessary provisions shall be made on the turbine shaft to accommodate the overspeed device. The run out of the shaft including runner shall be checked initially in the Contractors workshop. The fitting and final alignment of the turbine shaft shall be performed at site during erection. Tolerances and procedure for shaft run out in the workshop and at site shall conform to NEMA Standards for Vertical Hydraulic Turbine generator Shaft Run out Tolerances.
1.13.2.1
Cooperation with Generator Manufacturer

The manufacturers of turbine and generator shall closely cooperate in order to solve all problems with respect to the entire turbine generator shaft system. In particular, the following questions shall be treated by both manufacturers: The shaft for the complete unit shall be designed jointly, and the Contractor shall be responsible for ensuring that the calculation of the corresponding critical speeds of the shaft system, which shall be safely above the runaway speed, is coordinated between both manufacturers. Size of shaft and shaft coupling shall be mutually agreed upon, and subsequently be reviewed by the Engineer. The necessary clearances shall be provided for lowering the turbine runner, and respectively for lifting the generator rotor and thus allowing the placement or removal of the thrust bearing segments. If deemed necessary, a common template and boring tool shall be supplied by the Contractor and made available for the generator manufacturer to drill and machine the mating coupling flange of the generator shaft. All expenses incurred for the transport of the template from one manufacturers workshop to the other and vice versa shall be included in the contract price. Copies of all important technical correspondence concerning the coordination of the turbine and the generator design shall be submitted to the Engineer, also with regard to the remaining interfaces.
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1.13.2.2
Coupling Bolts, uts and ut Guards

The Contractor shall provide all pre-stressed coupling bolts and nuts for the upper and lower coupling. The Locking of the bolts shall be made by extension of the bolts within their elastic limit. The device for the measuring of the coupling bolts elongation shall be included in the supply.
1.13.3
1.13.3.1
Turbine Guide Bearing Design

The Contractor shall provide a guide bearing mounted on the head cover of each turbine as near to the runner as possible. The guide bearing shall be preferably of the oil lubricating self-pumping white metal lined pad type with individual adjustment of the position of each pad and adjustment of alignment. The guide bearing shall be suitable for continuous shaft rotation up to maximum turbine runaway speed. The bearing housing shall be made of welded steel plates, shall be split vertically and rigidly bolted together, and be designed to support the bearing pads rigidly and transmit the load to the head cover. The bearing pads shall be designed for easy adjustment of the gap between the pads and turbine shaft, via vertical setting wedges and bolts. The contact surfaces between bolts setting wedges, and pads shall be hardened to avoid local permanent yielding. The turbine guide bearing shall be arranged in a manner, that vertical movement of the shaft for adjusting and dismantling the unit thrust bearing and disconnecting the turbine and generator shafts is possible. The design of the bearing shall permit easy inspection, dismantling and maintenance without unnecessary loss of time. Effective measures shall be taken to avoid water from entering into the lubrication system and loss of oil by leakage or overflow from any part of the oil circulating system. The different pressure conditions in the turbine head cover due to the different turbine operating conditions must be considered.
1.13.3.2
Dimensioning
In order to assure quiet operation of the running shaft, the necessary arrangements shall be made with regard to bearing clearance, load assumptions, etc. The guide bearing shall be designed to operate under the following conditions:
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Continuous operation between 50% and 110% of rated speed. During continuous operation, the maximal temperature in the bearing pads shall not exceed 60 C. For 30 minutes between 110% of rated speed and steady state runaway speed. For 30 minutes at rated speed and for 15 minutes at steady state runaway speed without cooling water supply, if an oil heat exchanger is provided. Compliance with the specified values shall be proved by respective calculations and verified by field tests. Furthermore, the bearing shall be designed to withstand without distortion or damage the most unfavourable combination of unbalanced turbine loads and generator loads. Provision shall be made for fitting to the bearing instrumentation specified in Clause 1.17 of this Section 1. Means shall be provided for preventing the escape of oil vapour from the guide bearing housing into the turbine pit. Provisions next to the guide bearing respectively the pads shall be provided to enable monitoring of turbine shaft vibrations. Special care must be taken to provide proper lubrication at low speeds (i.e. loss of governor oil pressure or guide vane shear pin breaking and therefore no-load speed below synchronous speed).
1.13.3.3
Lubrication and Cooling

The lubrication and cooling of the guide bearing shall be effected by oil circulation through it. If the bearing is not equipped with self- pumping pads the oil circulating shall be provided by rotating oil reservoir arranged around the bearing. Flow indicators shall be provided for the oil flow. One main and one stand by twin tube heat exchangers (2 x 100%), if it is necessary to cool the turbine guide bearing oil with water cooling, shall be of stainless steel designed for a nominal pressure of 1000 kPa, and shall be arranged outside of the bearing housing and easily replaceable. The head loss on the waterside shall not exceed 50 kPa under maximum consumption. The replacement of one of the heat exchangers for maintenance and / or cleaning purposes shall be possible without interruption of the cooling water circulation. For the purpose of periodic oil purification, the lubrication system shall be fitted with two ports for pipe connections terminated by lockable stop valves and screwed caps on
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the guide bearing cover surface, suitable for connection of the portable re-circulating oil conditioning system to be supplied by the Contractor as specified under Section 1.20. Under any mode of operation, no water shall enter the lubrication system and there shall be no excessive frothing of the oil or loss of oil by leakage, vaporisation of overflow from any part. Means shall be provided for release of trapped air from the lubrication system when filling. The Employer will accept only systems and plant with absolutely no oil leakage. The Employer reserves the right to reject systems or components in case of oil leakage. A double magnetic and mesh cartridge oil filter shall be provided, equipped with indicators and switches for the differential pressure monitoring. The heat exchanger shall be designed to minimize sediment accumulation. The cooling water entrance temperature will not be higher than 25 C. Further provisions for the heat exchangers are stated in Section 20, Cooling Water System. For the calorimetric measurement of losses, thermometer pockets shall be provided at suitable places, in the incoming and outgoing oil pipes as well as in the incoming and outgoing water pipes. The scope of supply shall include all piping, the same type, make and grade of oil as the bearings of the generators, and the oil systems of the governors. This oil should be readily available commercially in India.
1.13.4
Main Shaft Seal

The Contractor shall supply a (operational) shaft seal, a maintenance seal, and a seal water supply system. The seal shall operate satisfactorily during any maintenance work over the tap cover even when the draft tube is not dewatered.
1.13.4.1
Design
The shaft seal shall be of the radial or axial sliding ring type, preferably a combination of labyrinth type and axial sliding ring type. A packing gland or stuffing box is not acceptable. The shaft seal shall prevent entering of water from the head cover into the guide bearing or into the turbine pit above the guide bearing. Special attention shall be given to the conditions when the turbine is at a standstill under maximum tail water level. The sealing elements have to be easily replaceable without dismantling the turbine shaft i.e. an easy access, suitable for human entry, is to be provided up to the seal.
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The seal shall be designed so that quick and easy inspections, adjustment and exchange of worn parts are possible. Suitable combinations of corrosion resistant materials shall be used so, that the axial movable parts cannot become jammed due to oxidation, deposit of solid elements carried along by the water, etc. The design shall include suitable precautions against contamination of the guide bearing oil due to a malfunction of the shaft seal. The Contractor shall specify and supply all instruments necessary for safe operation and monitoring. However, a suitable sealing wear indicator shall be provided at an easy accessible place on the head cover. It shall be equipped with a limit switch.
1.13.4.2
Shaft Seal Water Supply

Reference is made to Flow Diagram No. 71.1164.08.905 Appropriately cleaned water is supplied for the shaft seal. The Contractor determines the required level of sealing water consumption depending on the construction of shaft seal applied.
1.13.5
Standstill (Maintenance) Seal

A separate maintenance seal shall be provided to prevent ingress of water from the tail water side to the above operational seal during turbine maintenance. This maintenance shaft seal shall be actuated by compressed air and interlocked with the generator brakes, in such manner that it can be engaged only when the brakes are engaged. The maintenance seal shall be arranged in the lowest part of the head cover below the shaft seal. It shall consist of an elastic ring which, when pressed against the non-rotating shaft flange, seals the space of the shaft seal against the maximum tail water pressure stipulated in Clause 1.4.2 of this Section 1.
1.14
TECH ICAL SPECIFICATIO FOR THRUST BEARI G

Reference is made to Section 3 Generators and Auxiliaries where the combined thrust and guide bearing is specified.
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1.15 1.15.1
TECH ICAL SPECIFICATIO S FOR MISCELLA EOUS COMPO E TS Walkways, Acces Platforms And Stairs
Reference is made to Clause 1.10.4, draft tube and Clause 1.10.5, turbine pit liner and coverings of this Section 1.
1.15.2
Lifting Devices
Reference is made to Clause 1.4.10, safety requirements and Clause 1.10.5, turbine pit liner and coverings, of this Section 1.
1.15.3
Special Tools
Refer to Clause 2.12 of General Technical Specifications. Special Tools for each part of plant (especially considering dimensions) shall be provided by the Contractor as necessary for erection, overhaul and maintenance. The following special tools shall be provided: Special equipment for the locking and dismantling of the runner coupling bolts. A hydraulically operated equipment, including measuring device for coupling bolt elongation, shall be provided. 2 complete sets of all lifting equipment necessary for the assembly and dismantling of all turbine parts. All necessary devices and slings for the suspension of turbine cover, turbine shaft with runner, etc. All devices suitable for assembly and dismantling of all aforementioned parts, as well as for easy moving by means of the above mentioned lifting equipment. Special device, if at all possible means of hydraulic jacks, for lowering and lifting the turbine shaft with runner in case of dismantling. Special device for dismantling and assembly of the turbine guide bearing in case of replacement of bearing segments Special tools and devices for dismantling and assembly of the turbine main shaft seal. Device for changing guide vane shear pins.
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Device for dismantling regulating arms and levers. Device for turning turbine shaft along its axis. 1 circular detachable I-beam inside turbine pit carrying one electric hoist for lifting the heaviest single item within the turbine pit. The Tenderer shall indicate separately the special tools specified above and in addition those special tools he deems necessary for the purpose mentioned above. All special tools so determined shall be listed for each Section or Sub-Section and indicated in a separate list attached to Price Schedules and Supplementary Information.
1.15.4
Turbine Pit Hoist

Reference is made to Clause 1.10.5, turbine pit liner and coverings, of this Section 1.
1.15.5
ameplate
Each machine, motor, switchboard and each unit, as well as all cable connections, shall be permanently labelled, not only with the name of the Contractor, but also giving information as to the purpose. This is required, at the latest, at delivery or during assembly. Each of these components has a permanent label (KKS label) that indicates all details necessary for clear identification. Cables are to be labelled at both ends and the cores sequentially numbered. Size and content of the labels are to be reviewed by the Engineer. The labelling shall be in the English language.
1.16 1.16.1
TECH ICAL SPECIFICATIO FOR AUXILIARY SYSTEMS Bearing Lubrication Systems

Reference is made to Clause 1.13.3, turbine guide bearing of this Section 1.
1.16.2
Runner Pressure Balancing And Pressure Relief Lines

Reference is made to Clause 1.11.1, head cover, of this Section 1 (pressure balance pipe).
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1.16.3
Turbine Pit Drainage

Two electric motor driven pumps (2 x 100%) shall be installed in the lower part of the head cover to automatically remove any water which may accumulate in the space below the turbine guide bearing, due to leakage of the seal water and leakage from the wicket gate seals. The drainage water shall be pumped to drainage system of the powerhouse. Each pump shall have a sufficient capacity to handle the leakage if the shaft seal fails. Head of the pump shall be sufficient to overcome the static head and friction losses in the drainage pipe. The pumps shall be close coupled with the A.C. motors and mounted on the turbine head cover with the suction pipe extending into the head cover sump. The intake of the suction pipe shall be provided with corrosion-resistant screens. The pumps shall be controlled automatically by float switches which signal and alarm in case of excessive rise of water.
1.16.4
Lubrication For Guide Vane Regulation System

Reference is made to Clause 1.12, technical specifications for guide vane regulating apparatus. All parts having relative motion in contact shall be provided with maintenance free self lubrication bearings (i.e. Deva or other suitable material).
1.16.5
Air Admission
If air admission is necessary to achieve the guaranteed limits of power fluctuation and draft tube pressure fluctuations, the Contractor shall provide a complete system for the automatic admission of whatever air quantity is required at no additional cost. In the first instance, the model test shall prove if air admission is required and if it can be admitted by means of natural aspiration through a pipe system in the draft tube. If natural aspiration should prove to be insufficient then the Contractor shall supply a compressed air system for injection of air. Air admission shall be drawn from outside the power station. The air admission compressors shall be located on the turbine floor. Regardless of whether the need for air admission is envisaged or not, the Contractor shall provide: The embedded portions of a suitable piping system. The internal fixings in the draft tube liner for air admission by natural aspiration.
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The internal fixings in the head cover for a compressed air injection system.
1.16.6
1.16.6.1
Compressed Air System The Compressed air concept

The compressed air system of the power house consists of two separate systems: Low pressure air system (service air system and compressed air supply for the generator brakes) High pressure air system (compressed air supply for governor and main inlet valve control) Reference is made to Flow Diagram No. 71.1164.08.906 All accessories necessary for all parts of the equipment complete and ready for operation when installation is completed shall be designed even if they are not mentioned in the Specifications. The Contractor shall furnish all foundation materials required to support and hold the diverse equipment as compressors, air/pressure vessels, piping, etc.
1.16.6.2
Low pressure air system

Described in Section 29 LP Compressed Air System of Particulars Technical Specifications
1.16.6.3
High pressure air system

An independent system for compressed air supply to units 1 & 2 shall be provided, equipped with 2 compressors and 1 compressed air vessel. The compressors and the air vessels shall be installed in the compressor room. The capacity of each compressor shall be such that the required air capacity of one governor pressure oil accumulator can be prepared within two hours. One compressor shall automatically be switched-on and off depending on the air pressure in the vessel and both shall periodically be transferred from normal service to stand-by and vice versa.
1.16.6.3.1
Scope of supply
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2 high pressure compressor sets (one as main the other as stand-by), for the main inlet valve and governor pressure oil accumulator, complete with electrical motors and all control and protection accessories including interface to the DC, strainers, driers. 2 double air drier units for compressor sets. 2 high pressure compressed air vessels, for the compressed air supply to the main inlet valve and governor pressure oil accumulator, hot dip galvanized. Complete supply piping, from the compressors to air driers, from air driers to the compressed air vessels and from the vessels to the main inlet valve accumulator and governor pressure oil accumulator, made of stainless steel. Complete set of valves, including solenoid operated supply valves, safety valves for the compressed air vessels and pressure reducing valves. Non return valves will be provided wherever necessary. Plant for control and supervision including cabling between the individual panel and the plant. Individual control panel, for the compressor sets, and for the solenoid operated air supply valves to the air vessels, including cabling.
1.16.6.4
Data
Air temperature at compressor inlet Cooling water temperature inlet Initial air pressure required for generator braking C C kPa 40.0 25.0 approx. 400 approx. 0.4
Compressed air consumption for one full braking kg operation on one unit
The true values of air pressures and compressed air consumptions have to be in accordance with the actual requirements of the individual consumers.
1.16.6.5
Compressors
Air compressors, each equipped with intake air filter, water cooled interstage and after coolers, condensate separators, valves, flywheel. Compressor and drive motor shall be installed on a common base frame. Provisions shall be made for vibration damping. Journal bearings and cylinders shall be pressure oil lubricated by means of directly driven lubrication pumps. The compressors shall be of modern design and appropriate dimensions, taking into account the available space conditions of the power house.
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1.16.6.6
Motors
They shall be made in accordance with Clause 5.2.1 of General Technical Specifications.
1.16.6.7
Compressed Air Vessels

They shall be of welded steel design, all surfaces hot dip galvanized and designed, manufactured and equipped in accordance with ASME Code Section VIII Rules for Construction of Pressure Vessels. The air pressure vessels shall be of the cylindrical, vertical standing type. The air pressure vessel shall be mounted on a structural steel base. The air pressure inlet connections shall be in the lower part, the air pressure outlet connections in the upper part of the vessel. Additionally, the vessel shall be equipped with 4 pressure switches for compressor control. A manhole as well as a burst safety has to be integrated respectively installed in the vessels.
1.16.6.8
Piping
The piping shall consist of stainless steel pipes of guaranteed quality. It shall be arranged that no excessive vibrations or forces can occur and provisions shall be made to prevent pulsations. The outlets for different equipments / points for L.P air supply shall be equipped with cock type valves.
1.16.7
1.16.7.1
Governors Scope and Limit of Supply

In this Clause, the principal plant to be provided and the services to be performed are specified. However, all plant necessary for the proper functioning of the governors have to be provided. Each turbine shall be equipped with 1 electro-hydraulic governor for controlling the speed and output of the turbine including governor oil pumping system with all ancillary devices. Each of the governor systems specified under this Section 1 shall include but not be limited to:
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1 cubicle with main and emergency digital-electronic controller with operator panel for supervision and manual operation of the turbine shall be integrated in the control board 1 speed measurement and monitoring system with 3 speed sensors and 1 pole wheel (steel toothed wheel). The speed of the turbine shall be measured also by using the voltage of the generator. Electronic part of system shall be integrated in the unit control board. 1 power supply unit (DC / DC converters) with intermediate relays and converters. 1 pressure oil supply unit with 1 oil-air accumulator, oil coolers, two oil pumping sets complete with the necessary check valves, non-return valves, safety relief valves, etc. and sump tank. 1 leakage oil tank including one oil pump set complete with the necessary check valves, non-return valves, safety relief valves, etc. and sump tank, located in the turbine pit.
1 complete set of supply piping, valves, filters, etc.
1 complete set of controls and instruments to be provided for each turbine in accordance with Clause 1.17 of this Section including feedback wiring, etc.
1 (one) mechanical overspeed device
1.16.7.2
Governor Requirements
Each turbine shall be provided with an efficient automatic governor system of adequate capacity to control the turbine under all conditions. Each governor shall be of the P.I.D. electro-hydraulic type capable of: Power control. Reservoir level supervision. Flow control. Speed respectively frequency control (no- load and isolated operation). Opening control. Limitation of surge tanks swings.
As far as applicable, the governing system shall comply with IEC 61362 and IEC 60308.
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The governing system shall control the speed and the unit output within the specified and guaranteed limits of operation, without hunting and shall enable the units to operate stable and satisfactorily in parallel with each other and/or the interconnected electrical system. This shall include isolated system operation of one or any number of the units. The capacity of the governor shall be adequate for all operating conditions of the turbine and for change-over from any operating condition to another. All equipment for fully automatic operation shall be provided. An automatic start-up control system shall enable start-up and synchronizing of the generating sets in less than 2 minutes counting from the start command up to synchronizing under the condition of frequency fluctuations of 1 % in the grid. Each governor shall be capable of responding to deviations in frequency greater than 0.01Hz. and shall be capable of responding to load changes greater than 5 percent of rated capacity by initiating servomotor movement within 0.2 s. In case of a sudden drop in system frequency, the unit shall be able to accept load at the maximum wicket gate travel rate. Means shall be provided to ensure automatic followup of the load set point, to match generator output. During this frequency action smooth changeover back to normal operation shall be ensured while the frequency is restored. The positioning time of the controller for the set points of speed, power and guide vane position shall be adjustable during commissioning between 12 and 60 seconds. In order to attain a good optimization, the amplification and integral action time of the controller shall be as smoothly adjustable as possible over a large range. The controller shall ensure stable operation under all operating conditions. Therefore, a distinction shall be made between parallel operation with the system (parallel operation with other units in the system) and isolated operation. The general arrangement of the governor and the corresponding compressed air system are shown in Drawings. The governors compressed air system is specified in Clause 1.16.6 of this Section.
1.16.7.3
Description of Quick Shutdown and Emergency Shutdown of the Turbine

Quick Shutdown Shutdown of the unit in case of a defect, with the governor system operating normally. Quick Shutdown I: QSD I
1.16.7.3.1
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Immediate shutdown of the unit in case of mechanical defects avoiding a speed increase: actuate the quick shutdown control of the governor and open main circuit breaker of generator at approximately zero load. Quick Shutdown II: QSD II Immediate shutdown of the unit in case of electrical defects: actuate quick shutdown control of the governor, open main circuit breaker of generator immediately Quick shutdown shall not be reset before the cause of defect has been located and eliminated. 1.16.7.3.2 Emergency Shutdown (ESD) ESD shutdown of the unit in case of a defect with the governor system out of operation. ESD shall be initiated by: The over speed protection. Failure of quick shutdown. Manual operation. Emergency shutdown initiates the following operations: Actuation of the emergency shutdown device of the turbine. Immediate opening of the main circuit breaker of the generator. Note: The main inlet valve will be designed to stop the units, in emergency, at any turbine discharge under emergency shutdown conditions respectively runaway conditions in case of failure of the wicket gates.
1.16.7.4
Digital-Electronic Controller
The electrical part of the controller shall be installed in a cubicle incorporated in the unit control board. This cubicle shall be designed and supplied to be fully compatible with the adjacent cubicles. Actuating elements (push-buttons) for manual change-over from parallel operation with the system to isolated operation (speed control) respectively vice versa, manual actuation of start-up control system, etc., with the corresponding signal lights shall be mounted visibly inside the cabinet. That means outside of the controller cabinet neither instruments nor actuators shall be provided. The cubicle shall contain the reliable power supply unit for the electrical control units. The controller preferably shall be constructed of electronic components which are interchangeable and can be easily replaced. All important functions shall be brought out
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to test terminals in order to facilitate testing and trouble-shooting. All important settings such as amplification integral action time, droop, etc., shall be adjustable in a simple manner at the controller. The corresponding calibration curve shall be supplied when the corresponding settings cannot be read directly. The setting of the power controller shall be optimised for parallel operation with the system. The speed droop shall be adjustable between 0 and 8 %. Change-over to the speed governor shall be automatic for isolated operation; it shall be affected at the latest when abnormal control behaviour occurs and shall definitely take place before undue swinging occurs. The speed governor shall operate in a stable condition for isolated operation of the station when the generating sets are running up to maximum power including over load. The speed governor shall be optimised for isolated operation of the power plant with full load operation as far as practicable. Local and remote control for each governor shall allow manual selection of a minimum of three separate sets of P.I.D. gain parameters. Two sets of parameters shall be optimised for on-load operation, one set for supplying power to the electrical system and the other set for supplying power to an isolated load. It shall not be possible to select these parameters when the generator is off-load. The third set of parameters shall be optimised for off-load operation, and the governor shall automatically select these parameters whenever the generator circuit-breaker is opened. All set-point adjusters shall be suitable for local and for remote operations. All the electronic equipment shall be protected against the high voltage spikes or interference expected in the supply voltages and from any electromagnetic influence or interference produced by the surrounding equipment. The system shall be designed and guaranteed for operating permanently under a temperature up to 50C and at 95 % relative humidity. The following requirements for the digital-electronic controller shall be fulfilled:
CPU Speed I/O Memory
At least regular 16 Bit with co-processor and multi processor capability. At least 16 MHz. At least 2 RS 232C serial ports and additionally 2 parallel ports. ROM Base (EPROM) for OS and control structure storing and additional RAM.
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Bus Software
VME Bus or similar. Menu-driven or block type configurable, programming by a recognized language. Configuration, diagnosing, simulating and testing, and possibility of transfer to the controller from a PC shall be possible. System programming shall be possible at site. Programming unit shall be furnished.
Digital I/O Analog I/O Pulse input

1.16.7.5
Full protection and signal conditioning. 12 Bit resolution, selectable range. For speed input signal.
Speed Measuring Device

The speed measuring device shall measure the speed of the generating unit and shall be arranged appropriately between the turbine and the generator. The speed signal shall be given by a toothed disk respectively wheel and electronic detectors furnished by the turbine manufacturer. The Contractor shall deliver minimum 3 speed signal transmitter of 4 to 20 mA type. The speed measurement range for the digital-electronic controller for purpose of automatic control and formation of speed droop and exact limit values shall cover at least a range of 85 to 115 % of the rated speed. The devices shall respond to deviations of less than 0.002 Hz. The measurement range for indication and for other limit values shall be given fully independently from the speed control of the governor and cover a range of at least 20 to 150 % of the rated speed. All values of speed required for the automatic system and for protection (e.g., overspeed, standstill signal, etc.) shall be provided by this device.
1.16.7.6
Oil Pressure Unit

The oil pressure unit essentially comprises the sump tank, the screw type oil pumps, and the pressure vessel. It shall be installed on the turbine floor near the turbines. The Employer will accept only systems and plant with absolutely no oil leakage. The Employer reserves the right to reject systems or components in case of oil leakage.
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The oil for the governor system shall be suitable for use with the same type, make and grade of oil as the bearings of the generators, and the bearing of the turbines, which oil shall be readily available commercially. 1.16.7.6.1 Air/Oil Pressure Vessel The air/oil pressure vessel shall be designed, built and tested in accordance with ASME pressure vessel code, section VIII, Division 1. The Contractor shall also arrange the test on the pressure vessel to be conducted in the presence of the Employer, Engineer and relevant local authorities. Provision shall be made so that each vessel can be isolated for annual inspection by local authorities and /or owner. The pressure vessel shall be designed to allow with certainty at least: Three (3) full travels of the guide vane servomotors (single strokes) without restoration of the pressure by pumps becoming necessary. The load of air in the pressure vessel shall occur automatically from the air pressure vessel of the governor air system specified under Clause 1.16.6, controlled by solenoid valves. The Air/Oil pressure vessel shall be arranged on the turbine floor near the turbine. It shall be completed with the following: Manhole not less than 600 mm diameter. Suitable flanges for connection of the oil pressure system, compressed air system, oil treatment, etc. Hydraulically actuated main oil valve. Special devices for automatic control of pressure and oil volume within the air/oil vessel during any operating conditions. 1.16.7.6.2 Oil Sump Tank The oil sump tank shall be made of welded steel plate construction. Its capacity shall be at least 10 % higher than the total oil quantity contained in the fully charged air/oil pressure vessel, guide vane servomotors, all associated pipes, valves, filters and coolers. All oil drainage, leakage and/or exhaust pipes shall be conveyed to the oil sump tank. If water cooling is required the system shall be such that with the oil at steady temperature and with the oil pump in operation (re-circulating the oil) the system shall withstand at least 15 minutes without cooling water and 5 minutes without oil external circulation without reaching dangerous temperatures. In any case the operation temperature shall not exceed the value of 45C.
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Furthermore, during fully charged air/oil pressure vessel and steady operation of the governor pump the remainder oil within the oil sump tank shall have such volume that it will not circulate more than 10 times within an hour. All control devices and accessories shall be installed inside the oil sump tank and shall be easily accessible for maintenance and setting. The oil tank shall also be equipped with a suitable access opening, level indicator, filtered air vent, connection for filling and draining magnetic filters and with plugs for the connection to the oil transfer and treatment system. 1.16.7.6.3 Governor Oil Pumps For the pressure oil supply, 2 screw pumps (2 x 100%; permitted max. speed 1500 rpm) shall be installed in the sump tanks; the pumps shall be electric motor driven from the AC-distribution system and each shall have a capacity of at least 3 times the total guide vane servomotors volume per minute. One of the two pumps shall run continuously when the generating set is in operation or in readiness to operate; the oil shall discharge into the pressure vessel or recirculate in the oil sump tank depending on the pressure in the pressure vessel. A device (unloader valve) shall be provided separately for each pump. The second pump shall serve as a stand by and shall cut in automatically, in case of abnormal loss of pressure. The service pump is cut out when the generating set is shut down. The stand-by pump, maintains the pressure in the pressure vessel according to the selected mode of operation. Each pump shall be equipped with check valve, outlet valve, safety valve and all other accessories necessary for fully reliable operation. Provisions shall be made to allow the complete disconnection of whichever pump from the system for maintenance purpose without compromising the system operation. 1.16.7.6.4 Filter and Cooler If water cooling is required the oil cooler (oil-water heat exchanger) shall be placed outside the oil sump tank. The cooling water temperature will be not higher than 25C; the design pressure of the cooling water piping shall be at least 10 kg/cm2. The head loss shall not exceed 0.5 kg/cm2 under maximum consumption. One main and one stand by twin tube heat exchangers (2 x 100%), if required, shall be of stainless steel designed for a nominal pressure of 10 kg/cm2, and shall be easily replaceable. The head loss on the waterside shall not exceed 0.5 kg/cm2 under maximum consumption. The replacement of one of the heat exchangers for maintenance and or cleaning purposes shall be possible without interruption of the
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cooling water circulation. The oil cooler shall be dimensioned for a cooling capacity of 120 % the rated cooling capacity. Twin full-flow magnetic and mesh cartridge filters shall be provided and shall allow, by means of 3-way valves the cleaning or replacement of the mesh cartridge from one filter side without interruption of the filtering procedure. A differential pressure indicator with alarm contacts shall be provided. The filter shall be arranged on or within the oil sump tank in such way that maintenance works can be done easily. Provisions shall be made for connections to the oil transfer and treatment system. 1.16.7.6.5 Electro-Hydraulic Actuator and Hydraulic Amplifier The electro-hydraulic actuator shall convert the signals from the digital electronic controller into corresponding mechanical quantities. The hydraulic amplifier consists essentially of the main pilot and control valve connected by pressure piping to the guide vane servomotors and the pressure vessel of the oil supply system. An independent emergency turbine shut-down solenoid valve shall be provided, which actuates the pilot servomotor in closing position by overriding the signals from the controller. The associated parts of the electro-hydraulic actuator and the hydraulic amplifier shall be accommodated very near to the oil tank of the oil pressure unit.
1.16.7.7
Control Devices
Plant provided shall include all necessary components, such as valves, pipes, limit switches, pressure gauges, terminal box, etc., for manual and remote control. Plant shall be selected in accordance with the requirements for the instrumentation and control devices of the entire plant. It has to be of robust and reliable design. The governor shall be monitored with regards to its power supply, voltages and auxiliary voltages, set points, feedback, signal transfer, etc., that means monitoring of all essential functions of the complete governor. The oil level in the governor oil sump tank shall be monitored in 2 positions, at too high ant too low oil levels. Oil level and pressure in the air/oil pressure vessel shall be monitored. When the oil level is too high, the vessel shall be replenished automatically with compressed air. If the deviation is too large, an alarm shall be initiated. When the oil level is too low, an alarm shall be similarly initiated. If the deviation is too large, emergency shut-down of the turbine shall be initiated.
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The pressure in the vessel also shall be monitored in three steps. When the pressure is too high or too low, alarm shall be initiated. For upper pressure alarm and emergency shut-down, pressure switches shall be used. The hysteresis of these switches shall be taken into account. The function of oil pressure units, air/oil pressure vessels and oil sump tanks shall be checked in detail, each pump shall run continuously for at lest six (6) hours. During this operation test calibration of valves, checking of oil leakage through pilot and control valve at steady conditions, checking the change-over procedure from one cooler or filter element to the other, and adjustments for the closing and opening times of the servomotors shall be performed.
1.17 1.17.1
TECH ICAL SPECIFICATIO FOR I STRUME TATIO General Requirements

A sufficient number of local and remote- reading instruments for the purpose of reliable plant operation, detailed alarm indication and recording as well as thorough and analytical fault finding are to be provided. Design and performance of sensors and instruments shall comply with the general requirements of I&C instruments stipulated elsewhere under these General or Detailed Technical Specifications. As far as possible and applicable, all supervisory instruments shall be arranged inside local racks or boards. Cables (minimal 1.5 mm2), free of halogen with metal armouring or sheath have to be used and all control and measuring circuits shall be wired in metal or plastic conduits up to easily accessible common terminal boards. The following measuring sensors shall be considered in the design: Resistance thermometers (RTD), platinum with 100 ohms at 0C, 4 wire type. Dial type thermometer (DT) with adjustable contact assembly, (spring type, number of adjustable digital contacts according to requirements, 1 set NO, 1 set NC as minimum). Thermostats (TH) with spring type contact assembly (number of dry contacts according to requirements, 1 set NO, 1 set NC as minimum). Limit switches (LS), heavy industrial type IP-55, with two (2) NO - NC contacts. Pressure gauge and parallel pressure switch (PG) with adjustable contact assembly.
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Vibrometer of two channel displacement type or acceptable equivalent.
1.17.2
Control And Instruments For Turbine And Governor

For general requirements of controls and instruments refer to Clause 5.2.3 of the General Technical Specification. The following controls and instruments shall be furnished to be locally mounted on each turbine and represent the minimum requirements. However, the Contractor is bound to provide a complete set of equipment for the perfect operation of the turbine, governor and the auxiliary systems. Pos Service 1 Temperature: Turbine guide bearing 4 RTD per bearing metal diametrically opposite Oil cooler oil inlet 1 RTD for each cooler located Remote (Alarm, Trip) Remote (Alarm) Instruments for the turbine and Remote or auxiliaries local services
1 DT or thermometer for each Local cooler Oil cooler oil outlet 1 RTD for each cooler Remote (Alarm)
1 DT or thermometer for each Local cooler Cooling water inlet Cooling water outlet Cooling Water System 1RTD or thermometer for each Local cooler 1RTD or thermometer for each Local cooler see Section 20 Cooling Water System
Pressure Oil pressure turbine 1 PG Remote
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Pos Service bearing
Instruments for the turbine and Remote or auxiliaries local services (Alarm) 1 Manometer Local
Compressed air
1 PG for each compressed air Local / Remote system (MIV, governor air, generator brakes, draft tube depressing, draft tube air admission if required) 1 Manometer Local
Water pressure spiral 2 piezometer and 2 pressure gauge Local / Remote casing Water pressure draft 2 piezometer (for net head Remote tube outlet calculation together with the water pressure in the spiral casing) Tail water elevation Turbine Head 2 pressure gauge with transmitter Local / Remote
Operating Derived from average upstream Remote and tail water pressures Local / Remote Local / Remote Local
Water pressure draft 1 PG tube Water pressure main 1 PG shaft seal Water pressure runner 2 PG labyrinth seals
Differential Pressure 1 PG for differential pressure for Local / Remote on water filter for each water filter main shaft seal Pressure A vacuum and pressure Local compound gauge shall be provided and connected to the head cover to permit measuring the pressure between the head cover and runner. The gauge shall be mounted on the pit liner.
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Pos Service
Instruments for the turbine and Remote or auxiliaries local services
Flow Bearing oil cooler oil Bearing outlet oil 1 flow switch of each cooler Remote Local Remote Local & Remote (Alarm, Trip)
cooler 1 sight glass each
Water flow main shaft 1 flow switch of each cooler seal Water flow runner 2 sight glass each labyrinth seals Turbine water flow
Turbine discharge shall be Remote continuously measured for each unit. The adequate method shall be determined by the Contractor, the equipment applied shall be provided by the Contractor as well. see Section 20
Cooling Water System
Level Oil level in bearing oil tank the 1 oil level (contact from local Remote sensor) for high and low level (Alarm, Trip) 1 oil level indicator for each tank Turbine dewatering 2 Level indicators system: Depressed water level Local Remote (Alarm, Trip)
Special Measurements Overspeed device 1 LS Remote
1 mechanical overspeed device to Remote

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Pos Service
Instruments for the turbine and Remote or auxiliaries local services be mounted on the turbine shaft for hydraulic actuation in order to shut down the unit.
Vibration
2 vibration meter (x, y) for each Remote guide bearing for turbine and generator (total minimal 4) vane Remote
Failure of shear pin 1 LS for each guide from guide van equipped with a shear pin operating mechanism Sealing wear indicator 1 LS
Remote
Pos Service 1 Temperature:
Instruments for the governor
Remote or local services
Governor pressure 2 TD or RTD for regulation of Remote oil supply unit governor oil temperature during standstill by starting a governor oil pump and for start up conditions 1 Thermometer Local
Pressure Governor oil pumping Minimal 1 PG per pump sets Oil arrangement piping Minimal 1 PG Minimal 2 PG Local / Remote Local / Remote Local / Remote
Oil / air accumulator
Flow
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Pos Service
Instruments for the governor
Remote or local services Remote Local see Section 20
Governor oil cooler 1 flow switch of each cooler oil (if required) Governor oil cooler 1 sight glass each outlet (if required) Cooling Water System
Level Governor pressure 2 Oil level float switches with Local / Remote oil supply unit maximum and minimum contacts Oil / air accumulator 1 float device with a series of Local / Remote contacts
Special Measurements Feedback system 1 position transmitter servomotor movement 2 LS for open and servomotor position for Remote closed Remote Local
1 servomotor position indicator
LS PG TD RTD
limit switch (pressure gauge) analogue sensor temperature detector (potentially free contact) resistance temperature sensor (Pt 100)
1.17.3
1.17.3.1
Contact Devices General

Various limit switches (LS) for interlock, control and supervision, Various dry-type contacts converted from analogue sensors (PG) for interlock, control and supervision.
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All generator auxiliaries such as braking and lifting devices, oil pumps shall be embraced into the sequential unit control but shall also have local control facilities.
1.17.3.2
Creep Speed Detector

A creep speed detector shall be provided which becomes activated once the unit has come up to rest and the mechanical brakes have been applied. This detector shall be equipped with one alarm contact for signalisation of any further slow motion shaft movement and one contact to effect starting and stopping of the jacking oil pump if on automatic control.
1.17.3.3
Flow Meter for Turbine Discharge

For reasons of recording water consumption as well as of testing performance and efficiency guarantees, water discharge measurement will be continuously carried out in each turbine unit. Reference is made to Clause 1.20.4.5: Verification of Model Test Results by Field Tests.
1.17.3.4
Vibration Monitoring System

A vibration monitoring system, vibro meter, two channel displacement type or acceptable equivalent, complete with detector, proximitor, control unit and time delay relays shall be supplied with the generator. The vibration monitoring system shall measure the radial shaft vibration in x-y direction in the combined thrust / guide bearing of the generator and in the guide bearing of the turbine. The detector shall be mounted in a location best suited to detect excessive vibrations of the rotating parts. The monitor with its control accessories shall be located in each Unit Control Board. Turbine Contractor supplies the detectors for the parts of the turbine. Detectors for the generator will be supplied, installed and commissioned by the Contractor of the generator. Additionally, monitoring system shall measure the vibration induced by pressure pulsation of flow within the turbine. The detectors shall be located: On the head cover near the interaction region between runner and guide vanes In the draft tube cone
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The detectors shall be mounted on locations best suited to detect excessive vibration. The monitoring device with its control accessories shall be located in the unit control board under the responsibility of Contractor of the generator.
1.17.3.5
Overspeed Device
A mechanical overspeed device to be mounted on the turbine shaft for the shutdown of the unit in case of excessive overspeed shall be provided. This device shall have hydraulic action on the governor oil pressure system and thus initiate the closing of the turbine guide vanes. The device shall be adjustable within a certain range above the theoretical maximum load rejection speed and be equipped with the necessary oil pipes and isolating valves for the connection to the governor oil supply system.
1.18 1.18.1
SPARE PARTS General

For general requirements Specifications, Clause 2.13. concerning spare parts, refer General Technical
1.18.2
Specified Spare Parts

Specified spare parts shall include the following.
1.18.2.1
For the turbines:

1 runner complete with moving labyrinth seals, runner cone and fixing bolts set of guide vanes with stems completely machined with levers and links. 1 set of guide van stem journal bearing bushing including all fixing and sealing elements for the upper and lower stem bearing. 3 sets of safety elements for the guide vane regulating mechanism. 1 complete set of turbine guide bearing pads. 1 complete set of wearing rings and facing plates for one turbine. 1 of each type of all control and measuring instruments. 1 of each type of solenoid operated control valves. 1 set of oil pumps with motor.
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1.18.2.2
100 % spare oil for guide bearing 1 set of seals
For the governor systems

1 complete electronic speed signal detector including speed signal transmitter. 1 set of pilot and control valves. 1 set of electronic printed cards. 1 set of oil pumps with motor. 1 of each type of all control and measuring instruments. 1 set of seals
Note: 1 set is defined as the total quantity used for one turbine respectively governor. Any other specified spare parts shall be indicated in Price Schedules and Supplementary Information.
1.18.3
Recommended Spare Parts

If any additional spare parts are recommended by the Contractor, these shall be specified in Price Schedules and Supplementary Information.
1.19 1.19.1
MODEL ACCEPTA CE TESTS General

The Contractor shall carry out model tests as hereinafter described to ensure a satisfactory design and manufacture of the units. Such tests shall include all tests prescribed in the applicable standards and the ones listed in these Specifications. The Contractor shall perform all work and provide all material, equipment and services required for construction and testing of the model turbine and for preparation and distribution of the results including the model test report. The Contractor shall perform tests on a model turbine which is homologous to the turbine the Contractor proposes to supply. The main purpose of the model tests shall be to demonstrate that the prototype performance predicted by the model tests satisfies the performance guarantees established in this Section, to obtain the model complete performance and cavitation
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characteristics, and to allow investigation of pressure pulsation phenomena as a function of the turbine discharge. When the Contractor has achieved acceptable model performance in preliminary model tests, an acceptance test shall he conducted by the Contractor in the presence of the Employer and the Engineer. The individual tests to be conducted during this witnessed acceptance test shall be defined by the Engineer, who will have the right to request those tests which he deems necessary to demonstrate to his satisfaction the Contractors compliance with the respective parts of the Specifications. The Contractor shall submit outline drawings of the model. All tests of the model including the tests witnessed by the Employer and the Engineer shall be completed before starting manufacturing and casting of the turbine components. The results of measurement of the model test have to be converted to prototype scale in agreement with IEC 60193. In case the prototype performance predicted by the model tests do not satisfy the guaranteed performance, the Contractor shall execute at his own expenses all necessary modifications in order to ensure compliance with the guaranteed performance. In case the Contractor has at his disposal a turbine model that he considers suitable for the designs of the turbine subject to these Specifications and this model has been already tested, the Tenderer shall include in his Tender, for information, the model test report relevant to the existing model. The turbine model shall be homologous to the turbine the Contractor proposes to supply. The model shall reproduce the water passages of the turbine from the inlet of the spiral case to the end of the draft tube. The model shall have provisions for visually observing the cavitation occurring on the outlet side of the runner and core vortex in draft tube. Therefore, transparent parts in the discharge ring and the draft tube stroboscopic lighting shall also be provided. The model turbine runner shall have a reference diameter D (= Ds according to IEC 60193) of not less than 0.30 m
1.19.2
Performance Of Model Tests

The model tests shall be performed in accordance with the latest edition of the International Code for Model Acceptance Test of Hydraulic Turbines, IEC Publication 60193. The Contractor shall submit a detailed description of his proposed methods of testing, including but not limited to his methods of measuring head, discharge, speed and torque in the hydraulic laboratory. Net heads shall be defined for the purpose of these tests as being the difference between the total head measurements at the spiral case inlet and the outlet section of the draft tube.
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The inaccuracies in measurements according to above code shall be considered in the tests. Measuring inaccuracies comprising random and systematic errors shall be combined statically to produce an overall accuracy band. The Tenderer shall submit with his Tender full details relevant to the inaccuracies in measurement.
1.19.3
Model Performance Data

The model test report shall include, but shall not be limited to the following performance data: Complete turbine quadrant diagrams Q11-n11 and T11-n11 for constant wicket gates angles (from 0% to full opening). The turbine quadrant curves shall be plotted with sufficient test points in an extended range of investigated operating conditions in order to guarantee high reliability. Complete performance diagram of the turbine giving efficiencies versus unit speed and unit discharge for different guide vane openings, spaced at intervals of 10 % of guide vane opening and starting from 30 % to full opening. The diagram shall be extended in a wide range of unit speed. Runaway unit speed versus discharge and guide vane opening. Complete cavitation characteristic curves for the turbine, showing critical values of the cavitation parameter sigma versus unit speed and unit discharge for different guide vane openings. Visual observations of cavitation on turbine blades shall be recorded by digital pictures. Model turbine cavitation test results showing unit power, unit discharge and efficiency as functions of sigma (i & p) for guide vane openings and values of unit speed. Results of model tests demonstrating the effect of auxiliary devices, if any, (e.g. air admission), designed to improve prototype performance. The effect of these devices shall be considered in the other reported model tests data. Pressure pulsations in spiral case and draft tube, between runner and wicket gates, between head cover and runner crown for various unit speed and in all the range of plant sigma, and for guide vane openings from 30 % to full opening, spaced at 10 % interval. Frequency analysis of pressure pulsations shall be included. If any device is adopted to minimise pressure pulsations (i.e. air admission), an additional set of curves shall be given.
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During the model tests the best location of the Winter-Kennedy taps shall be determined. The pressure taps shall be arranged in accordance with IEC 60041. The utmost attention shall be paid to the calibration of the taps on which the Index tests on site shall be based. Hydraulic axial and radial thrust enabling the verification of the maximum hydraulic thrust of the prototype under the most unfavourable operating conditions within the whole range of operation. Torque oscillations and frequency analysis. Check of torque on the guide vane stems. Torque characteristics for the complete opening range from 0% to 100%.
1.19.4
Acceptance Of Model Tests

The performances of the Contractors model turbine shall be considered as acceptable only when the model performances meet the criteria stipulated in the IEC Publication 60193, and when the model turbine operates under conditions which are hydrodynamically similar to those for which the guarantees are made. Acceptance of the turbine model performance shall not relieve the Contractor from his responsibility in respect of the operation guarantees of the prototype, stipulated in this Chapter. No time extension shall be granted for any delay of the model tests. In case of unsatisfactory results, the Employer shall have the right: To permit a further period for testing. To conditionally accept the best model performance. To terminate the Contract. In case the witness tests shall be repeated, the Contractor bears all related costs and expenses. The Employer shall have the right to terminate the Contract due to the Contractors failure to remedy Defects according to General Conditions of Contract in case of: An efficiency default on the turbine average weighted efficiency, such that the maximum agreed amount of the relevant penalties would be exceeded.
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Power lower than that guaranteed. Maximum steady state runaway speed and hydraulic thrust higher than the guaranteed values. Amplitude and/or frequency of the draft tube pressure pulsations exceeding the respective threshold values. In case of conditional acceptance the Contractor shall: Accept to pay the relevant penalties. Or take all the corrective measures necessary to guarantee that the prototype shall work according to the specified requirements. In any case the penalties shall be held until the results of the index tests and commissioning tests on site are available.
1.19.5
Homology Model To Prototype

The homology between the model and the prototype shall be checked by comparing the various dimensions of the prototype with the corresponding model dimensions. Permissible deviations in the geometric similarity between the prototype and the model are those stated by the latest edition of the International Code for Model Acceptance Test of Hydraulic Turbines, IEC Publication 60193 At least the following parts of the prototype shall be checked by templates, obtained from the model which has been tested with satisfactory results: Profile of guide vane Profile and angles of runner blades The other main dimensions of the runner, guide and stay vanes, spiral case and draft tube shall be checked by appropriate measures.
1.19.6
Test Report
After completion of the model tests including additional test and measurements suggested and included by the Contractor or arranged later by mutual agreement, the Contractor shall prepare a detailed test report, comprising all data, measurements and curves and making conversion and interpretation of the results with a view to prototype conditions.
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The test report shall include (in accordance to IEC 60193): Description and drawings of test equipment, minutes of dimensional inspections, calibration data of test instruments. Turbine performance curves of the model for various wicket gate openings for the full range of specified heads. Turbine quadrant diagrams Q11-n11 and T11-n11 for constant wicket gates angles (from 0% to full opening). Complete cavitation characteristic curves. Pressure differential measurement (Winter Kennedy). Pressure fluctuations measurements in spiral case and in draft tube with the frequency analysis. Curves of runaway speed. Hydraulic axial and radial thrust. Operation at extreme low level of head. Torque oscillations and frequency analysis. Torque on the guide vane stem. Sample calculation. Comparison of guaranteed and tested data. A draft of the test report shall be submitted for review within 4 weeks after completion of the tests.
1.20 1.20.1
ERECTIO A D TESTS O COMPLETIO General

Erection and commissioning of the plant shall be carried out by the Contractors personnel under the direction of his responsible staff. The services of the Contractors personnel shall include also the trial operation period during which they will attend to t he plant and instruct he Employers staff in operation and maintenance of the plant. The Contractors activities will include any work related to the erection, adjustment and commissioning of all plant supplied under this contract, including interfaces with other
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Contractors supplies. All minor work necessary for the completeness of erection and commissioning shall be included. For the erection and commissioning of the supply covered by this contract, the following main requirements are applicable in addition to the general erection requirements, as applicable in accordance with clause 6, erection requirements, of General Technical Specifications.
1.20.2
1.20.2.1
Erection Procedures Draft Tube Liner

The lower portion of the draft tube liner shall be assembled and erected for embedding in the second stage concrete to suit the program of the civil works and electromechanical time schedule. Depending on the time schedule, embedding into the first stage concrete may also be considered. The embedded draft tube liner will be pressure grouted by others but under supervision of the Contractor. Extreme care shall be taken to avoid buckling of the draft tube liner by grout pressure. All grout holes shall be plugged, welded, and ground flush by the Contractor upon completion of the grouting operation.
1.20.2.2
Spiral Case and Stay Ring

Any required anchor and anchor bolts to be placed in the first stage concrete shall be supplied by the Contractor and their position and anchorage indicated in the foundation drawings. After assembly of the spiral case sections and at regular intervals during welding of the field joints (including welding of the points between bottom/discharge ring and upper draft tube liner), the alignment, levelling and roundness of the construction shall be carefully checked and record shall be taken and submitted to the Engineer for review. After complete erection the spiral case shall be prepared for hydrostatic pressure testing by bolting or welding the pressure head cover to the extension pipe, inserting the test ring into the stay ring and by adequately bracing the stay ring according to the detailed instructions of the Contractor. For the performance of the hydrostatic pressure test, test pressure shall be gradually increased to the test value stipulated in Clause 1.4 of this Section 1 and be maintained at this pressure for at least 1 hour, after all leaks have been eliminated. All details for the test procedure shall be determined by the Contractor.
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During and after the hydrostatic pressure test, micrometer measurements shall be taken to determine the amount of movement of the machined surface of the stay ring and to check the expansion of the spiral casing circular portions. Records of these measurements shall be taken and submitted to the Engineer for review. For pressure testing all piping attached to the spiral casing including piezometer piping shall be erected and pressure- tested together with the spiral casing. All equipment for performing the hydrostatic pressure tests, bulk heads, seals including pump, valves, gauges, thermometers, and micrometer, shall be provided and installed by the Contractor. After successful completion of the hydrostatic pressure test the spiral casing shall be prepared for second stage concrete embedding. The concrete embedding procedure shall be proposed by the Contractor, and is subject to the review of the Engineer. During the concrete embedding and curing period the spiral casing shall remain filled with water at a pressure specified in the embedding procedure. The water in the spiral case shall be continuously circulated by suitable means provided by the Contractor for cooling of the concrete. The furnishing and placing of the second stage concrete will be done by others. Placement of the second stage concrete will be subject to approval by the Contractor. Care shall be taken to ensure that all piping such as pressure measurement tappings will not be deformed or damaged during Contraction of the spiral casing after release of pressure. 1.20.2.2.1 Pressure Grouting of Embedded Turbine Parts After the spiral case has been embedded and the concrete has set for not less than 3 days, but before the pressure in the spiral case is released, the cavities below the stay ring / spiral case shall be pressure-grouted. Pressure grouting of the embedded spiral case will be performed by others, including supply of the grout. The pressure used for grouting, and all other details of the grouting operation, shall be determined by the Contractor and reviewed by the Engineer. Extreme care shall be taken to avoid movement of the spiral casing by grout pressure. All grout holes shall be plugged, welded, and ground flush by the Contractor upon completion of the grouting operations. 1.20.2.2.2 Erection Tolerances of Spiral Case The parts of the spiral case shall be installed so that the concentricity, level, alignment, and fit of the parts are as close as possible to the design requirements. The
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following tolerances shall be permitted, provided that tolerances preventing satisfactory operation of the turbine or related plant will not be accepted. Setting of stay ring and spiral case shall not deviate from the vertical and horizontal centre line elevation and dimensions shown on the Drawings by more than 5 mm. The level of the finished surface that will support the head cover, when measured at eight points 45 apart, shall be maintained to within 0.2 mm maximum variation from highest to lowest point. The circularity and concentricity of the stay ring and other parts, at points that will affect impeller runner clearances and at points that will affect the fit of nonembedded parts, shall be maintained to such tolerances that he net clearances for rotating parts shall be not less than one-half of the design clearances. 1.20.2.2.3 Connection of Spiral Case / Spherical Valve / Upstream Connection Pipe to the Penstock The Connection of the spiral case respectively spherical valve and upstream connection pipe to the penstock shall be made after embedment of the spiral case. The upstream connection pipe between the main inlet valve and the penstock requires to be adapted to suit the actual location of the penstock.
1.20.2.3
Erection of Removable Turbine Parts

The removable parts shall be carefully cleaned from protective coatings and any traces of corrosion shall be removed before erection. Before starting Tests on Completion the following checks shall be performed: Verification of the perfect alignment of all turbine parts. For the alignment and run out of the shaft the procedure as provided in the NEMA standards, Publication No. MG 5.21972 (Installation of Vertical Hydraulic Turbine-Driven Generators and Reversible Generator Motors for Pumped Storage Installation) shall apply. Check of all clearances with particular view to runner and wicket gate clearances, and guide bearing. Performance of a pressure test of servomotors and all control piping with double the normal working pressure. Check of the pre-stressing and perfect locking of the bolted connections.
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After coupling with the generator shaft, alignments and run out checks shall be performed. Inspection of corrosion protection. The Contractor shall make permanent records of all elevations, clearances, tolerances, measurements established at the time of erection. This record shall be checked and, if necessary, supplemented by additional measurements taken by the Contractor at the direction of the Engineer immediately before taking over of each unit. Final check and locking of all nuts where necessary and establishing a list of pending items until termination of work.
1.20.3
Tests During Erection

Reference is made to Clause 1.20.2, erection procedure, of this Section 1.
1.20.4
Tests On Completion
Tests on Completion of the turbines shall be carried out after successful termination of erection. Refer to Clause 7.4 of General Technical Specifications and Conditions of Contract. All measuring equipment required for Tests on Completion shall be provided by the Contractor.
1.20.4.1
Pre-commissioning Tests (Dry Tests)

Pre-commissioning Test shall comprise at least the following items: Verification of proper, complete and satisfactory erection of all parts. Inspection of the complete water passages of the turbine, including penstock shaft and draft tube to ensure removal of all foreign or loose objects which might cause damage, verification of the measuring sections and tapping points for acceptance tests. Adjustment of guide vanes for uniform closure and sealing, dry tests of operating times of guide sealing, dry tests of operating times of wicket gates, calibration of scales for wicket gate opening.
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Electric control of correct wiring and cabling of all control, alarm and auxiliary power circuits. Testing and setting of all relays, protective equipment and transmitters, including calibration of the electric control equipment. Operational tests on pressure oil supply unit and compressed air supply unit, which shall include the correct functioning of the switching over from service unit to standby unit, adjusting, setting and checking the operation of any kind of valves, relief valves, distribution valves pressure switches, etc. Checking of the cooling water circuits with appropriate control valves and preliminary measurement of the cooling water flow. Preliminary adjustment of opening and closing times of wicket gate operating mechanism. Complete function test of governing equipment, simulating manual and automatic starting and stopping sequences, operation of pressure oil units, checking of oil levels and pressure in regulating system. 24 hours continuous operation of pressure oil system. Verification of oil, grease and water supply to all bearings and main shaft seal requiring lubrication and cooling. Operation of generator braking system. Verification of proper fastening of all manhole covers.
1.20.4.2
Commissioning Tests
To be performed in close cooperation and coordination with generator and electrical manufactures as well as other involved parties and at least comprising the following items: Check of the whole waterway Slow filling of waterways from tail water side, check for leaks in the entire water conveyance system. Unit dewatering test. Pressurising of spiral case.
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Initial run of unit, stepwise increase of unit speed up to rated speed with observation of temperature behaviours of bearings and shaft sealing, shaft run out, deformation of covers and bearing supports, measurement of vibrations. Check operational behaviour of bearings under normal load conditions. Check on action of generator braking system. Governor test in speed no- load condition. Function test of complete control system, manual and automatic starting and stopping sequence up to rated speed. Increasing speed of unit up to maximum overspeed with verifications of shaft run out, clearances, vibrations and deformation. Adjustment and setting of safety devices, speed switches and overspeed trip. Synchronising of the unit.
Preliminary load run and load rejection tests, determining speed and pressure rises at rejections of 25 %, 50 %, 75 % and full load. The load shall be increased by steps and a load rejection is to be made from each successively higher load up to maximum expected for the prevailing net head. At the completion of each load rejection test, the pressure rise and overspeed data shall be analysed to ensure that the unit will not exceed the prescribed safety limits at the next greater load rejection. Test of the correct functioning of the entire governor system under any possible operating condition in accordance with the respective IEC code. Final load rejection tests in order to prove the guarantee values of maximum pressure and transient speed rise at load rejections of 25 %, 50 %, 75 % and full load as stated in the Data Schedules.
Load step response test of turbine generator unit with osciliographic measurement of frequency deviation, increment of generated power, unit speed, spiral case pressure, wicket gate opening, terminal voltage, excitation voltage and excitation current unit maximum output, size and number of steps to be decided later in consideration of actual conditions by the Engineer.
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During the period of load rejection tests, any precautions necessary shall be taken to ensure that safe values of pressure in the penstock, as well as of turbine unit stresses, shall not be exceeded. Such precautions may include setting of governor timing at rates slower than design rates. Where adjustments are made on governor or regulating devices, the tests made prior to such adjustments shall be repeated.
1.20.4.3
Trial Operation
Refer to Sub-Clause 28.10 of the Special Conditions of Contract. After successful termination of all commissioning operations including testing, the plant shall be subject to a Trial Operation. The Trial Operation shall be carried out under the supervision and responsibility of the Contractor. At the same time, the period is deemed to be an instruction period for the Employers personnel. The Trial Operation shall give proof of the ability of the plant for continuous operation, identical or close to commercial operation conditions, i.e. with automatic control and without any need for adjustments or overhauls and under the loads required by the Employer. The Trial Operation shall, therefore, only be interrupted in exceptional cases, subject to the consent of the Engineer. The duration of the Trial Operation shall be less than two (2) months, if not otherwise stated in General Technical Specifications. If the Trial Operation is unduly interrupted by the Contractor for repairs or modifications, its duration may be extended as directed by the Engineer, without additional costs. During the Trial Operation the unit shall run continuously for at least two (2) weeks. Should any of the tests required in this Section 1 not have been carried out by the date of taking over, the Taking-Over Certificate shall contain reservations on the tests not made, and provisions for their being carried out as soon as possible. The additional costs of such delayed tests shall be borne by the Contractor, except if the postponement of such tests was expressly required by the Employer. Postponement of one of some performance tests by mutual agreement of Engineer and Contractor will not prevent beginning of the trial operation. This refers also and particularly to the tests still to be carried out at higher heads.
1.20.4.4
Performance Tests
Subsequent to the commissioning tests the following performance tests shall be carried out:
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1.20.4.4.1
Index tests. Power output tests at rated net head in order to confirm the guaranteed values. Runaway speed test might be performed at the option of the Employer, giving the maximum runaway speed under the maximum operating net head for a duration of 5 minutes. Hydraulic thrust test for steady state and transient conditions, in order to verify the guaranteed values. All tests as described above shall be carried out at the head available at the time of commissioning the respective unit. For heads higher than the above mentioned test head, all main tests shall be repeated at intervals to be agreed between the parties depending on the rate of increase in available head. These tests shall be repeated up to the maximum operating head, even if the latter occurs after expiry of the Defects Liability Period. The Contractors obligations with regard to specific guarantees, compliance with which has not yet been proved by tests, shall be extended accordingly.
1.20.4.5
Verification of Model Test Results by Field Tests

The performance and efficiency guarantees shall be expressed for the prototype. Model test results are therefore subject to verification by field tests at the option of the Employer. The details of the methods of measurement, of the conditions and conduct of these tests at site shall be mutually agreed between Engineer and Contractor, and laid down in a separate program to be submitted by the Contractor to the Engineer 60 days before commencement of commissioning, defining the sequence of the tests, the equipment preparation and operation procedure to be followed. Employer and Engineer will jointly decide on specific conditions to be fulfilled before performing the tests, such as unit availability, flow, electrical grid, coordination with other Contractors, etc. All tests shall be carried out by the Contractors personnel, consisting of an experienced hydraulic Engineer, and of additional experienced associate Technicians. Appropriate instruments, such as multi-channel recorders for the registration of transient conditions and other measuring equipment shall be provided by the Contractor, as part of his test activities. Index tests and power output tests will be conducted on each unit. In case the guaranteed data are not fulfilled, the relevant guarantee conditions of the Contract shall apply.
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The tests shall be subject to the latest edition of the following standard: IEC Code No. 60041 International Code for the Field Acceptance Tests of Hydraulic Turbines. Evaluation of the test results and elaboration of the test report by the Contractor. The test report shall be prepared in draft form within two months after the tests and the final form one month after review of this draft. The accuracy of the measured efficiency values shall be established during testing in accordance with the relevant IEC Code. When designing the turbines, the Contractor shall make the necessary provisions for testing on all units. The relevant drawings shall be submitted to the Engineer. The Employer shall have the right to designate an expert of a recognised institution to approve the test program, assists the testing and to check and approve test reports. 1.20.4.5.1 Index Tests Index tests by Winter Kennedy method, and in accordance with IEC Code No. 60041, to be performed on each turbine prototype, providing relative values of efficiency at five test points at and above 40 % wicket gate opening.
1.20.4.6
Power Output Tests

For the output measurement of each turbine prototype, the indirect method by means of the coupled generator adding the various electrical and mechanical losses as per IEC Code No. 60041 shall be applied.
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E 2 01 Turbines and Governors

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E 2 01 Turbines and Governors

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Gati Infrastructure Bhasmey Power Private Limited.

TURBI ES A D GOVER ORS

1 1.1 1.2 1.3 1.4

MECHANICAL DESIGN CRITERIA ................................................................................27 1.6.1 Design Standards......................................................................................................27

MATERIALS AND CONSTRUCTION .............................................................................35

SHOP INSPECTION AND TESTING................................................................................42

TECHNICAL SPECIFICATIONS FOR FIXED / EMBEDDED COMPONENTS ...........52

TECHNICAL SPECIFICATION FOR AUXILIARY SYSTEMS .....................................72

ERECTION AND TESTS ON COMPLETION..................................................................98 1.20.1 1.20.2 1.20.3 1.20.4

The Copyright remains with AF Colenco Ltd.

TURBI ES A D GOVER ORS

TECH ICAL REQUIREME TS

Auxiliary Power Systems

Cooling Water System

466.20 460.0 0.981

As per General Project Information 1000 9.81 50 400

Range of ambient humidity

Guaranteed Turbine Operating Range

30.00 Turbine Power Output (MW)

1MAX MW=27.64 at Q=29.17, H=102.51m, eff=94.2%

3MAX MW=29.80 at Q=27.82, H=115.85m, eff=94.2%

at Pmax at Pmax at Pmin Hrated Hmax Hmin

29.17 107.50 94.20% 28.98

27.82 115.85 94.20% 29.78

11.13 102.51 85.00% 9.51

11.13 115.85 94.20% 11.91

Efficiency (%) 94.20% Power output 27.64 (MW)

Turbine Effeciency (%)

HLHP = KHP1 x Q2 HLHP = KHP2 x Q2

(when one unit in operation) (when two units in operation)

where: HLHP Q KHP1 = 2.51 * 10-3 KHP2 = 2.51 * 10-3

where: HLLP Q KLP1 = 3.14*10-5 KLP2 = 2.15*10-5

[m] [m3/s] [s2/m5]

Head loss coefficient when two units in operation [s2/m5]

Losses in the low pressure side

Specified Conditions Modes of Operation

MVA MVA rpm kV % Hz Hz kWs/ kVA

Maximum power P3TU,MAX

29.7 MW at maximum 115.85m, head H3TU

The weighted average efficiency to be guaranteed by the Contractor is defined as follows:

i being the individual efficiency and Wi the corresponding weighting coefficient

Guaranteed Maximal Momentary Pressure

Guaranteed Maximum Momentary Overspeed

Guaranteed Maximum Steady-State Runaway Speed

Cavitation Guarantees Verified on the Turbine Model Test

Cavitation Pitting Guarantees

Guaranteed Hydraulic Thrust

Guaranteed Maximum Weights And Dimensions

Other Technical Guarantees Wicket Gate Torque

MECHA ICAL DESIG CRITERIA Design Standards

Stresses And Deflections

The following design requirements to working stresses shall be applied:

Pos. Working conditions

Maximum unit stress in % of yield point ultimate stress

Turbine parts under normal load conditions 1):

Special Design Considerations General

Calculation of Critical Bending and Torsion Vibration Speeds of the Shaft

DESIG DOCUME TATIO General

Data For The Employers Design Information To The Engineer

Operation and Maintenance Manuals:

Workshop Assembly and Workshop Tests

Seaworthy Packing, Dispatch and Transport

Erection, Commissioning and Trial Operation

where: HLLP Q KLP1 = 3.1410-5 KLP2 = 2.1510-5