6.4.1 Particular Technical Specification Mechanical Works

6.
4
Particular Technical Specification
6.4.1
Mechanical Equipment
Upper Tamor HPP Part 6.4 Particular Technical Specifications
Electro-Mechanical Works Equipment
Table of Contents
6.4.1.1. General 1
6.4.1.2. Hydraulic Turbines, Governors & MIVs 1

6.4.1.2. Scope of Supply 1
6.4.1.2. Pelton Turbines 1
6.4.1.2.2.1 Turbine operating conditions 1
6.4.1.2.2.2 Scope of supply 1
6.4.1.2.2.3 Type and arrangement 2
6.4.1.2.2.4 Water levels and head ranges 3
6.4.1.2.2.5 Turbine type and rating 3
6.4.1.2.2.6 Model test of Pelton turbine 6
6.4.1.2.2.7 Vibrations 8
6.4.1.2.2.8 Critical speed 8
6.4.1.2.2.9 Frequency analysis 9
6.4.1.2.2.10 Design requirements for main components 9
6.4.1.2. Governors 22
6.4.1.2.3.1 General 22
6.4.1.2.3.2 Design requirements 23
6.4.1.2. Main Inlet Valves 28
6.4.1.2.4.1 Scope of supply 28
6.4.1.2.4.2 Type and construction 28
6.4.1.2.4.3 Operation 29
6.4.1.2.4.4 Pressure oil system 30
6.4.1.2.4.5 By-pass valve 31
6.4.1.2.4.6 Control and instrumentation (C&I) 31
6.4.1.2.4.7 Dismantling/extension pipe 32
6.4.1.2.4.8 Bulkhead 32
6.4.1.2. Anti-corrosive treatment and painting 32
6.4.1.2. Lubricating and Hydraulic Pressure System Oil 33
6.4.1.2. Tools for Erection, Installation and Maintenance 33
6.4.1.2. Spare Parts 33
6.4.1.2. Shop and Site Assembly, Inspections and Tests 34
6.4.1.2.9.1 Tests during manufacturing 34
6.4.1.2.9.2 Site tests and commissioning 35
6.4.1.3. Mechanical Auxiliary Systems 36

6.4.1.3. Cooling Water System 36
6.4.1.3.1.2 Equipment particulars 37
6.4.1.3.1.3 Spare parts 38
6.4.1.3.1.4 Tests 39
6.4.1.3. Drainage and Dewatering System 39
6.4.1.3.2.2 Tests 41
6.4.1.3.2.3 Spare parts 41
6.4.1.3. Compressed Air System 42
6.4.1.3.3.2 Control devices 43
6.4.1.3.3.3 Control panel 43
6.4.1.3.3.4 Spare parts 43
6.4.1.3. Fire Fighting System 44
6.4.1.3.4.1 Fire fighting system study 44
6.4.1.3.4.2 General description of the fire fighting system 44
6.4.1.3.4.4 Spare parts 47
6.4.1.3. Heating, Ventilation and Air Conditioning (HVAC) System 48
6.4.1.3.5.2 Design data 49
6.4.1.3.5.3 Fire Protection Considerations in the Design of the
Ventilation System 50
6.4.1.3.5.4 Code and Standards 50
6.4.1.3.5.5 Internal Temperature Requirements 50
6.4.1.3.5.6 Duct Air Velocities 51
6.4.1.3.5.7 Spare parts 51
6.4.1.3. Oil Handling System 51
6.4.1.3.6.2 Storage tanks 52
6.4.1.3.6.3 Transfer pumps 52
6.4.1.3.6.4 Oil filtration plant 52
6.4.1.3. Mechanical Workshop 53

6.4.1.3. Powerhouse Crane 54
6.4.1.3.8.2 Shop assembly and tests 56
6.4.1.3.8.3 Site performance tests 56
6.4.1.3.8.4 Spare parts 57
6.4.1.1. General
These Particular Technical Specifications are part of the Employer’s
Requirements of this contract. They are based on the design of the project
carried out by the Employer which is represented in the technical drawings
(Part II, Section 6.7 Tender Drawings) and the Design Calculations and
Design Memorandum Reports, November 2019 (Part IV Reports) produced
by the Employer.
6.4.1.2. Hydraulic Turbines, Governors & MIVs
6.4.1.2. Scope of Supply
· three (3) vertical Pelton turbines with six (6) nozzles, operating at
synchronous speed of 300 rpm
· three (3) digital electronic - hydraulic governors including pressure oil
system
· three (3) main inlet valves (MIVs) of the spherical valve type, including
pressure oil systems
· hydraulic quantities measuring system
· spare parts and special tools
· model testing of Pelton turbine
· shop and field tests
· installation and commissioning.
The scope of supply shall include all components which are required for
performance, durability and satisfactory operation of the turbines, governing
systems and main inlet valves even though not individually or specifically
stated in this specification.
6.4.1.2. Pelton Turbines
6.4.1.2.2.1 Turbine operating conditions

Four hours peak operation shall be carried out every day with a maximum
turbine discharge of 68.64 m³/s. After four hours peak operation, another 18
hours will be used for head pond filling and off-peak operation in parallel.
During the dry season, the headpond with a storage capacity of

approximately 0.8 million m³ shall ensure four hours peak operation in the
dry season, because the inflow in the dry season is less than the maximum
turbine discharge of 68.64 m³/s.
6.4.1.2.2.2 Scope of supply

The scope of supply shall include, but not be limited to the following:
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· three (3) vertical shaft Pelton type hydraulic turbines each with six (6)
nozzles and a specified turbine output of not less than 87.4 MW at a rated
net head of 433.42 mWC and a rated discharge of 22.88 m³/s
· turbine model testing
· three (3) dismantling/expansion pipes
· service platforms, runner removal cart and runner removal doors
· dewatering pipes and valves
· measuring pipes and instruments
· oil piping between servomotors and governor oil systems
· brake jet assemblies
· lifting facilities and electric illumination for the turbine shaft pit
· assembly and tests in the workshop
· transportation and delivery to site
· storage at site
· site installation, commissioning and acceptance testing of the turbines
including thermodynamic measurements
· corrosion protection coating
· first lubricant fill plus a 10% extra in barrels
· tools, slings and devices required for assembly and maintenance
· preparation and submission of operation and maintenance manuals and
training of Employers operating and maintenance staff; and
· spare parts required for operation and maintenance.
6.4.1.2.2.3 Type and arrangement

Each Pelton turbine shall be a vertical-shaft type machine with six jet
nozzles and deflectors. The jet nozzles are for regulation of power output
and for control of speed during start, synchronizing, and shut down.
The turbines’ direction of rotation shall be clockwise when viewed from top
(generator side).
For the unit design the following vertical unit arrangement it is envisioned
that the Pelton turbines are coupled to a generator which is equipped with
combined thrust/guide bearing above and one guide bearing below the rotor
(bearing arrangement according to DIN EN 60034-7, IM 8421).
Nevertheless, the Contractor may propose a different bearing arrangement

based on his own experience and references.
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6.4.1.2.2.4 Water levels and head ranges
6.4.1.2.2.4.1 Water levels
Reservoir:
· Maximum Operating Level e11352.0 m a.s.l.
· Minimum Operating Level 1339.0 m a.s.l.
Turbine runner and tailwater:

· Runner/nozzle centreline elevation e 900.0 m a.s.l.
· Tailwater level 891.8 m a.s.l
· Maximum Level during 100-year design flood e 895.4 m a.s.l.
6.4.1.2.2.4.2 Gross head

Corresponding to the level variations of the Upper Tamor HPP headpond
and the turbine runner centreline elevation the Pelton turbines shall operate
under the following gross heads:
· Maximum gross head 452 mWC

· Minimum gross head 439 mWC
6.4.1.2.2.5 Turbine type and rating

The turbines shall be of the vertical shaft Pelton type coupled directly to a
generator.
The basic data for the turbine design is as follows:
Rated gross head Hg 450.0 mWC
Rated net head (1 unit in operation) Hn 433.42 mWC
Rated discharge per unit Qr 22.88 m3/s
Power at rated condition per unit Pr 87.4 MW
Synchronous speed n 300.0 rpm
Centreline elevation of turbine runner ÑCLrun 900.0 m a.s.l.
The turbines shall be designed and manufactured for daily starts and stops
and continuous operation between minimum and maximum output and
within the head range specified, without exceeding the allowable stresses
and bearing temperatures.
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The turbine shall be able to operate safely and satisfactorily under any
conditions of load and the given water level without excessive vibration,
noise, wear (erosion) and tear.
6.4.1.2.2.5.1 Turbine efficiency guarantee

The Contractor is required to guarantee efficiencies from 20 to 100% of the
power output from the maximum to the minimum net head. The guaranteed
turbine efficiency η shall be checked at site; liquidated damages for
efficiency default are foreseen on the base of the difference between the
weighted average efficiency, measured at the heads available during test and
corrected to one of the three guaranteed heads in accordance with IEC, and
the guaranteed value. Deviations on single points shall not be considered.
The weighted average efficiencies ηw1, ηw2 and ηw3 of the prototype shall
be calculated according to the following formula. The average efficiency
ηwi shall be calculated according to the following formula:
ηwi = (∑j wi, j ×ηi, j) / (wi1 + wi2 +... + wi5)
where ηi,j is the efficiency in the i,j conditions and wi,j is the relevant
weight according to the following table.
Net Guaranteed Weights at the following fractions of

Heads Capacity capacity
i
[m] [MW] j=1 j=2 j=3 j=4 j=5
10/10 8/10 6/10 4/10 2/10
Max.
net 1 87.7 2.5% 5% 10% 5% 2.55
head
Rated
net 2 87.4 2.5% 10% 30% 5% 2.5%
head
Min.
net 3 85.1 2.5% 2.5% 15% 2.5% 2.5%
head
The prototype guaranteed weighted average efficiency ηw2 at rated net head
shall not be lower than 89%.
Moreover, the guaranteed efficiencies in the individual points for the

various net heads and the various fractions of the capacity at the
corresponding heads shall not be lower than the following values.
Net Guaranteed Guaranteed efficiencies at the following

Heads Capacity fractions of capacities
[m] [MW]
10/10 8/10 6/10 4/10 2/10
4
Max.
net 87.7 88.9 89.9 89.9 89.4 87.4
head
Rated
net 87.4 89.0 89.9 89.9 89.4 87.5
head
Min.
net 85.1 88.9 90.1 90.1 89.5 87.6
head
Values lower than 1.5% (one point five of percent) at any single point will
constitute an efficiency default condition.
6.4.1.2.2.5.2 Cavitation pitting guarantee

The Contractor shall guarantee the turbine runner against excessive pitting
due to cavitation for a period of 8,000 operating hours from the date it is put
into commercial operation in accordance with IEC 60609-2. Excessive
pitting is defined as the removal of metal from the turbine runner resulting
from the impact of cavitation at a rate in excess of the amount given by the
formula:
W = 0.6 x Z x B2 x t/8000
Where,
W = permissible weight of metal in kilograms
t = hours of operation
Z = number of runner buckets
B = inner width of runner buckets in meters
Should the loss of material in kilograms per ‘t’ hours during the basic
guarantee period exceed the permissible limit as per the aforementioned
formula, the Contractor shall repair and rectify by welding, grinding and
polishing. If after a further period of 8,000 operating hours, the runner again
has suffered loss of material in excess of the limit per ‘t’ hour, the runner
shall be rejected in which case the Contractor shall design, model test,
construct and supply free of charge to the Employer a new runner with
satisfactory cavitation performance.
6.4.1.2.2.5.3 Speed and pressure variations

The operation of the needles and jet deflectors shall be such as to
accommodate the changes in water supply with a minimum of oscillation in
the output of the unit, and with a pressure rise in the penstock that does not
exceed the unit design value, which is the maximum static head and the
pressure rise.
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6.4.1.2.2.5.4 Inertia constant

The inertia constant of the generating unit must be determined in
coordination with the generator supplier.
The Contractor shall verify and adjust his design to meet the limitations of
the speed and pressure transients and to comply with stability and regulation
requirements of the grid.
6.4.1.2.2.6 Model test of Pelton turbine

The Contractor shall perform turbine model acceptance tests on a scale
model to verify the guaranteed performances.
6.4.1.2.2.6.1 Applicable standards

The scale model tests shall be performed in compliance with the last
revision of the IEC 60193: Hydraulic turbines, storage pumps and pump-
turbines – Model acceptance tests.
6.4.1.2.2.6.2 Scale model characteristics

The scale model shall have a vertical axis and be fully homologous with the
prototype from the inlet of the distributor to the turbine chamber, including
all baffles, dummy deflectors and rode shafts, air vents and all other
obstructions to the runner discharge which shall be installed in the
prototype.
The reference diameter of the runner shall be at least 250 mm, the bucket
width shall not be smaller than 80 mm respectively.
Piezometer taps locations on the model should reflect and resemble the
prototype locations. The number and locations shall be established by the
Contractor in accordance with the IEC requirements and shall be to the
acceptance of the Employer.
6.4.1.2.2.6.3 Scale model test contents

The program of the scale model tests shall be adapted to conditions
encountered on the project, and shall include, but shall not be limited to the
following items.
The turbine performance tests shall determine:
· the turbine efficiency for the entire operating range

· the maximum efficiency of the scale model
· the maximum mechanical output power of the scale model
· the minimum mechanical output power of the scale model.
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The values obtained shall be scaled according to IEC 60193, Annex K,

Efficiency scale-up for Pelton turbines.
6.4.1.2.2.6.4 Turbine characteristics

The n11, Q11, T11 characteristics shall be determined on the scale model and
scaled up to prototype conditions.
Additionally, H, Q characteristics shall be provided for prototype

conditions.
6.4.1.2.2.6.5 Runaway speed tests

Runaway speed tests shall be carried out to determine the maximum
runaway speed that is attained in the operating range with respect to the
number of turbine nozzles in operation.
6.4.1.2.2.6.6 Preliminary scale model test report

The Contractor shall submit a preliminary scale model test report at least 30
days prior to the beginning of the acceptance test. This preliminary report
shall contain all the measurements, calculations and analysis of the results
for the tests described above.
6.4.1.2.2.6.7 Acceptance tests

When the Contractor has achieved acceptable model performance in
preliminary model tests, a scale model acceptance tests shall be performed
in presence of the Employer, on the Contractor’s premises or in an
internationally recognized independent laboratory.
The Employer shall be notified 30 days in advance of the final tests and may
witness final tests to verify the model performance.
6.4.1.2.2.6.8 Final model test report

The model test report shall include, but not necessarily be limited to, the
following:
· a description of the test equipment

· model test equipment and instruments with completely dimensioned
drawings of all model water passages
· the test procedures and data. performance curves and sample calculations
· analysis of the data pertaining to the final design, and model performance
characteristics
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· expected prototype performance characteristics; the prototype

performance data shall include curves of power output, discharge, and
efficiency for various needle openings and the runaway characteristics.
Final scale model acceptance tests report shall be submitted to the Employer
upon completion of the tests. It shall include, in particular, all the prototype
hill curves within the installation operating range, as well as all results of
the tests, calculations, measurements and observations performed.
6.4.1.2.2.6.9 Scale model preservation

The Contractor shall keep, with no modification, the turbine scale model
and the special equipment used to perform the tests, until the end of the
Defects Notification Period.
6.4.1.2.2.7 Vibrations
The unit vibrations shall be assessed according to the following standards:
Non-rotating parts:
· ISO 10816-1 (1995), Mechanical vibration, Evaluation of machine
vibration by measurements on non-rotating parts, Part 1: General
guidelines
· ISO 10816-5 (2000), Mechanical vibration, Evaluation of machine
vibration by measurements on non-rotating parts, Part 5: Machine sets in
hydraulic power generating and pumping plants.
Rotating parts (shaft vibrations):

· ISO 7919-1 (1996), Mechanical vibration of non-reciprocating machines,
Measurements on rotating shafts and evaluation criteria, Part 1: General
guidelines
· ISO 7919-5 (1997), Mechanical vibration of non-reciprocating machines,
Measurements on rotating shafts and evaluation criteria, Part 5: Machine
sets in hydraulic power generating and pumping plants
The Contractor shall guarantee that the vibration level of the unit, when new
and running under normal operating conditions shall not exceed values
defined by:
· zones A/B according to ISO 10816-5, Annex A

· zones A/B according to ISO 7919-5, Annex A.
The vibration guarantee applies to the generating unit, as a whole.
6.4.1.2.2.8 Critical speed

The critical speed of the combined turbine and generator shaft shall be
calculated by the Contractor and the first critical speed shall be at least 15%
above the maximum runaway speed.
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6.4.1.2.2.9 Frequency analysis

At least the following frequency analysis shall be made for the whole
generating unit:
Investigation Criteria
Water passage water hammer Compare with natural frequencies of
pressure wave: the turbine and generator components
F = V/4L (separately for the entire and unit rotating element.
length of the water passage and for
the intake up to the nozzles).
Dynamic unbalance of rotating parts: Compare with natural frequencies of
F = N/60 the turbine and generator components
and unit rotating element.
Runner bucket passing frequency: Compare with natural frequencies of
F = N*B/60 the turbine and generator components
and unit rotating element.
Runner bucket and nozzle passing Compare with natural frequencies of
frequency: the turbine and generator components
F = N*B*B’/60 and unit rotating element.
Nomenclature:
F= Frequency, Hz
N= Speed, rpm
B= Number of runner buckets
B’ = Number of nozzles
V= Velocity of pressure waves in water passages, m/s
L= Length of respective water passage section, m
6.4.1.2.2.10 Design requirements for main components
6.4.1.2.2.10.1 Distributor
A distributor shall be furnished extending from the downstream side of the
spherical valve dismantling joint to the nozzles. The distributor shall be
fabricated from welded carbon steel plates, in the minimum number of
sections dictated by shipping/transport clearance requirements. Bolting
flanges shall be provided on the branches to connect the nozzles to the
distributor.
A connection pipe with one expansion joint, as part of the spherical valve
supply shall be provided between the distributor and the spherical valve on
the dismantling pipe. The spherical valve shall be located upstream of the
longitudinal central line of the units. The connection pipe and the expansion
joints shall be made of high strength fine grain steel.
The design, construction and non-destructive testing shall conform to the

applicable requirements of the ASME Boiler and Pressure Vessel Code,
Section VIII, Division 2. Although the distributor shall be completely
9
embedded in concrete, the steel structure must be considered to act alone in

the stress analysis without any contribution from the surrounding concrete.
The distributor shall be furnace stress relieved after welding and before
machining. The welds shall be 100% tested by the ultrasonic method.
Adequate carbon steel plates shall be used for the distributor and all welding
edges shall be properly prepared.
The lower side of the distributor shall be provided with pads for levelling
during the erection. Jacks and tie down rods and turnbuckles for aligning,
levelling and holding the distributor in place while embedding in concrete
shall be supplied. The Contractor shall provide enough lifting provisions for
handling.
A set of four stainless steel piezometer taps at a point where flow conditions
will be most favourable for accurate measurement of pressure head shall be
provided. The piezometer taps shall be equally spaced around the
circumference of the inlet section and shall be located 45 degrees from the
vertical centreline. All necessary tubing, fittings, valves and air vents shall
be supplied.
The distributor shall have a drain outlet for water removal after the turbine
shut off and by-pass valves are closed. A manually operated plug or gate
valve shall be provided which shall be arranged at an accessible location.
The valve, drain line and fittings shall be adequate to fully discharge all
leakage water under maximum hydrostatic pressure.
A combined air and vacuum relief valve shall be provided at the highest
point of the distributor or inlet section. The air valve shall function as an air
vent when the distributor is filling and shall function as a vacuum breaker
during unwatering of the distributor. The valve body and all interior parts
shall be designed to withstand the turbine design head.
The valves shall be supplied complete with piping, fittings and drain line.
The distributor shall be furnished with a pressure switch and a float-
operated switch for mounting adjacent to the air release valve. The switch
shall be incorporated in the turbine main inlet valve control circuits to
prevent opening of the main inlet valve until the distributor is filled with
water. Each switch shall be equipped with two contacts, which shall act
when the distributor is filled with water.
The complete distributor shall be pressure tested under a pressure of 1.5

times the maximum design pressure at site after completion of erection and
before embedding in concrete. The pressure test heads for each nozzle
flange and the distributor inlet together with all required tools, seals, jacks,
bolts and nuts shall be provided. The hydraulic pressure pumping
equipment, gauges, valves and piping shall be supplied to perform the
test. The embedding in concrete shall be under a pressure of 0.75 times the
maximal working pressure.
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6.4.1.2.2.10.2 Turbine cover

The turbine cover shall be stationary, whereas, removable parts shall be
flanged to the upper turbine housing. It shall serve as support and casing for
the turbine guide bearing. The cover shall have adequate strength and
rigidity to transmit safely all forces from the guide bearing to the runner pit
housing without undue stresses or deformations.
The turbine cover shall support the combined weight of the runner and
turbine shaft, when disconnected from the generator shaft.
The turbine cover shall be designed in a way that easy inspection,

adjustment, maintenance and dismantling of all parts located inside and
attached to the cover is possible. The lower flange of the turbine shaft shall
pass through the cover, when the guide bearing is dismantled.
The lower part of the turbine cover shall be provided with stiffeners and
fixed on the runner pit housing.
6.4.1.2.2.10.3 Turbine housing

The turbine housing shall consist of:
· upper turbine housing (runner pit housing)

· lower turbine housing (runner pit liner)
· accessories, like runner removal door, manhole, service platform together
with supporting stand, runner handling cart, etc.
The upper and lower turbine housing shall facilitate the efficient discharge
of the water from the turbine runner.
The upper and lower turbine housing shall be designed for a suitable
number of sections required and practicable for shipping and transportation
to site. The housing cover shall be supplied in a minimum of two (2) or
more sections. The housing shell joints shall be prepared for field welding.
Pit housing and pit liner shall be assembled on site by welding and
embedded in concrete.
2.2.10.3.1 Runner pit housing

The upper turbine housing, serving as support for the turbine cover with
guide bearing, shall be fabricated of plate steel. It shall have adequate
strength and rigidity to support the floor of the turbine shaft pit, the turbine
cover with guide bearing and associated parts under all operating conditions
including runaway speed.
The steel/concrete structure shall support the dead weight of the turbine
shaft and the runner when the shaft is disconnected from the generator
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shaft, the deflector shaft bearings, the needle control restoring and pipe
connection and other components as necessary. The design shall also
consider the lifting of the nozzles and of the runner by using lifting eyes
provided at the housing ceiling.
The housing shall be strongly reinforced on the outside by means of suitably

shaped structural steel and adequate means shall be provided for secure
anchoring to the 1st stage concrete. The reinforcement shall be designed to
withstand all loads while the concrete is being placed.
All openings provided for erection and alignment, inspection, service

connections, jet deflector shafts, etc., must be closed in a suitable manner.
The housing shall be provided with all necessary eyebolts, etc. to facilitate
attachment of hoisting equipment for the purpose of erection, maintenance
and dismantling of nozzles, deflectors and runner.
The upper turbine housing, together with the pit liner, turbine distributor,
nozzles, etc. shall be completely assembled and match-marked in the shop
and shipped in as few sections as practical.
2.2.10.3.2 Runner pit liner

The runner pit liner shall be of welded construction and shall reach down to
the inspection platform and shall terminate at the point of the tailrace ceiling
on the downstream side.
The above requirement for reinforcement rigidity, anchoring in the concrete,

etc. specified for the upper turbine housing shall also be applicable for the
pit liner.
Enough levelling screws and holding-down bolts with turnbuckles shall be

provided to permit centring, levelling and secure fixing of the liner in proper
position during concreting around.
The pit liner shall be equipped with adequate baffles to dissipate the energy
of maximum continuous discharge of the jets under maximum head.
2.2.10.3.3 Additional provisions

The turbine housing shall be equipped with the following:
· Lifting eyes, to handle nozzles, deflectors and the runner during

replacement. The holes shall be filled with corrosion-resistant plugs
during turbine operation.
· Provision for air piping system shall be sized to supply enough air to the
turbine at maximum load.
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· A drain connection together with all fittings, gate valve(s) with stem and
stools, piping gaskets, flanges, bolts etc. all way along the length of
powerhouse and up to the discharge level shall be provided.
2.2.10.3.4 Service platform

The platform in the runner pit shall be designed to allow convenient access
to the runner, deflectors and nozzles for inspection, maintenance and
dismantling, which shall be done within the shortest possible time.
The platform shall consist of steel beams, floor gratings and steel support in
the runner pit and shall be designed to support the runner handling cart. The
beams have to withstand the impact of the water discharge from the
deflectors and runner without excessive vibration. Special provisions shall
be made for corrosion protection of the beams and other parts of the
platform which are installed permanently in the runner pit. The floor
gratings shall be galvanized.
2.2.10.3.5 Runner removal door

A runner removal door shall be provided in the runner pit liner. The inside
surface of the door shall be flushed with the turbine housing. The clear
opening shall allow clear passage of the runner and cart.
The door shall be hinged in self-lubricated bronze bearings and supported

by rollers with roller bearings.
Suitable rubber seals shall be provided at the bolted joints to avoid water
leakage under the most severe operating conditions.
A small access door with a clear opening of 0.80 m height and 0.80 m width
shall be integrated in the runner removal door. This door shall also be
equipped with door-hinges, rubber seals and bolted joints. The access door
shall be arranged at an elevation convenient to enter the service platform.
2.2.10.3.6 Runner handling cart

A runner handling cart shall be provided to transport the runner into and out
of the runner pit housing. The cart shall be equipped with all necessary
facilities to dismantle, lower, remove and replace the runner. Adequate
lifting devices, complete with accessories, shall be provided to facilitate the
handling of the runner.
On the top of the service platform, rails shall be provided to accommodate

the runner handling cart. The rails shall be provided with all necessary
anchoring devices and with cart stops at each end. The rails shall extend
past the runner removal hatch for handling by the powerhouse crane.
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6.4.1.2.2.10.4 Injector system

The turbine shall be equipped with six nozzles of the straight-flow type with
built-in servomotors, each operated by pressure oil from the governor
pressure oil unit.
2.2.10.4.1 Operation requirements

Electronic means in the governor system shall be provided to permit
selection of only one nozzle or any combination of nozzles in normal
operation. The selection shall consider the optimum use of the available
water.
The operation of the needles and jet deflectors shall be such as to

accommodate the changes in water supply with a minimum of oscillation in
the output of the unit, and with a pressure rise in the penstock that does not
exceed the unit design value, which is the maximum static head, and the
pressure rise.
The needles shall be balanced by springs and other means to obtain closing
tendency from fully open to fully closed needle position in the event of
failure of governor oil pressure under the applicable operating heads.
2.2.10.4.2 Nozzle design

The nozzle body and nozzle head shall be made of cast steel or welded steel
plate normalized and tempered. A flange connection shall be provided
between the nozzle pipe and nozzle body.
The nozzle pipe shall be bolted to the manifold branch pipe. Provisions shall
be made to facilitate alignment, inspection, maintenance and dismantling of
parts (e.g. replacement of seat rings, needle tips, etc.) and for removal of the
complete nozzle without dismantling the runner.
The nozzle body shall be provided with a removable Stellit or HVOF seat
ring at the point of final water discharge. Removal and replacement of the
seat ring shall be possible without dismantling the runner, jet deflector or
nozzle body.
The needle shall be made of GX4CrNiMo13-4 steel with hard coating

HVOF. Location of the split plane shall be upstream of the zone of notable
wear of the needle surface. Removal and replacement of the tip shall be
possible after dismantling of the nozzle seat ring without dismantling further
parts of the turbine. The leakage of a closed needle under the maximum
operating head and without governor oil pressure shall not exceed 0.1 l/min.
The selection of GX4CrNiMo13-4 or Stellite for the seat ring and needle tip
shall combine the feature of high resistance against abrasion with the
possibility of re-machining of deteriorated surfaces. The needle arrangement
14
shall consequently be designed to allow the re-adjustment of the needle

stroke to the initial value upon re-installation of re-machined seat ring and
needle tip.
2.2.10.4.3 Design of injector servomotor

The servomotor shall be of the oil pressure actuated, single-acting type and
shall have enough capacity to move the needle through a full opening
stroke. Closing of the servomotor shall be by means of spring force. The
spring shall ensure safe and reliable closing of the servomotor at all
operating conditions from maximum opening to fully closed position. The
servomotor design shall ensure reliable operation in required time at
maximum head and minimum governor oil pressure as well as high and
reliable positioning accuracy.
Packings and seals of needle and injector servomotor shall be adequately

dimensioned and designed. As far as possible, packings of the automatic
pressure-actuated type shall be used.
Suitable means shall be provided to prevent water from entering into the oil
system and vice versa.
Care shall be taken to protect the needle guides against erosion and wear,
caused by fine-grain sand.
Electro-magnetic feedback transducers for the needle stroke shall be

provided for each nozzle.
Pipe sleeves or ducts to route the piping and restoring linkage from the
nozzles to the shaft pit floor shall be of corrosion-resistant material.
A hydraulic locking system by which the servomotor can be held securely in

closed position shall be provided for each needle servomotor.
6.4.1.2.2.10.5 Jet deflectors

All injectors shall be equipped with deflectors. The deflectors shall be
actuated by deflector servomotor(s), controlled by the governor.
The jet deflector shall be able to deflect the jet completely within 1.5
seconds. In order to reduce the loss of energy and wear of the deflector, for
small load changes the jet shall be controlled only by the needle.
The deflectors shall be made of forged steel or casting steel with martensitic
stainless-steel overlay as per standard practice.
The cutting edge of the deflector made of a stainless steel particularly

resistant against erosion shall be replaceable, to allow quick repair on site.
15
The deflector shall withstand safely the maximum continuous nozzle

discharge at maximum head.
The deflector shall be firmly attached to the deflector shaft. The shaft shall
be supported by self-lubricated bearings in the turbine cover and at the
nozzle body.
The design of the deflector and operating mechanism shall permit removal
of the deflector without extensive dismantling of other parts.
A mechanical position indicator for each deflector shall indicate the setting
of the deflector cutting edge.
2.2.10.5.1 Design of deflector servomotor(s) and operating mechanism

The servomotor(s) shall be of the single-acting type, controlled by the main
distribution valve in the governor actuator. The capacity of the servomotor
shall be enough to operate the deflectors under all conditions of head and
load with minimum oil pressure. The closing of the deflectors shall be done
by spring force to ensure closing in case of oil pressure failure. The
movement of the servomotor piston shall be cushioned on both ends of the
stroke.
An effective drainage of leakage oil from the servomotors to the governor

sump tank shall be provided.
The deflector operating mechanism shall permit individual adjustment of

each deflector. All joints shall be provided with self-lubricated bearings.
Suitable protection covers, etc., shall be supplied to avoid external impacts
on the operating mechanism. A suitable mechanical locking device,
dimensioned to withstand the full servomotor force, shall permit the
padlocking of the servomotors in closed and open position.
Replaceable orifices to adjust the period of time for full opening or closing
stroke shall be provided. The time shall be independently adjustable for both
stroke directions.
6.4.1.2.2.10.6 Turbine runner

The Pelton turbine runner with buckets shall be integrally cast or fully
forged and finished as one piece of GX4CrNiMo13-4 and suitable for field
weld repair.
The design and manufacture of the runner shall be robust in size and
strength to withstand safely the centrifugal forces and hydraulic jet forces on
the buckets under the severe operating conditions without exceeding the
allowable stresses and undue vibrations. The case of emergency shutdown
under maximum head at runaway speed, and all nozzles open should also be
considered. As proof of his ability, the Contractor shall submit typical
16
mathematical calculation supported by Finite Element Analysis before start

of runner manufacturing.
All runner surfaces subjected to high water velocities and alternating

stresses shall be carefully ground to smooth and accurate contours checked
by templates; surface quality according to Quality Sheet of CCH 70-3
(Cahier des Charges Hydrauliques, June 1996).
The surfaces shall be free from any defects. The dividing splitters of all
buckets shall accurately match the plane of the nozzle centre lines. The
surfaces on the back of the buckets which are in tangential contact with the
jet shall also be smoothly ground.
The finished turbine runner shall be statically balanced according DIN ISO
1940/VDI 2060 in the Manufacturer's workshop before shipment.
The Contractor shall be responsible for the final alignment and balancing of
the combined turbine generator rotor according to NEMA publication LG3
latest edition.
The fastening of the turbine runner on the turbine shaft shall be made in
such a manner that the transmission of the driving torque is guaranteed
under the severest working conditions and that the runner can be easily
removed. The coupling shall allow the interchange of the runners without
re-machining and additional adjustment of the coupling. Radial keys for
transferring the torque are acceptable, but the offered coupling shall be
described in detail. A sole friction coupling shall not be acceptable. The
coupling bolts and nuts shall be protected against the operating water by a
welded cover-ring, which shall also close the concentric hole of the turbine
shaft.
All necessary coupling bolts and accessories shall be supplied together with
suitable locking devices. The pre-stressing of the bolts shall be carried out
by a hydraulic jack.
6.4.1.2.2.10.7 Turbine shaft and flange
2.2.10.7.1 Material
The turbine shaft shall be made of open-hearth carbon or alloy steel with
integrally forged upper and lower flanges for bolting to the generator shaft
and the runner respectively. The shaft shall be subject to careful heat
treatment after the forging process.
The shaft shall have a centre hole, not less than 150 mm in diameter, bored
axially throughout the entire length. The machining of this hole shall be
sufficiently smooth to permit visual inspection of the metal in the interior of
the shaft.
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2.2.10.7.2 Dimensioning
The shaft shall be of robust size to operate in combination with the
generator shaft safely at any speed including runaway speed without
detrimental vibration or distortion. Operating at normal speed and maximum
output, the stress in the highest stressed cross section shall not exceed 25%
of the yield strength of the shaft material. For temporary overloads
exceeding the rated output, the unit stress shall not exceed 50% of the yield
strength.
The shaft and coupling dimensions shall be sufficient to safely transmit the
torque and bending load due to the maximum radial thrust at the most
unfavourable combination of jet impacts.
The Contractor shall coordinate the criteria about overall design, load
calculation and critical speed. The relevant criteria and the determination of
maximum starting torque, short-circuit forces, etc. shall be submitted in the
form of calculation to the Employer for approval before start of
manufacturing.
2.2.10.7.3 Coupling
All coupling dimensions shall conform to ANSI B 49.1, "Shaft Couplings,
Integrally Forged Flange Type for Hydroelectric Units".
The coupling bolts and nuts for the connection of the generator shaft to the
turbine shaft, suitable metal guards to cover the bolts and nuts and all
wrenches and special equipment necessary for shop and field assembly of
the couplings shall be supplied by the Contractor. The coupling bolts shall
be provided with locking devices and shall have dimensions and tolerances
in accordance with ANSI Standard B 49.1, Table 2, or an equivalent,
approved standard.
Tapped holes for jacking screws or other devices shall be provided for
separation of the coupling joint during disassembly.
If fitted both are used for transmitting the driving torque, the coupling bolt
holes rough drilled on "short measure" shall be reamed during site assembly
to "real measure". This work shall be carried out and the necessary tools
(reamer and equipment for parallel guiding of reamer) shall be delivered by
the Contractor.
The amount of shaft run-out shall be checked and shall not exceed the
tolerances recommended for shafts as per NEMA standard publication no.
5.1, paragraph 63, „Vertical Hydraulic-Turbine Generator Shaft Run-Out
Tolerances Shop Check “.
All design and manufacturing works shall be coordinated with generator

supplier.
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2.2.10.7.4 Matching and tolerances

The turbine shaft shall be free from flaws and imperfections and shall be
accurately and smoothly machined all over and polished at bearing, seal
surfaces and the coupling periphery for alignment checks. The shaft run out
shall be checked by rotating the finished shaft in a lathe or aligning device,
and shall not exceed the tolerances recommended for turbine shafts in the
ANSI/IEEE Std. 810 "Standard for Hydraulic Turbine and Generator
Integrally Forged Shaft Couplings and Shaft Run out Tolerances" or by
NEMA Standards Publication No. 5.1, Paragraph 63, "Vertical Hydraulic
Turbine Generator Shaft Run-out Tolerances Shop Check".
During run-out tests highest/lowest axial point of flanges shall be clearly

marked so that it can be assembled with the best fitting point of mating
flanges.
2.2.10.7.5 Lifting clearance and positioning

Vertical clearance shall be provided in the turbine bearing to a height
required for dismantling of the generator thrust bearing. A collar or other
means shall be provided to support the turbine shaft with coupled runner
when the turbine shaft is disconnected from the generator shaft.
6.4.1.2.2.10.8 Turbine guide bearing

The turbine guide bearing shall be of the multi-segments Babbitt-lined, self
aligned and self-contained lubricating type capable of operating
continuously at any speed from 50% to 110% of rated speed; for 30 minutes
at any speed from 110% of rated to maximum runaway speed. In addition,
the bearing shall be guaranteed for correct operation for 15 minutes
operation without cooling water supply and for 5 minutes without oil
circulation.
Cooling shall be accomplished by circulating the oil through external

oil/water heat exchangers either by self-pumping or using two (2)
circulating pumps, one as the service pump and the other one as a standby
pump.
The heat exchanger shall be shop-tested at twice the maximum operating

pressure. A flow relay with independent contacts for interlocking with the
automatic starting sequence and to provide an alarm signal at low flow shall
be installed in the cooling water discharge line.
For the bearing temperatures the Contractor shall guarantee the following
values:
Temp (°C)
Max. Permissible Alarm Emergency Shutdown
Guide Bearing Pads 70 75 80
Bearing Oil 60 55 60
19
An oil reservoir shall be provided around the bearing from which the oil
shall circulate through the bearing. The major portion of the bearing shall be
continuously immersed by the oil to provide initial lubrication when starting
the unit.
The volume of the reservoir shall be determined in such a way that the
lubrication oil shall not circulate more than 15 times per hour.
The lubrication oil system shall be designed to be enough under all

conditions of operation and shall allow safe shutdown of the unit, if the
cooling water flow has failed.
The design of the coolers shall permit easy maintenance and cleaning during
turbine operation without unnecessary loss of time and leakage water. The
cooling pipes shall be of corrosion resistant material.
A suitable sealing between shaft and bearing housing shall be provided to

avoid oil vapour leaking through the upper part of the bearing housing.
6.4.1.2.2.10.9 Acoustic turbine flow meter

An acoustic flow meter shall be provided for each turbine to indicate flow
over the long term to give input for flow integration and on-line efficiency
monitoring as further specified in Schedule 1, Annex 1, Part B2.25
Waterway Instrumentation. The Contractor shall supply and install all
equipment necessary for the above functions unless specifically stated
otherwise.
2.2.10.9.1 Type and arrangement

The acoustic system shall comprise piezoelectric transducers mounted in
pairs to form at least two crossed paths. Locating and installation of the
transducers shall be done by the Contractor. Mounting shall be such that the
transducer can be removed through a valve system with the penstock/branch
under pressure.
2.2.10.9.2 Accuracy
The acoustic system shall have proven accuracy of <+1.0% and shall be
suitable for conducting the site efficiency tests in accordance with IEC
60041.
The turbine flow meter electronic system shall automatically compensate for
changes in water temperature. The Contractor shall indicate any
penstock/branch taps to meet this requirement. These taps shall be provided
by the Contractor itself.
20
2.2.10.9.3 Indication and alarms

The following indications and alarms shall be provided on the turbine Flow
Meter Panel (FMP):
· FMP
· Back power supply operating
· Power systems failure
· Transducer failure (for each transducer)
· Internal Fault
· Over velocity trip activated
· Unit control board (UCB)
· Turbine flow (for this the Contractor shall supply a suitable flow
indicator for mounting in the UCB).
Signals for:
· Turbine flow meter general fault alarm

· Over velocity emergency shut down
· Differential flow emergency shut down.
6.4.1.2.2.10.10 Ventilation system

Adequately designed and arranged openings with water deflecting baffles
for permanent air admission shall be provided on the runner pit liner and be
connected to ventilation pipes embedded in the surrounding concrete.
6.4.1.2.2.10.11 Control and safety devices

The turbine and its auxiliary equipment shall be furnished with all
instruments, controls, cables, etc. necessary for manual and automatic start-
up, shutdown and supervision of the operation as stipulated in this section.
All conditions of importance for operation shall be monitored. In case of a

failure, an alarm signal shall be given, and if a dangerous operating
condition occurs, emergency shutdown of the machine shall be initiated.
The supply shall include but shall not be limited to the devices and
instruments required for supervision and manual and automatic operation in
accordance with the start-stop-sequence diagram of the units.
A precision pressure gauge, with pulsation damping blow-out cock and

shut-off cock to measure the turbine inlet pressure shall be installed in the
unit panel. A change-over valve shall allow to measure the water pressure of
the spherical valve.
A mechanical oil-hydraulic overspeed device shall directly initiate deflector

and injector closing and spherical valve closing, independent from any
electrical power supply.
21
A speed switch on the turbine shaft shall monitor the maximum admissible
overspeed.
Other control devices shall include the following instruments:
· oil level indicator, to display oil level of guide bearing of turbine locally
· oil level relay for guide bearing, with upper and lower levels electric
contracts
· temperature monitoring and measuring device for guide bearing pads.
each pad is fitted with one resistance type temperature sensor, in which
two sets are connected to the electric contact thermometer via the
terminal board on the turbine pit wall with output of on-off quantity and
double upper limits; the others are connected to the unit RTU
· oil temperature monitoring and measuring device for the turbine guide
bearings. Three resistance type temperature sensors shall be provided, in
which one set is connected to the electric contact thermometer via the
terminal board on the turbine pit wall with output of on-off quantity and
double upper limits; the others are connected to the unit RTU
· monitoring of needle position to detect wear on needle tips and seat rings
of the injectors.
6.4.1.2. Governors
6.4.1.2.3.1 General
The governor shall be of the PID type with electric feedback between the six
(6) injector servomotors and the digital governor, as well as between the
deflector servomotors and the digital governor.
The turbine governor shall perform the following governing tasks for the
regulation and control of the generating units:
· speed control (PID) at no-load, isolated operation and network operation

· automatic start and stop sequences, including automatic synchronisation
· power-frequency control (PI) with speed droop
· opening control (PID) without frequency influence
· flow control
· manual direct position control of the turbine needle and deflector
· load sharing between units in “joint control” mode
· quick shutdown in case of mechanical failures
· emergency shutdown in case of electrical failures.
Design and performance of the governors shall be in accordance with IEC

Publication No. 60308, International Code for Testing of Speed Governing
Systems for Hydraulic Turbines is specifically applicable for design and
performance of the governor.
22
6.4.1.2.3.2 Design requirements
6.4.1.2.3.2.1 System and plant conditions

The design of the governing system and relevant guarantees shall be based
on the following conditions:
Power supply: 400 V / 230 V, 50 Hz

110 V DC for DC motors
110 V DC for power/control (IT system)
Rated frequency: 50 Hz
Rated turbine speed: 300 rpm
Turbine design pressure: 4.5 MPa
Turbine power output: 87.4 MW
Rated generator capacity: 100 MVA
Generator flywheel effect GD²: to be determined in coordination with

generator supplier
Max. operating pressure of 18 MPa

governor oil system:
Self-regulation factor for determination of governor stability: 1.0
6.4.1.2.3.2.2 Performance criteria of PID governor

The parameters shall meet the requirements for stable operation of the unit
and shall be continuously adjustable within the following ranges:
a) Speed control mode:
Setting range of set point 0 – 110%
Permanent speed droop bp: 0 – 10%
Temporary speed droop bt: 1 – 200%
Integral action time Td: 0.1 – 100s
Derivative gain KV: 0.0 – 10.0
Derivative action time TV: 0 – 10s
Required total governing system dead time (measured with a 0.25s

step load change of 10% rated output)
b) Power-frequency control mode:
23
Setting range of set point 0 – 110%
Permanent speed droop bp: 0 – 10%
Temporary speed droop bt: 1 – 3000%
Integral action time Td: 0.1 – 600s
Required total governing system dead time (measured with a 0.25s

step load change of 10% rated output)
In opening control mode opening limitation shall be adjustable in a range of

0 – 110%.
Opening and closing time of both, nozzle and deflector, servomotors shall
be adjustable. However, the minimum closing and opening time of the
governor shall be in accordance with the requirements in the turbine
specifications regarding speed and pressure variations.
6.4.1.2.3.2.3 Digital governor

The digital governor shall be of the digital programmable type. The
equipment shall include all necessary devices for local, manual control and
remote control.
The Contractor shall:

· use the same computer hardware (same make and type) as for the Control
and Monitoring System (CMS) in the cavern, GIS building and Head
Works building
· The computer hardware shall have hot redundancy with redundant CPUs
and shall provide instant process correction when a failure is detected and
provide a seamless transfer of the I/O during the changeover between
processors. This changeover shall be reported, including fault caused the
changeover to the CMS.
· use the same software platform for the turbine governor as for the CMS
in the cavern, GIS building and Head Works building.
6.4.1.2.3.2.4 Speed measuring system
· Speed monitors:
Three (3) fully independent speed measuring systems shall be provided:

i. two (2) inductive proximity sensor(s) activated by toothed wheel on
the generating unit shaft including a speed detection switch
adjustable in the speed range of 0 - 200 % of nominal speed each
sensor.
ii. one (1) measurement of the residual voltage of the voltage
transformer.
24
The speed measuring system for governing purposes shall respond to

frequency deviations down to 0.002 Hz. The controller shall accomplish
automatic speed control in the range of 85% to 115% of the rated speed.
The speed measuring system for monitoring and supervision purposes

shall be independent from the speed measuring system for governing
purposes
Sufficient adjustable speed contacts as necessary for the control system

design shall be provided.
· Creep detection:
Creep detection shall be implemented detecting any kind of rotational

movement of the unit shaft line.
· Centrifugal over speed safety device

A centrifugal over speed safety device shall be provided and arranged for
setting at 5 per cent above maximum momentary speed on full load
rejection with normal governor action. The device trip switch shall be
snap-acting at its operating speed and the setting shall be adjustable and
shall be unaffected by vibration of the generator at the operating speed.
The over speed safety device shall be mounted in a readily accessible
position and shall be provided with a transparent cover. The device itself
shall be capable of being tested separately without requiring the
generating Unit to be run to over speed. The overspeed device shall
include a limit switch for alarm indication and shutdown of the unit with
subsequent closing of the spherical valve (MIV).
2.3.2.4.1 Needle control

Six (6) coil-operated hydraulic valves operating as the electro-hydraulic
converters shall act as pilot valves on the needle distribution valves.
The six (6) distributor valves shall control the needle servomotors. Each
distribution valve shall be equipped with a feedback transmitter. The
converters shall be connected to the digital governor by electric wiring for
transmission of controlling signals and feedback signals.
Signal instruments and the wiring shall be redundant. For safety reasons, the
converters shall be designed for closing tendency.
Pilot valves and distributing valves shall be connected to the needle

servomotors and to the air/oil accumulator of the oil supply system by
means of stainless-steel pressure pipes.
2.3.2.4.2 Deflector control

The coil-operated hydraulic valve operating as the electro-hydraulic
converter shall act as pilot valve on the deflector distribution valve.
25
The distribution valve shall control the deflector servomotors. The

distribution valve shall be equipped with a feedback transmitter.
The converter and the feedback transmitter shall be connected to the digital
governor by electric wiring. The converter shall be designed for closing
tendency.
Oil piping shall be made of stainless steel.
2.3.2.4.3 Digital governor board

The digital governor board shall be equipped with:
· the digital governor
· Redundant 110VDC power supply:
The supply utilized by the digital governor shall be from the Station
DC battery supplies.
2 feeding power lines from separate battery sources, protected with
suitable MCBs, merged together with coupling diodes.
· DC/DC converters: internal low voltage DC supply (e.g. 24VDC)
shall be created redundantly by two DC/DC converters from the
110VDC power supply of the digital governor board merged
together with coupling diodes.
· Communication devices (network switches, input/output modules,
PLCs,…) shall have redundant power supply (2 feeders from
different MCBs). Failure of one DC battery supply or failure of any
DC to DC convertor shall not affect the supply to the governor
equipment, decentral periphery or to the instruments and controls.
· Terminals where all external cables shall be connected to. Knife
terminal shall be foreseen. 20 percent spare terminal shall be added
to the design.
· 19” rack fiber optic splice boxes. All fiber optic cables from extern
shall be spliced into these boxes. One box each cable. All fibers of a
cable shall be spliced.
· two (2) network switches. Fiber optic patch cables shall connect the
2 network switches. The plant bus fiber optic shall be connected to
the remaining fiber optic sockets for redundancy purpose. Each CPU
of the redundant PLC shall be connected to one of the switches.
· suitable monitoring system. All MCBs, DC/DC converters, power
supply (relay contact), communication modules, network switches
shall be monitored and supervised by the digital governor and shall
be made available to the CMS. Suitable alarms shall be created in a
way to enable operator to track down the fault in a minimum of time
The Contractor shall:

· integrate the computer hardware of the digital governor via 2
network switches located in the digital governor board into the plant
bus of the power plant (integration into ring). Each CPU of the
redundant controller shall be connected to a different switch for
redundancy reason.
26
· implement communication to the CMS via Ethernet based protocol,

preferable IEC 60870-5-104.
· provide hardware (trip request and trip reception) and software
(detailed information) interface to the CMS.
· provide a Human Machine Interface (HMI) enabling the operator to
operate the digital governor in local mode (automatic and manual).
all events/alarms/trips shall be displayed.
· provide “local/remote” switch to transfer control of the digital
governor to CMS. In “remote” the digital governor switches
automatically to AUTO Mode. In local the digital governor may be
switched to manual mode.
6.4.1.2.3.2.5 Pressure oil system
· General
Oil pressure levels of the pressure oil system shall be defined by the
Contractor.
The oil pressure system shall be equipped with nitrogen filled piston type
accumulators. The capacity for the accumulators shall be three (3) full
servomotor strokes (close-open-close) of nozzle and one (1) full opening
of deflector without pumps active at lowest accumulator pressure level
and highest accumulator oil level.
The accumulators shall be delivered nitrogen filled and equipped with a

complete nitrogen filling system.
· The hydraulic pressure system (HPU)
The HPU shall include a tank, pumps, any required valve for the safe
operation of the hydraulic system (control valves, emergency shutdown
valves, manual shutdown valve and pressure relief valves), accumulators
with nitrogen bottles, all necessary instrumentation, etc.
Duplicate AC motor driven pumps shall be provided for normal and

standby duty respectively, each rated 100 percent capacity. Each motor
and pump shall be complete with its own strainer, safety valve, non-
return valve and stop valve so that either pump with its accessories may
be withdrawn from service without affecting the other.
All necessary piping, safety fittings and accessories such as safety valves,
pressure gauges and control devices with control switches, meters,
counters etc shall be included.
· Control and Instrumentation (C&I)
27
The HPU shall be controlled, operated and monitored by the CMS. A

local control board attached (or closely located) to the HPU shall house
the decentral periphery (input/output modules of the CMS).
All instrumentation and actuators of the HPU shall be connected to the

local control board.
Trip relevant signal (e. g. oil level) shall be redundant in the following
manor:
· multiple PT100 sensors at close position
· level switch (binary, tipping when closed) AND level sensor
(4…20 mA, trip created internally)
· pressure switch (binary, tipping when closed) AND pressure sensor
· flow switch (binary, tipping when closed) AND flow sensor
(4…20 mA, trip created internally).
6.4.1.2. Main Inlet Valves
6.4.1.2.4.1 Scope of supply

The scope of supply shall include three (3) spherical valves, each consisting
of the following parts:
· the complete spherical valves and servomotors

· the bypass and all other piping required
· aeration valve
· outlet pipe
· inlet pipe (upstream side) and drain line
· the control and auxiliary devices
· one blind flange.
6.4.1.2.4.2 Type and construction

A main inlet valve shall be provided for each turbine complete with an
upstream make-up pipe, downstream dismantling/expansion joint, by-pass
valve and all associated operating equipment.
The main inlet valve shall be at the spherical type designed for minimum
head less and disturbance and having a net cross-sectional area at the throat
not less than that of the distributor inlet.
Under all operating conditions the main inlet valves shall be free from
excessive vibration and noise. Acceptable levels of vibration under all
operating conditions shall be guaranteed.
28
The main elements of the valve shall be of cast, forged or fabricated steel. If
fabricated construction is used, all welds stressed directly or indirectly by
pipeline pressure shall, to the maximum extent practicable, be full
penetration butt or tee butt welds. All wearing parts shall be replaceable and
these in contact with water shall be of corrosion resistant material or be
sleeved with corrosion resistant material.
Sealing shall be achieved by solid metal contact between the rotor seals and
the body seats. There shall be two seals hydraulically operated by pipeline
pressure, a downstream located service seal comprising a stainless-steel
sealing ring against a stainless-steel body seat and a similar designed
upstream located maintenance seal. It shall be possible to adjust the sealing
elements without major dismantling of the valve. Both the service and
maintenance seals shall be double acting.
The trunnion and servomotor connecting rod bushes shall be of the self-
lubricating type. Provision shall be made to prevent dirt and foreign matter
from entering the top of the servomotor.
The seals, seats, trunnion bushes and trunnion glands shall be so arranged
that they can be removed or installed without dismantling the valve bodies
or removing the valves from the penstock when the penstock is drained.
Each valve shall be provided with manually operated scour valves and
appropriate piping for the services and maintenance seals. These scour
valves shall be located at the lowest point of the valve body.
Each main inlet valve shall be fitted with an air release valve mounted on
the highest point of the valve body. The air release valve shall be provided
with appropriate piping and controls.
Each inlet valve shall be provided with an access platform to enable

inspection and maintenance of the valve trunnions and operating equipment.
6.4.1.2.4.3 Operation
The valve shall be capable of closing against any flow up to and including
that due to free discharge at the outlet of the valve with maximum flood
level in the headpond.
Each valve shall be operated in the opening direction by an oil pressure

servomotor and in the closing direction by weights. The oil pressure for
operating the main inlet valve shall be provided by a unit oil/nitrogen
accumulator, which is supplied with high-pressure oil from a unitised
pumping set.
The operating servomotor/s shall be separately mounted on the main inlet

valve floor to avoid transference of operating forces to the main inlet valve
components.
29
The servomotor/s and its mounting, pressure piping and control valves shall
be adequate for the pressure produced in the servomotor with the most
adverse conditions of unbalanced closure against free discharge.
A manually operated mechanical lock for securing each main inlet valve
rotor in the closed and open position shall be provided and shall be of
adequate strength to resist both the thrust of the servomotor in the opening
direction and the force from the weights in the closing direction. The locks
shall embody provision for padlocking in the inserted and withdrawn
positions.
A system shall be provided for automatically collecting and returning to the

pumping set’s sump tank any oil leakage past the servomotor piston and, if
fitted, glands.
The initiation of opening of the main inlet valve shall be interlocked with
the establishment of a pressure in the distributor substantially equal to
pipeline pressure and that the maintenance seal is in the “off” position.
The inlet valve opening and closing times shall be independently adjustable,
but the adjustments shall be of a form that cannot be readily or inadvertently
be altered. In the interests of minimising the time necessary to shut down in
an emergency, the closing times shall be the minimum consistent with safe
operation.
6.4.1.2.4.4 Pressure oil system

A unitised pressure pumping set shall be provided to supply pressure oil to
the servomotor operating valves and nitrogen/oil accumulator by duplicate
pumps located on the oil tank.
Each unit pressure accumulator shall have sufficient active nitrogen and oil
storage at normal minimum oil level and pressure to complete an opening
and closing stroke of the main inlet valve without the pumps operating.
Duplicate a.c. motor driven pumps shall be provided for normal and standby
duty respectively, each rated 100 percent capacity. Each motor and pump
shall be of sufficient capacity to recharge a unit accumulator to normal
maximum level and pressure within 5 minutes after an opening stroke of
each main inlet valve. Each motor and pump shall be complete with its own
strainer, safety valve, non-return valve and stop valve so that either pump
with its accessories may be withdrawn from service without affecting the
other. The control of the pumps shall be by level switches on the
accumulators.
The oil pumping system shall be complete with sump tank, oil level gauges
for the accumulators and sump tank, means for automatically maintaining
the correct quantity of nitrogen in the receiver, and all necessary pipes,
valves, coolers, drain connections and other fittings including oil level and
pressure relays required for the control of the pumps. A continuous and
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independent all purification system shall be provided. Suction and return oil
connections for oil centrifuge equipment shall be provided in the sump tank.
A strainer shall be provided in the main oil pressure supply pipe to each unit
main inlet valve of sufficiently fine filtering capacity to prevent damage to
any portion of the valve control and operating mechanism by foreign matter.
6.4.1.2.4.5 By-pass valve

The by-pass valve and piping shall be dimensioned to obtain full upstream
water pressure within the distributor in a time not exceeding 45 seconds
from commencement of the by-pass valve opening. This time shall be based
on the complete filling of the distributor.
The by-pass valve shall be hydraulically operated using high pressure oil
from the main inlet valve hydraulic pump unit.
In order to reduce cavitation within the by-pass piping and valve, the by-
pass valve shall be located adjacent to the distributor and its discharge set at
an angle reducing potential erosion effects on the surfaces within the
distributor.
Isolation guard valves shall be provided both upstream and down stream of
the by-pass valves for maintenance purposes.
6.4.1.2.4.6 Control and instrumentation (C&I)

The main inlet valve including auxiliary systems (e.g. pressure oil system)
shall be controlled by the CMS. Therefore, a local control board with the
necessary input/output/communication modules, local/remote switch,
open/close pushbuttons, open/close and actual opening indications shall be
supplied.
All necessary instrumentation (open/30%/close, actual opening,

level/pressure of oil accumulator and level of oil sump,...) shall be supplied.
Trip relevant signal (e. g. oil level) shall be redundant in the following
manor:
· multiple PT100 sensors at close position
· level switch (binary, tipping when closed) AND level sensor
· pressure switch (binary, tipping when closed) AND pressure sensor
· flow switch (binary, tipping when closed) AND flow sensor
A pressure differential penstock over velocity device shall be provided for

each unit, which shall cause the main inlet valve to automatically close on
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detection of an over velocity condition. Normal setting of over velocity trip

setting shall be 10 percent above normal maximum flow.
6.4.1.2.4.7 Dismantling/extension pipe

A flanged dismantling joint of telescopic type complete with nuts, bolts and
seals shall be provided with each inlet valve, located immediately on the
turbine side of the valve. The dismantling joint shall permit installation and
removal of the valve. If the design of the dismantling joint permits relative
movement between the inlet valve and spiral casing, then the sealing surface
of the dismantling joint shall be stainless steel.
The design of the dismantling joint shall allow for removal of the
dismantling joint from the penstock and replacement with the bulkhead to
be bolt directly onto the inlet valve downstream flange.
Stub pipes shall be provided with each value, including a flange for bolting
to the upstream side of the inlet valve and a cylindrical length of pipe of the
same nominal bore as the inlet valve. The cylindrical section shall be made
of a steel of equivalent strength and quality and compatible for welding to
the penstock.
6.4.1.2.4.8 Bulkhead
One flanged circular steel bulkhead, complete with all necessary bolts, nuts
and sealing rings and suitable for installation on either the main inlet valve
downstream body flange or the upstream pipeline flange mating with the
main inlet valve shall be provided for pressure testing and maintenance
purposes.
The bulkhead shall be supplied complete with drainpipe and isolation valve.
6.4.1.2. Anti-corrosive treatment and painting

The manufacturer's own painting system can be generally used if it is equal
to or better than the requirements stated in the General Technical
Specifications in respect to proper protection, quality, easiness of repairs
and longevity.
Recommendations and rules of the following organizations are considered

generally applicable to the anti-corrosive treatment and painting:
· SSPC Standards (The Society for Protective Coatings, originally Steel

Structures Painting Council)
· NACE (The National Association of Corrosion Engineers)
· SIS Surface Preparations Standards for Painting Steel Surface
· Equivalent national standards (subject to acceptance by the Employer).
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6.4.1.2. Lubricating and Hydraulic Pressure System Oil

Oil for first filling of the governor and main inlet valve pressure oil systems
and for the turbine thrust bearing with 10% as extra oil volume (after
commissioning) shall be supplied by the Contractor.
The oils used in the systems shall be commercially available in Nepal.
The Contractor is encouraged to propose the use of bio-degradable oils but

only if he has a proven experience record in this field of application.
6.4.1.2. Tools for Erection, Installation and Maintenance

The scope of supply shall include all special tools and devices which are
specially made and/or required for complete erection, dismantling,
adjustment and maintenance of all equipment specified.
Selection of tools and devices for delivery shall be made considering the
facts that all maintenance and repair works which require standstill of the
turbine must be carried out within the shortest possible time. Therefore, all
turbine components to be dismantled shall be equipped with eyebolts, lugs
and/or other devices to facilitate handling, installation and removal.
6.4.1.2. Spare Parts

The Contractor shall supply the spare parts listed below and stores, shelves,
cabinets for permanent storage.
The Contractor shall provide electronic file(s) of spare parts with complete
data (identification number, description, quantities, address/phone/fax of
suppliers and manufacturers, unit prices, delivery time, etc.). The lists shall
be cross-indexed with the assembly, sub-assembly drawings.
One set means of specified spare parts shall be understood as one set for all
four units.
Turbine:
· one (1) turbine runner
· one (1) set of injector nozzle tip and seat ring
· one (1) jet deflector
· one (1) set of turbine bearing pads
· one (1) oil cooler of each type
· one (1) complete pump unit with motor of each type
· one (1) measuring instrument/sensor of each type.
Turbine governor:
· two (2) motor pump sets for the governor pressure oil unit
· two (2) limit switches of each type (pressure, temperature, level etc.)
· one (1) set of all measuring and indicating instruments, transducers etc.
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· one hundred percent of signalling lamps, indicating lamps, fuses,

minimum one piece of each type
· twenty percent of contactors, relays, circuit breakers, push buttons,
selector switches, optocouplers, minimum one (1) of each type
· one (1) measuring and indicating instrument of each type
· two (2) complete sets of electronic governor cards, and power supplies
· two (2) control/proportional valves of each type and size
· one (1) directional valve of each type and size
· one (1) set of coils for each type of solenoid in use
· two (2) sets of all seals and gaskets
· one (1) set of spare parts for speed measuring system
· on e (1) set of filter elements of each type.
Main inlet valve:

· two (2) complete sets of seals and seat rings
· one (1) complete bypass valve
· two (2) complete sets of seal rings for the dismantling and expansion
joints
· two (2) motor pump sets for the pressure oil unit
· two (2) limit switches of each type (position, pressure, temperature, level
etc.)
· one (1) set of all measuring and indicating instruments, transducers etc.
· one hundred percent of signalling lamps, indicating lamps, fuses,
minimum one piece of each type
· twenty percent of contactors, relays, circuit breakers, push buttons,
selector switches, minimum one piece of each type
· one (1) measuring and indicating instrument of each type
· one (1) control valve of each type and size
· one (1) set of coils for each type of solenoid in use
· four (4) sets of filters of each type
· two (2) sets of all seals and gaskets.
6.4.1.2. Shop and Site Assembly, Inspections and Tests

Assembly, inspections and test in the workshop shall be performed in
accordance with the General Technical Specifications. Additionally, the
following shall be observed:
6.4.1.2.9.1 Tests during manufacturing

As a minimum the following tests shall be performed:
1) Material tests in compliance with applicable standards, including

chemical analysis, mechanical tests and non-destructive tests
2) All parts subject to internal or external pressure or containing any liquid
or gases temporarily or permanently during operation shall be pressure
tested prior to painting as per relevant standards and specifications.
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3) Following tests, measurements and assemblies shall be carried out on all

four units in the workshop:
a) Dimensional checks and recording of all major dimensions relevant
for site assembly and Performance Guarantees.
b) Static balancing of all runners.
c) Complete assembly and test of injectors.
d) Trial assembly of turbine bearing.
e) Operational test of governor and main inlet valve oil pressure units.
f) Operational test of electronic governor on a test stand.
g) Complete shop assembly of main inlet valve.
h) Pressure and sealing test on the main inlet valve.
6.4.1.2.9.2 Site tests and commissioning

Site and commissioning tests shall be performed in accordance to IEC
60545.
6.4.1.2.9.2.1 Mechanical tests before and during start-up

During erection and before and during start-up the following measurements
and tests shall be performed as a minimum:
· visual inspection and dimensional checks

· checking of the alignment of the ready assembled turbine and generator
shaft in the dry
· checking of bearing clearances
· checking of the bearing oil cooling installation
· 2 hours hydrostatic pressure and tightness tests of all equipment
containing/carrying water, oil or compressed air
· distributor dry test and measurements of nozzle openings
· adjust of injector opening/closing times
· main inlet valves functional and signal tests
· adjust main inlet valve opening/closing time
· governor logic, start-up and shut down sequences in the dry, checking of
interlocks, indications and characteristic
· operational tests on all turbine auxiliary equipment, including calibration
of related electric control instruments, and checks for correctness of
wiring and piping
· checking of alarm and protection devices, verification of alarm and
tripping settings of all supervisory instrumentation
· initial mechanical run including overspeed test
· mechanical run for bearing temperature stabilisation
· measurements of shaft run out (eccentricity) over complete speed and
load range
· vibration measurements in order to judge about general vibration level
and to assess balance of assembled rotating equipment
· injector servomotor pressure indexing over complete range of loads.
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6.4.1.2.9.2.2 Commissioning and acceptance tests / Tests on

Completion
As a minimum the following tests shall be performed on all units:
· load rejection tests at 25, 50, 75, 100% of rated load and at the maximum
load
· no-load tests under manual control in discrete steps up to the maximum
overspeed
· load acceptance tests
· governor stability and response tests
· pressure fluctuations, vibrations, and noise measurements
· reliability run on all four units.
In addition, field acceptance tests in accordance to IEC 60041 shall be

performed on all units to verify discharge and efficiency of the prototype
unit. The tests shall be made using the thermodynamic method.
6.4.1.3. Mechanical Auxiliary Systems
6.4.1.3. Cooling Water System

Each generating unit shall be provided with a fully autonomous and separate
twin circuit cooling water system with intermediate heat exchanger between
the primary and secondary circuits.
The raw water for each unit (primary circuit) shall be taken from the tailrace
tunnel by one of two centrifugal pumps (one operating and one standby)
through check valves, flow meters, maintenance valves, regulating orifices,
automatic self-cleaning filters and intermediate heat exchanger and
discharged to the tailwater.
The secondary (closed loop) water circuit shall also be provided with two
pumps. The pumps shall circulate the cooling water through the various
equipment coolers. Water returns to the pump suction side through the
intermediate heat exchanger where it is re-cooled. The cooling water system
shall be filled with clean fresh water treated with anticorrosion additives.
The anticorrosion additives must be compatible with local environmental
rules and regulations.
Connecting points shall be provided to supply the heating system of the

powerhouse.
A make up water tank with an automatic filling valve in the feed line shall
be provided for the secondary systems.
As an option a single circuit cooling water system (open circuit cooling

water system) can be offered. In case a single circuit system shall be used,
the Contractor must ensure, that all installed filters, pumps, etc. shall allow
36
reliable, durable and safe operation of the complete cooling water system
with low maintenance and inspection effort.

The temperature of the raw water at the entrance into the circuit shall not be
increased by more than 5°C before discharging into the tailwater.
The capacity of the cooling water system shall be such that requirements of
temperature rise for generator air temperatures and of the bearing and
governor oil temperatures specified in the pertinent section of these
Technical Specifications shall be met.
Heat exchangers, filters, strainers etc. shall be designed for cold water
working pressure rating of not less than 6 bar.
The valves, piping, regulating orifices shall be selected for cold water
working pressure rating of not less than 10 bar.
Final system design pressure shall be determined during detail design,

considering pressure hammer effect due to pump failure.
Fluid velocities in the pipes shall not exceed 2.5 m/s.
6.4.1.3.1.2 Equipment particulars
6.4.1.3.1.2.1 Intermediate heat exchanger

The intermediate heat exchanger shall be wide gap, plate type capable of
transferring all the heat gained during the circulation through the various
equipment coolers to raw water.
Temperature indicators and remote temperature detectors shall be provided,

both at the inlet and the outlet, at the primary and at the secondary water
side of the heat exchanger.
Differential pressure switches between inlet and outlet on both sides of the
heat exchanger with visual indication and potential free electrical contacts
for alarm purposes shall also be installed.
6.4.1.3.1.2.2 Automatic self-cleaning filter

An automatic self-flushing filter with mash of 1000 microns or less shall be
provided in primary circuit upstream of the intermediate heat exchanger. All
material in contact with the water shall be corrosion resistant suitable for the
prevailing water conditions.
37
6.4.1.3.1.2.3 Pumps, valves, piping

The raw water pumps in the primary circuit and the circulating pumps in the
secondary circuit shall be horizontal centrifugal type pumps.
The speed of pumps shall not be more than 1500 rpm. Pump bearings shall
be water lubricated in case of wet-rotor pumps.
The suction strainer of raw water pumps shall be bronze or brass.

Flow indicators with two potential free contacts for remote indication for
alarm and start blocking shall be provided for water flow for each pump.
Shut-off valves and check valves shall be provided to allow disconnection
and switching of each pump without emptying pipes.
6.4.1.3.1.2.4 Control and distribution board

Control and supervision of the cooling water system shall be integrated in
the unit control board. Additional for each unit a local control, supervision
and indication panel for the twin circuit cooling water shall be installed. The
following local controls and indications shall be provided as a minimum:
· remote/local selector switch

· start/stop push buttons
· pump selector switch
· running time counter for each pump
· emergency stop pushbutton switch
· alarm indications.
The distribution board (containing the pump-motor feeders, etc.) of the

cooling water system shall be combined with the local control panel. All
actors and sensors of the cooling water system, including the components
supplied with the generators and turbines shall be connected to these
distribution board/control panel.
6.4.1.3.1.3 Spare parts

The following spare parts shall be furnished:
· one (1) complete pump with motor of each type used

· ten (10) plates for the heat exchanger
· twenty (20) plate seals for the heat exchangers
· one (1) complete automatic self-cleaning filter
· two (2) shut-off valves, check valves, regulating valves etc. of each type
· two (2) instruments, detectors, switches and indicators of each type used
· two (2) protection devices, contactors, motor starters, relays, miniature
circuit breakers, indication lamps, etc. of each type used.
38
6.4.1.3.1.4 Tests
6.4.1.3.1.4.1 Workshop tests

The equipment shall be type and routine tested in the manufacturer’s
workshop as per relevant standards. All coolers shall be pressure tested at
1.5 times the design pressure.
6.4.1.3.1.4.2 Site tests

After installation the complete systems shall be pressure tested at 1.5 times
the design pressure. The system shall maintain the test pressure for 2 hours
without any sign of pressure loss.
The complete systems shall be tested for correct operation, indication and
function of protection devices. Insulation resistance measurements as per
relevant IEC standards shall be performed.
A simultaneous shut down test of all pumps with measurement of the water
hammer shall prove that the design pressure is not exceeded.
6.4.1.3. Drainage and Dewatering System

The powerhouse shall have one common drainage and dewatering system
arranged as a free level sump collecting the shaft seal leakage from the three
units, and surface leakage from other power station floors consisting of:
· Drainage and dewatering pumps, pipes, required armature, control

system etc.
· Permanent lifting equipment for pump removal and installation
· Sump covers
· Sump access ladders

The drainage and dewatering system shall normally serve for draining the
seepage water of the powerhouse and transformer cavern, dewatering of
waterways and pumping out of leakage water, if a pipe fracture occurs.
The drainage and dewatering system consist of two free surface sumps sized
to collect all leakage from the shaft seals and from the floor drains.
During emptying of the units for inspection and/or maintenance the water
volume between the closed main inlet valve and the distributor shall be
drained through the drainage and dewatering sump and pumped into the
tailrace tunnel.
39
All seepage and leakage (including water resulting from fire fighting
operation) into the powerhouse shall be collected in a sump.
All drainage water from the powerhouse shall pass through an oil separator
before entering the drainage and dewatering sump. The oil separator shall be
sized large enough to collect appropriate leakage volume according to the
oil volume of the governing system and the bearings.
The sump shall have two continuous duty submersible pumps with water
level switches for auto starting and stopping of pumps. One local control
panel for automatic/manual operation of pumps shall also be provided with
pumps.
In the automatic lead/lag operation, the pumps shall be controlled by a set of

level switches installed in the sump. There shall be a master float switch for
very high level which puts all pumps into operation and a master float
switch for excessive low level to function as dry run protection to shut down
the pumps and to initiate an alarm.
Two emergency float switches shall be provided for the case of local
flooding at the main inlet valve floor.
The water from powerhouse drainage sump shall be pumped out into the
tailrace tunnel.
6.4.1.3.2.1.1 Pump design and rating

The pumps shall be submersible type suitable for continuous operation and
directly driven by electric motors. The rotational speed of which shall not be
more than 1450/1500 rpm.
6.4.1.3.2.1.2 Piping, armatures and instrumentation

The following requirements are valid for all piping and armatures installed
in the system:
Design pressure: 6 bar

Water velocity in piping:
· in suction pipes maximum 1.5 m/s
· in discharge pipes approx. 2.5 m/s
All pipes in the power station, embedded as well as surface mounted, shall
be made of stainless-steel tubes.
Each pump line shall have a flow meter for monitoring and alarm purposes.
40
6.4.1.3.2.1.3 Control panel

The control panel shall include the following components:
· key operated selector switch, three positions, "Off", "Manual" and

"Automatic"
· push buttons "On" and "Off" for each pump
· indication lamps "On", "Off" and "Failure" for each pump
· operating hour counters for each pump
· manual selector switches for assigning the pumps as:
· lead pump
· lag pump
· spare pump
· emergency stop push-button switch
· collective alarm output.
6.4.1.3.2.2 Tests
6.4.1.3.2.2.1 Workshop tests

The equipment shall be type and routine tested in the manufacturer’s
workshop as per relevant standards. All coolers shall be pressure tested at
1.5 times the design pressure.
6.4.1.3.2.2.2 Site tests

After installation the complete systems shall be pressure tested at 1.5 times
the design pressure. The system shall maintain the test pressure for 2 hours
without any sign of pressure loss.
The complete systems shall be tested for correct operation, indication and
function of protection devices. Insulation resistance measurements as per
relevant IEC standards shall be performed.
A simultaneous shut down test of all pumps with measurement of the water
hammer shall prove that the design pressure is not exceeded.

The following spare parts shall be supplied:
· one (1) complete pump set with power cables

· two (2) shut-off valves, control valves, non-return valves, drain valves
and air vents valve of each type used
· two (2) sets of pump shaft seals
· two (2) flow meters
· two (2) pressure gauges of each type used
· two (2) sets of indicating instruments
41
· four (4) complete sets of all indicating lamp types used

· two (2) float switches of each type used
· one (1) motor starter of each type
· two (2) relays of each type.
6.4.1.3. Compressed Air System

The system shall be designed to supply pressurized air at working pressure
of 1 MPa to various consumers in the power station, such as:
· inflatable standstill and maintenance seals on the turbine shaft

· generator brakes
· service air take-off points located throughout the power station for air
supply to pneumatic tools and other equipment/devices.
The compressed air system shall comprise the following:

· compressor station with two compressors and all accessories
· one main air receiver and three local air pressure accumulators
· distribution circuits up to the various consumer points.

The low pressure compressed air shall be produced by two motor driven
screw type compressors, one operating as the duty compressor, the other one
as stand-by. The compressors shall deliver the air to a main air receiver.
From the main receiver the air shall be distributed to various consumption
points in the power station via a network of steel pipes, namely to:
· three (3) air accumulators supplying the mechanical generator brakes and
the inflatable maintenance seals on the turbine shaft. The air
accumulators shall be located on the generator floor each having enough
capacity for three braking operations without recharging. The feeding
lines to those accumulators shall connect directly to the main air tank,
without service taps.
· four (4) tapping points at the machine hall elevation.
· four (4) tapping points at the generator floor elevation.
· four (4) tapping points at the turbine floor elevation.
· four (4) tapping points at the valve floor elevation.
The low pressure compressed air system shall be designed for automatic
operation with the possibility of local manual control of the individual
compressors from the local control panel. In the automatic mode, the
compressors shall respond automatically to pressure fluctuation in the main
air receiver. An automatic change over shall be initiated in case of failure of
the operating compressor.
The low pressure compressed air system shall be rated for a nominal
pressure of 10 bar with an hourly delivery of not less than 150 m³/h. The
42
capacity of compressors shall be such that normally one compressor shall

meet the 100% requirement of system and second compressor shall act as a
standby.
The air receiver and the pressure accumulators shall be designed for normal
working pressure of 12 bar in compliance with applicable international
standards, considering national rules and regulations for obtaining
operational allowance.
All pipes and armatures with inside diameter less than 50 mm shall be
stainless steel. Other pipes shall be made of hot dip galvanized steel
seamless tubes.
6.4.1.3.3.2 Control devices

The compressors shall be controlled by pressure switches at the vessels.
Normally only one compressor shall operate. If after starting of the first
compressor the pressure continues to decrease, the second (reserve)
compressor shall start by a second pressure switch. The compressors shall
be stopped in the opposite sequence.
6.4.1.3.3.3 Control panel

The control panel shall accommodate the control equipment, motor starters,
motor protection equipment and provisions for local and remote alarm,
electric heating etc.
The control equipment shall include the following components:
· key operated selector switch, three positions, "Off", "Manual" and

"Automatic"
· push buttons "On" and "Off" for both compressors
· indication lamps "On", "Off" and "Failure" for both compressors
· operating hour counters for both compressors
· manual selector switches for assigning the compressors as:
· main duty
· standby
· emergency stop push button switch
· collective alarm output.

· two (2) shut-off valves, control valves, non-return valves, drain valves of
each type used
· two (2) pressure switches of each type used
43

· one (1) motor starter of each type
6.4.1.3. Fire Fighting System

The fire fighting equipment shall comprise of the following:
· fire hydrant system for the power station

· automatic water spray system for the transformers
· raw water distribution network
· microprocessor based fire detection and alarm system
· portable and mobile type chemical fire extinguishers.
6.4.1.3.4.1 Fire fighting system study

The Contractor shall carry out fire fighting system study in line with NFPA
and other recognized international standards, considering the applicable
national rules and regulations for fire fighting and fire safety requirements.
The fire fighting system study shall form the basis for the Contractor’s
design of the fire fighting system.
6.4.1.3.4.2 General description of the fire fighting system

A storage tank with sufficient storage capacity to meet the requirements for
fire fighting duration determined in the fire fighting system study shall be
provided to achieve the required system pressure.
A manually controlled filling pump shall be used to fill the storage tank
from the tailwater.
A minimum number of hydrants shall be installed as follows:
· two (2) along the outside perimeter of the powerhouse building

· two (2) within the transformer yard
· one (1) within the erection bay
· two (2) at the generator floor
· two (2) at the turbine floor
· two (2) at the valve floor.

All equipment for fire protection, detection and alarm system shall be
designed, erected and commissioned in accordance with NFPA regulations
and fire fighting and fire safety requirements and applicable national rules
and regulations.
44
6.4.1.3.4.3.1 Automatic water sprinkler system

The system shall be designed as a dry pipe, deluge type, ring main network
of spray nozzles around the main transformers.
The deluge valve shall be actuated by rupture due to heat of one or more
quartzite bulb heat detectors placed around the equipment to be protected.
The system shall be suitable for operation automatically as well as by
remote and local manual control.
The water requirement for fire protection of the main transformers shall
meet the requirements of NFPA Standard 15.
6.4.1.3.4.3.2 Outdoor water hydrant system

Outdoor fire hydrants shall have two 65 mm instantaneous female outlets
with separate control valve for each outlet and 100 mm inlet with water
supply.
Hose reels carts shall have two tyred wheels and shall be suitable to
accommodate 40 m of fire hose, 63 mm diameter, in two equal lengths, with
necessary hose couplings and nozzles.
6.4.1.3.4.3.3 Indoor hydrants and fire hose cabinets

Indoor fire hydrants shall have one 65 mm instantaneous female outlet with
a control valve.
Fire hose cabinets in the power station shall accommodate 30 meters of 63

mm diameter hose folded on automatic rack bracket and be provided with
single headed hydrant valve.
Provision shall be kept outside the fire hose boxes for mounting one
portable carbon dioxide cylinder of 5 kg capacity.
6.4.1.3.4.3.4 Raw water general service outlets

Ten (10) 25 mm diameter raw water general service outlets shall be
provided at various locations in the power station. The raw water outlets
shall be suitable for connection to 25 mm hosepipes through hose coupling.
6.4.1.3.4.3.5 Chemical fire extinguishers

An adequate number of portable and mobile chemical fire extinguishers of
carbon dioxide, foam and dry powder type shall be provided at suitable
locations inside the power station.
Fire extinguishers of foam and dry powder type shall be provided for valve
floor, turbine floor, cable trenches, diesel engine room, stores, offices, etc.
45
CO2 type extinguishers shall be provided in rooms containing low and

medium voltage electrical equipment.
6.4.1.3.4.3.6 Fire detectors

The fire detection system shall comprise the following types of point-
detector:
· optical smoke detectors, and

· heat detectors.
None of the mentioned detector types shall contain any moving parts or
parts subject to wear and tear.
All detector types shall be designed for low voltage (DC supply). In order to
keep the electric energy consumption as low as possible, the quiescent
current shall not exceed 0.3 mA per detector unit.
The fire detection system shall be designed such that the actuated detector
remains in the self hold state, even if the fire phenomenon no longer exists.
Within a detector zone only one detector unit shall simultaneously release
an alarm signal.
6.4.1.3.4.3.7 Optical Smoke detectors

The optical smoke detector shall be applied where smoke must be expected
in case of fire. In rooms, where in case of fire, different fire phenomena
(smoke, visible flames) may be expected, the optical detector shall be used
together with other detector types.
It shall be designed according to the light scattering or Tyndall principle

respectively.
6.4.1.3.4.3.8 Heat detectors

The heat detector shall be used in conjunction with the optical smoke
detector for monitoring rooms containing electrical and electronic
equipment.
6.4.1.3.4.3.9 Manual alarm

Alarm pushbuttons shall be used for manual alarm.
They shall be placed at points where they are well visible and easily
accessible, mostly in combination with a fire fighting set.
All pushbuttons shall have a separate line to the control unit.
46
6.4.1.3.4.3.10 Acoustical alarm device

Alarm horns shall be automatically activated by the control unit in case of
fire alarm.
The sound level of the alarm horns shall be 115 dB at 1 m distance.
6.4.1.3.4.3.11 Optical alarm device

All rotating lights shall be blue light types. The light source shall be a
halogen bulb with rotating reflector of 60 to 120 rpm.
6.4.1.3.4.3.12 Fire alarm and control panel

A microprocessor-based fire alarm, annunciation and control panel shall be
provided for annunciation and automatic operation of the system. The panel
shall be installed in the control room.
The alarm system shall consist of annunciation windows for visual and
audio signalling of outbreak of fire in any particular zone of the supervised
respectively protected areas.
The fire control panel shall have at least the following provisions:
· manual control of storage tank filling valves

· manual operation of deluge valves for main transformers
· indications of:
· water level in the storage tanks.
· failure of lead filling valve to open.

· one (1) complete outdoor fire hydrant

· one (1) complete indoor hydrant
· one (1) automatic storage filling valve
· two (2) deluge valves
· two (2) shut-off valves, control valves, non-return valves, drain valves
and air vent valves of each type used
· two (2) float switches of each type used
· two (2) fire detectors of each type used
47
6.4.1.3. Heating, Ventilation and Air Conditioning (HVAC) System

The power station ventilation air supply and exhaust system consisting of:
· two (2) air handling units, 100 % of the total required capacity each, with
air coolers
· appropriate number of air supply and exhaust fans in the ventilation
tunnel, transformer cavern and the access tunnel to ensure fresh air
supply and the required air exhaustion rates
· battery room exhaust system consisting of one (1) exhaust fan, air duct of
flame-resistant plastic material and exhaust louver
· intake screens, louvers, filters, air ducts and accessories including
registers, grilles, dampers, vanes etc.
· electrical control and instrumentation
· air-conditioning and ventilation system for the service building which
contains the control room, offices, associated facilities rooms, workshops
etc., consisting of:
· two (2) split air-cooling units for outdoor installation, 100 % of the
total required capacity each
· individual (per each room) air control units for control room, offices
and facility rooms (with possibility of independent temperature
controls in each air-conditioned room)
· one (1) air supply blower with air coolers for the workshops
· air ducts, piping, valves and accessories including intake filter, louver
screens ceiling diffusers and dampers, and access doors and electrical
control and instrumentation
· washrooms exhaust system consisting of two (2) exhaust fans, air ducts,
grilles and accessories.

For the powerhouse complex including the control room, transformer
cavern, access and power cable tunnels, a complete air conditioning and
ventilation system shall provide sufficient flow of air to all areas so that
equipment can operate as reliably as possible and at the same time, a safe
working environment is provided for people working within those areas.
The air conditioning and ventilation system must function as an integral part
of the overall fire protection and evacuation plan for the underground
complex.
The following criteria and assumptions shall be adopted for the design of
the air conditioning and ventilation system.
· comfort levels shall be particularly important in those areas (the machine

hall floor and service bay as well as the generator, turbine and valve floor
areas), where men shall be regularly working during plant operation or
routine maintenance.
48
· the gallery and transformer cavern are normally not classified as working
areas, and here the principal consideration shall be to control
temperatures to meet equipment operating requirements.
· the major potential fire hazard and source of smoke and products of
combustion are the transformers. The ventilation system must minimize
the circulation of combustion products should a fire occur.
· the heat losses generated by some equipment located in the rooms shall
be transported by means of air flow.
· toilets, battery or oil store / treatment or similar rooms must be ventilated
by exhaust air ventilation systems to prevent bad smelling air.
The proposed system shall draw fresh air through the ventilation and cable
tunnel and discharge it into the machine hall from where it shall circulate
down to the generator and the turbine floor, inlet valve gallery and be then
discharged through the transformer gallery and the access tunnel to the
outside. Air circulation shall be controlled by fans.
6.4.1.3.5.2 Design data

The following basic data shall be adopted for the design, after the contractor
confirmed the data:
· the walls of the underground caverns are assumed to be at constant

temperature of 20°C.
· a cooling water design temperature of 25°C.
· the following outside extreme air design temperature values:
· Maximum temperature: 20°C
· Minimum temperature: 0°C
Ventilation / exhaust air rate

The following minimum ventilation/exhaust air rate shall be considered for
various areas, if applicable:
· Machine hall 1 air change /h

· Generator floor 4 air changes /h
· Turbine floor 2 air changes /h
· Valve floor 2 air changes /h
· Transformer cavern 4 air changes /h
· Access tunnel 0.5 air changes /h
· Offices 6 air changes /h
· Stores 2 air changes /h
· Shops 6 air changes /h
· Toilets 8 air changes /h
· Kitchen 8 air changes /h
· Locker rooms 8 air changes /h
· Washrooms 8 air changes /h
Noise
49
The noise levels caused by operation of the systems shall not exceed:
· 45 dB(A) rooms of system D as in the control rooms, offices, meeting

room, tearoom.
· 60 dB(A) in all other rooms and areas, except in bus duct galleries,
transformer cells and in the corridor of the transformer cavern.
These levels shall be as measured at a distance of 1.5 m from any grill,

diffuser etc. Silencer, as required, shall be provided to ensure the above
sound levels are not exceeded.
6.4.1.3.5.3 Fire Protection Considerations in the Design of the Ventilation

System
The design of the powerhouse ventilation must be closely coordinated with
the need for the fire detection/annunciation system to react properly in
various modes of operation, depending on where the fire has been observed
or automatically detected, to ensure the safety of the personnel and the
equipment.
The ventilation system must accomplish the following:
· ensure a smoke-free route for personnel evacuation

· vent the smoke safely efficiently and rapidly.
For the purpose of fire ventilation, the powerhouse is divided into the
following areas:
· machine hall
· generator floor
· turbine floor, valve gallery
· transformer and switchgear cavern
· cable/ventilation tunnel
· access tunnel.
6.4.1.3.5.4 Code and Standards

The ventilation and air conditioning system shall comply with the
requirements of the following applicable standards and regulations:
ASHRAE, NFPA, DIN, EN, ISO, ANSI, AMCA, ARI.
6.4.1.3.5.5 Internal Temperature Requirements

The air conditioning system for use in the control room and associated
rooms shall be designed to provide a final temperature of 22°C and a
relative humidity level of 50%.
50
All remaining spaces in the power station shall be air ventilated. The air
coolers shall be capable of maintaining an indoor temperature not higher
than 30°C.
6.4.1.3.5.6 Duct Air Velocities

Air duct sections shall be designed for the following maximum air
velocities:
· Main ducts 10 m/s

· Branch ducts 6 m/s
· Air-conditioned rooms 3 m/s
· Air inlets and outlets 3 m/s
· one (1) electro motor/drive of each type

· two (2) sets of belts of each type
· one (1) set of seals
6.4.1.3. Oil Handling System

The scope of supply for the oil handling system shall include but is not
limited to, the following:
· clean and dirty oil storage tanks

· transfer pumps with associated pipe work and controls
· oil filtration plant for the turbine, generator and MIV oil.
Oil purifiers for the main transformer oil is included in the section of the
specification relevant to the main transformer.

The oil treatment plant shall be capable of the following functions:
· filtration, dehydration and degassing of oil supplied in drums or in a

tanker before filling into the bearing or governing systems.
· processing of oil after long periods of use to remove solid matter,
dissolved gasses, sludge, fibre, water etc.
· complete regeneration of oil after long periods of use to restore loss
factor, surface tension, saponification, acidity factor etc. to values
approaching those of new oil.
51
6.4.1.3.6.2 Storage tanks

Oil sump tanks shall be provided where applicable. Pipe work connections
to the oil filtration system shall be by separate dedicated and clearly marked
'clean oil' and 'dirty oil' filling and discharge pipes. The separate filling and
discharge pipes shall be provided with a 65 mm road tanker connection
point complete with in-line strainer, gate valve, and lockable cap with chain.
6.4.1.3.6.3 Transfer pumps

One fixed and one mobile transfer pump shall be provided, each complete
with all associated pipe work, valves, fittings and controls.
The fixed transfer pump shall be located adjacent to the oil sump tanks and
shall have capacity of one oil sump tank to be transferred to the oil filtration
unit within a 2-hour period.
The mobile transfer pump shall be a skid mounted self-contained unit with
all pipe work, valves, fittings and controls. The pump shall be sized to be
capable of transferring all the lubricating oil to or from the oil sumps of one
turbine/generator unit within a 4-hour period.
The skid shall be provided with lifting lugs to also allow lifting and
movement by the powerhouse crane as necessary.
6.4.1.3.6.4 Oil filtration plant

One oil filtration plant shall be provided for the “on-line” processing and
reconditioning of lubrication oil whilst the units are in operation.
The oil filtration plant shall have a capacity of 2.000 litre/hour. The self-
contained plant shall include a vacuum suction pump, thermostatically
controlled heaters, oil purifier, dehumidifier and degasser.
The oil filtration plant shall include all the necessary vacuum pumps,
vacuum tank with heating equipment, pressure pump, filter compartment
and the necessary drives and controls.
The filter elements shall remove all particulars of size greater than one
micron. They shall be designed and installed for easy removal and re-fitting.
It shall be possible to clean the filters without dismantling and their normal
service life should be at least ten years.
All inlet and outlet connections shall be provided and shall include fine
gauge filters of an easily removable type for cleaning.
The lockable control board shall comprise all necessary instrumentation.
52
The oil filtration plant shall be provided with steel-armoured hoses, with
connectors of sufficient length for the duty together with all other devices
and equipment required for the effective processing of the oil.
6.4.1.3. Mechanical Workshop

The mechanical workshop shall be equipped with machine tools, equipment
and tools necessary for normal maintenance and small repair of the turbines,
generators and auxiliary equipment.
The maintenance and repair work to be performed includes turning, drilling,

grinding, welding, etc.
At least, the following machines and tools, with all necessary accessories,
shall be provided:
· universal lathe capable of handling an item of 500 mm diameter above

the lathe bed and of 1800 mm length between centres
· milling machine
· eight-speed pillar drill of 30 mm
· four speed, swivel-head drill of 15 mm
· base-mounted universal drill grinder for drills and lathe tools
· 300 mm floor-stand grinder
· hack sawing machine
· electric circular saw for timber
· 7-bar compressed air portable grinding machine
· steel section work benches and three drawers equipped with a swivel-
head parallel vice
· tool cabinets made of steel plate
· mobile air compressor unit for workshop and maintenance, delivery 30
Nm³/h, nominal working pressure 8 bar at continuous operation
· set of universal racks shall be approx. 2.20 m to 2.30 m and the width 0.8
m; total length approximately 4.0 m (multiple sections)
· tube vice with stand
· hand operated pulley blocks; 2 ton
· several complete sets of small tools
· manual hydraulic pipe bending device with standard accessories and
additional bending tools
· mechanical measuring instruments containing:
· slide gauges for inside and outside measurements
· slide gauges for measuring depth
· outside micrometers
· inside micrometers
· precision rules of various types and lengths
· stopwatches
· thermometers
· electronic vibration meter and analyzer of hand held type
· one (1) electric overhead travelling crane for mechanical workshop,
hoisting capacity 2 ton, distance between centres of railway lines
53
approximately 6 m, rail track length approximately 10 m, control from

suspended control bulb
· one (1) electric welding machine capable for both SMAW and TIG
welding, for a range of 35 - 500 A, with all necessary accessories for
both SMAW and TIG welding
· one (1) set of gas-welding equipment etc.
· one (1) anvil
· one (1) welding table.
6.4.1.3. Powerhouse Crane

This section of the specification covers requirements for the design,
manufacture, workshop testing, protective coating, supply, delivery,
erection, commissioning, testing and setting to work of the electric overhead
travelling power house crane.
The scope of supply shall include, but not be limited to the following:
· One (1) double-girder, top running, electric overhead travelling bridge

crane, with approx. 260-ton main hoist on an individual trolley and one
auxiliary electric wire rope hoists of approx. 30-ton capacity operating on
the bottom flange of the bridge’s outer girder.
· One (1) runway rail system complete with rails, connecting plates, end
stops, supports, fittings and connections.
· One main runway conductor system complete with brackets,
interconnecting wiring fittings and connectors
The final capacity of the crane shall be verified by the Contractor within the
scope of his design according to the heaviest part to be lifted (generator
rotor) with safety. The capacity of the auxiliary hook shall be sufficient to
lift the heaviest part of the turbine (i.e. head cover or runner).

One overhead bridge crane shall be installed in the powerhouse machine
hall to facilitate assembly, installation and overhaul of the generating units,
the main inlet valves and all associated equipment. When installation is
complete, the crane shall be used for routine maintenance of the machinery
on a "standby service" basis.
The approximate capacity of the crane is estimated at 260/30 tons and is

defined by the heaviest piece for installation, i. e. the generator rotor. The
final lifting capacity shall be determined by the generator manufacturer
during the detail design stage considering the required flywheel effect of the
generator rotor which impacts the final weight.
The crane shall be operable from the operator cabin control panel. As an
option, additional crane control form from a portable radio station shall be
offered.
54
Bumpers shall be attached to the bridge trucks and the trolley. The bumpers
shall be spring or rubber type, capable of bringing the crane and the trolley
to stop when travelling at rated speed in either direction.
A signal horn shall sound automatically as soon as any movement of the
crane is initiated by the operator.
Crane classification:
· Type: double girder type

· Class of utilization: FEM (ISO) U3
· State of loading: FEM (ISO) Q1
· Group classification: FEM (ISO) A2
The crane shall travel the full length of the power station, including the
erection bay.
6.4.1.3.8.1.1 Design data
Rail base elevation Approx. 923.0 m a.s.l.

Rail track length Approx. 140 m
Number of Cranes One
Rated Capacity
· Main Hoist 260 t
(indicative, to be verified
by Contractor)
· Auxiliary Hoist 30 t
(indicative, to be verified
by Contractor)
Crane Span Approx. 24 m
Lift Height Approx. 30 m
Operating speeds (loaded)
· Long (bridge) Travel 1.5 to 20 m/min
· Cross (trolley) Travel 2 to 12 m/min
· Main Hoist lift 0.5 to 1.25 m/min
· Auxiliary Hoist lift 0.5 to 4 m/min
Total Lift (with load)

· Main Hook Approx. 25.0 m
· Auxiliary Hook Approx. 30.0 m

Jog Movement
· Main Hoist 1.0 mm
· Auxiliary Hoist 2.0 mm
· Bridge Travel 5.0 mm
55
· Trolley Travel 5.0 mm

Acceleration/deceleration for
· Bridge Travel 0.15 m/s2
· Trolley Travel 0.08 m/s2
The power station crane shall be supplied with three-phase, 400 V AC

power by means of a runway conductor system. All drives shall be variable
frequency types.
The crane shall be equipped with access ladders and platforms, handrails,
cover plates, curbing, etc., under consideration of applicable safety
standards.
6.4.1.3.8.2 Shop assembly and tests

The crane shall be shop assembled as completely as possible including:
· bridge beams with rail trucks and drives

· trolley hoists on bridge beams
· complete hoists with motors, brakes, gearboxes, controls, etc.
· complete bridge and trolley drives
· complete hook and sheave assemblies
· electrical control panels, starter, contactors, position indicators, etc.
· auxiliary hoist on the main trolley.
and then operated and function tested in the shop checking for adequacy of
design and suitability for reliable, safe and proper operation.
Hoisting device parts from motors to drums shall be load tested using a load
equivalent to the full testing load in final operation conditions.
The tests shall at least include the following:
· verification of dimensions
· all electric hoist shall be tested as per national/international standards
· operation of brakes
· hoisting devices parts from motors to drums shall be load tested using a
load equivalent to the full testing load in final operation conditions.
Disassembled parts shall be match marked and electrical connections tagged

after complete no-load shop testing.
6.4.1.3.8.3 Site performance tests

The Contractor shall carry out complete performance tests on the crane
including the load test.
56
The Contractor is responsible to make all arrangements necessary for the

load test and to provide the test weights.
The tests shall include the following:
Running Test:
· operation of each control switch, contactor relay and other control
devices
· test of all circuits, interlocks and sequences of operation
· test of all protective devices
· all crane motions operate correctly.
Load Test:
The crane shall have each motion tested with the main and auxiliary hook
carrying overload (110 % of the rated load).
Hoist brakes shall be tested with overload (125 % of the rated load).
Deflection Test:
The tests shall be carried out with the rated load at rest and the trolley in the
central position. The deflection measurement shall be taken only after the
load has been applied several times.
Brake Tests:
All brakes shall be tested under full-load conditions, from maximum speed
to rest, three times in quick succession without overheating.
The Contractor is responsible for final acceptance test by local authorities

and for obtaining operation permit.

The following spare parts for the power station crane shall be supplied:
· one (1) complete set of hoisting ropes

· one (1) complete set of gaskets for each type and size of gear case
· one (1) complete set of bearings of each type and size provided
· one (1) solenoid and one (1) set of brake pads/shoes for each type and
size of brake
· one (1) complete set of fixed and moving contacts for each type and size
of switch, contactor and relay
· one (1) push button mechanism of each type provided
· one (1) limit switch of each type provided
· 200% of all indicating lamps and fuses
· one (1) coil of each type
· one (1) set of runway conductors
· one (1) variable speed drive of each type.
57

6.4.1 Particular Technical Specification Mechanical Works

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6.4.1 Particular Technical Specification Mechanical Works

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6.

6.4.1.2. Hydraulic Turbines, Governors & MIVs 1

6.4.1.2.9.2 Site tests and commissioning 35

6.4.1.3. Mechanical Auxiliary Systems 36

6.4.1.3. Mechanical Workshop 53

6.4.1.2. Hydraulic Turbines, Governors & MIVs

6.4.1.2. Scope of Supply

6.4.1.2. Pelton Turbines

6.4.1.2.2.1 Turbine operating conditions

During the dry season, the headpond with a storage capacity of

6.4.1.2.2.2 Scope of supply

6.4.1.2.2.3 Type and arrangement

Nevertheless, the Contractor may propose a different bearing arrangement

6.4.1.2.2.4 Water levels and head ranges

6.4.1.2.2.4.1 Water levels

Turbine runner and tailwater:

6.4.1.2.2.4.2 Gross head

· Maximum gross head 452 mWC

6.4.1.2.2.5 Turbine type and rating

The basic data for the turbine design is as follows:

Rated gross head Hg 450.0 mWC

Rated net head (1 unit in operation) Hn 433.42 mWC

Rated discharge per unit Qr 22.88 m3/s

Power at rated condition per unit Pr 87.4 MW

Synchronous speed n 300.0 rpm

Centreline elevation of turbine runner ÑCLrun 900.0 m a.s.l.

6.4.1.2.2.5.1 Turbine efficiency guarantee

Net Guaranteed Weights at the following fractions of

Moreover, the guaranteed efficiencies in the individual points for the

Net Guaranteed Guaranteed efficiencies at the following

6.4.1.2.2.5.2 Cavitation pitting guarantee

6.4.1.2.2.5.3 Speed and pressure variations

6.4.1.2.2.5.4 Inertia constant

6.4.1.2.2.6 Model test of Pelton turbine

6.4.1.2.2.6.1 Applicable standards

6.4.1.2.2.6.2 Scale model characteristics

6.4.1.2.2.6.3 Scale model test contents

The turbine performance tests shall determine:

· the turbine efficiency for the entire operating range

The values obtained shall be scaled according to IEC 60193, Annex K,

6.4.1.2.2.6.4 Turbine characteristics

Additionally, H, Q characteristics shall be provided for prototype

6.4.1.2.2.6.5 Runaway speed tests

6.4.1.2.2.6.6 Preliminary scale model test report

6.4.1.2.2.6.7 Acceptance tests

6.4.1.2.2.6.8 Final model test report

· a description of the test equipment

· expected prototype performance characteristics; the prototype

6.4.1.2.2.6.9 Scale model preservation

Rotating parts (shaft vibrations):

· zones A/B according to ISO 10816-5, Annex A

The vibration guarantee applies to the generating unit, as a whole.

6.4.1.2.2.8 Critical speed

6.4.1.2.2.9 Frequency analysis

6.4.1.2.2.10 Design requirements for main components

The design, construction and non-destructive testing shall conform to the

embedded in concrete, the steel structure must be considered to act alone in

The complete distributor shall be pressure tested under a pressure of 1.5

6.4.1.2.2.10.2 Turbine cover

The turbine cover shall be designed in a way that easy inspection,

6.4.1.2.2.10.3 Turbine housing

· upper turbine housing (runner pit housing)

2.2.10.3.1 Runner pit housing

The housing shall be strongly reinforced on the outside by means of suitably