GB/T 8564-2023 (GB/T 8564-2003) PDF English
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GB/T 8564-2003: Specification installation of hydraulic turbine generator units---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/GBT8564-2003
F 22
NATIONAL STANDARD OF
THE PEOPLE’S REPUBLIC OF CHINA
GB/T 8564-2003
Replace GB/T 8564-1988
Specification for Installation of
Hydraulic Turbine Generator Units
Issued on September 15, 2003 Implemented on March 1, 2004
Issued by General Administration of Quality Supervision, Inspection and
Quarantine of the People's Republic of China and Standardization
Administration of the People's Republic of China
Table of Contents
1 Scope... 7
2 Normative standards... 7
3 General principles ... 8
4 General regulations... 9
5 Installation of vertical type reaction turbine ... 12
5.1 Installation of built-in fitting... 12
5.2 Runner installation ... 21
5.3 Preassembling of the guide apparatus... 24
5.4 Emplacement and installation of rotatable parts ... 26
5.5 Installation and adjustment of guide blade and/or servomotor ... 27
5.6 Installation of water conduit and main shaft seal ... 29
5.7 Installation of fittings... 30
6 Installation of tubular turbine ... 31
6.1 Installation of built-in fitting... 31
6.2 Installation of principal axes ... 34
6.3 Installation of guide apparatus ... 34
6.4 Installation of guide apparatus ... 34
6.5 Installation of the principal axes, runner and runner chamber ... 35
7 Installation of impulse turbine... 35
7.1 Installation of diversion conduit ... 35
7.2 Installation of case... 36
7.3 Installation of the bearing of turbine shaft ... 36
7.4 Installation of turbine shaft... 36
7.5 Installation of sprayer and servomotor ... 37
7.6 Installation of runner... 37
7.7 Installation and adjustment of control mechanism... 37
8 Installation and debugging of speed regulating system ... 37
8.1 Installation and debugging of oil pressure devices... 37
8.2 Installation of speed governor... 39
8.3 Oil filling adjustment test of speed regulating system ... 41
8.4 Simulation test of speed regulating system ... 42
9 Installation of vertical type hydrogenerator ... 42
9.1 Combination of framework ... 42
9.2 Grounding and scraping of bearing shell... 43
9.3 Stator installation ... 44
9.4 Rotor installation... 50
9.5 Overall installation... 56
9.6 Installation of excitation system and devices ... 64
10 Installation of horizontal hydraulic generator ... 65
10.1 Grounding and scraping of bearing bush ... 65
10.2 Installation of bearing pedestal... 66
10.3 Installation of stator, rotor and/or fitment ... 66
10.4 Checking of each part of the bearing and clearance adjustment... 67
11 Installation of bulb-type hydraulic generator ... 68
11.1 Installation of stator... 68
11.2 Installation of rotor ... 68
11.3 Installation of principal axes and composition bearing ... 68
11.4 Generator installation... 69
12 Installation of pipelineand and fitments... 70
12.1 Fabrication of pipe fittings and fitments of pipeline ... 70
12.2 Pipeline welding... 72
12.3 Installation of pipeline ... 73
12.4 Treatment of the inner wall of pipeline ... 75
12.5 Test of the conduit and pipe fittings ... 75
13 Installation of butterfly valve and ball valve ... 75
13.1 Installation of butterfly valve ... 75
13.2 Installation of ball valve... 76
13.3 Installation of flexible connector... 77
13.4 The installation of hydraulic control valve and air valve ... 77
13.5 Installation of operating mechanism ... 77
14 Electrical test of water-turbine generator set ... 78
15 Trial run of water-turbine generator set... 82
15.1 General specifications ... 82
15.2 Water filling test of assembling unit ... 83
15.3 Zero load trial run of unit ... 83
15.4 Test over paralleling in of unit and under load ... 86
Annex A... 90
Annex B... 94
Annex D... 96
Annex E... 98
Annex F ... 101
Annex G ... 104
Specification for
Installation of Hydraulic Turbine Generator Units
1 Scope
This national standard regulates the installation, debugging of hydraulic turbine
generator units and the requirements of test. It is applicable to the installation and/or
acceptance of hydraulic turbine generator units in compliance with the following
conditions:
a) Unit capacity of 15MW and/or higher
b) Impulse hydraulic turbine with its nominal diameter of runner at 1.5m and/or
above
c) Radial-axial flow turbine with its nominal diameter of runner at 2.0 m and/or
above
d) Axial flow, mixed flow variable pitch turbine, and tubular turbine, with
nominal diameter of runner at 3.0m and/or above.
Hydraulic turbine generator units with unit capacity smaller than 15MW and units
with nominal diameter of turbine runner smaller than that specified in b), c), and d).
This national standard is applicable to the installation and/or acceptance of reversible
pump storage unit.
2 Normative standards
The following normative documents contain provisions, which, through reference
in this text, constitute provisions of this national standard. For dated reference,
subsequent amendments to, or revisions of, any of these publications do not apply.
However, it is recommended parties reaching agreement according to this national
standard carry out a study on if the most updated version of these documents may be
applied or not . For undated reference, the latest edition of the normative document
referred to applies.
GB3323 Methods for radiographic inspection and classification of radiographs for
fusion welded butt joints in steel
GB/T7409.3 Excitation system for synchronous electrical machines-Technical
requirements of excitation system for large and medium synchronousgenerators;
GB/T7894 Fundamental technical requirements for hydraulic turbine generators;
GB/T9652.1 Specifications of governors and Pressure oil supply units for
hydraulic turbines;
GB/T9652.2 Test acceptance codes of governors and pressure oil supply units for
hydro-turbines;
GB/T10969 Specifications for water passage components of hydraulic turbines;
GB/T11120L-TSA Turbine Oil;
GB11345 Method for manual ultrasonic testing and classification of testing results
for ferritic steel welds;
GB/T18482 Start - up test code for reversible pump - storage units;
GB50150 Emending explanation of Standard for hand-over test of electric
equipment electric equipment;
GB50168 Code for construction and acceptance of cable levels electric equipment
installation engineering;
GB50171 Acceptance of switchboard outfit complete cubicle and secondary
Circuit Electric Machine;
DL/T507 Start-up test code for hydraulic-turbine and generator units;
DL/T679 Code for welder technical qualification;
DL/T827 Start-up test code for bulb tubular hydraulic-turbine and generator units;
JB/T4709 Welding specification for steel pressure vessels;
JB/T6204 Specification for withstand voltage test on stator coil and winding
insulation of high voltage AC machines;
JB/T8439Technical requirements on suppress corona of high-tension machines
used in high altitude areas
JB/T8660 Standard for hydroelectric set packing, transportation and preservation
3 General principles
3.1 Installation of water-turbine generator set shall proceed according to this
national standard in compliance with the installation drawing approved by design
organization and manufacturer as well as related technical documents. Special
requirements raised by the manufacturer shall be satisfied according to related technical
documents. Supplementary provisions for requirements not listed in this standard and
technical documents of manufacturer shall be specified additionally. In case of a
conflict between the technical requirements from the manufacturer and this standard,
generally, the requirements of the manufacturer shall proceed. Otherwise, consult with
the manufacturer for a settlement.
3.2 Other than this national standard, installation of unit and its auxiliary facilities
shall also comply with current related specifications on safety, environmental
protection, fire control, and so on issued by the state or related authorities.
3.3 Equipment for water-turbine generator units shall be in accordance with the
regulations of current national standard and purchase contract. After the equipment
arrives at the acceptance spot, the installation party may participate in unpacking,
counting, checking the supply list and random packing list, and then operate according
to JB/T8660.
The following documents shall be taken as important evidence for acceptance of
both unit and it auxiliary equipment as well as quality acceptance.
a) Equipment installation, operation, instruction on operation and maintenance and
technical documentation;
b) All random drawing materials (including equipment installation drawing and
structure drawing of spare parts);
c) Certificate of analysis, inspection and test records;
d) Material quality and performance certificate of vital parts.
3.4 Before the installation, read design drawing, factory inspection record and
related technical documents carefully and be familiar with them, and then make out a
logical construction design in compliance with the actual conditions.
3.5 Before the installation, read related civil design drawing and participate in the
acceptance of the delivered civil construction parts. For places with flaws, the
installation must be carried out after treatment.
3.6 All materials used in the installation of water-turbine generator unit shall be in
accordance with design requirements. Primary materials must possess inspection
certificate and certificate of analysis.
3.7 Plan the installation field integrated. The following requirements shall be met:
a) Installation field shall be windproof, rainproof and dustproof. Unit installation
must proceed after the completion of the factory building roofs of this unit and adjacent
units are sealed.
b) Generally, the temperature shall not be lower than 5°C. Relative humidity of air
shall not be higher than 85%. For other equipments and parts that have requirements
over temperature, humidity and other special conditions, the installations shall be
implemented according to the design specifications.
c) Enough illumination shall be provided on the construction field;
d) Safety facilities for construction in compliance with requirements must be
equipped on site. Places to put flammable, high explosive items must have
corresponding safety provisions;
e) Civilize production. Installation equipment, construction tools and materials
shall be placed in order. The construction site shall keep clean. Passage remains to be
smooth. Clear the site on the completion of work.
3.8 After the completion of the installation of water-turbine generator set, proceed
the test run according to this national standard and DL/T507. Comprehensively check
the quality of design, fabrication and installation. After the test run is proved qualified,
proceed the acceptance of the unloading phase of this unit. Hand over related materials
according to the requirements of Annex A.
4 General regulations
4.1 Before installation, clear and inspect the equipment overall. Check the main
dimensions and/or tolerance of primary parts according to the drawing requirements as
well as ex-factory records.
Equipment inspection and flaw treatment shall have records and licenses.
Packed equipment under warranty may not have to be dis-integrated.
4.2 Generally, deviation of the elevation of entombment of equipment foundation
bedplate shall not exceed - 5mm ~ 0mm. Deviation of the center and azimuth
distribution shall not be greater than 10mm. Horizontal deviation is no greater than
1mm/m.
4.3 After fitting entombment part, reinforce it. Foundation bolt, lifting jack,
fastener, wedge, and floor plate shall all be spot-welded and fixed. The built-in fitting
and the concrete binding surface shall be free of oil sludge and serious rustiness.
4.4 Installation of the anchor bolt shall comply with the following requirements:
a) Check if the anchor bolt hole is in the right position. The inner wall of the hole
shall be roughened and cleaned. Deviation of the screw center line and base center line
shall not be greater than 10mm; the elevation and depth of the bolt shall be in
compliance with the design requirement; squareness deviation of bolt hole wall shall
not be greater than L/200 (L refers to the length of anchor bolt mm, the same for the
following context) and shall be smaller than 10mm.
b) Centre of second phase concrete direct burial and casing flush type anchor bolt
shall comply with design requirement. The deviation of center shall not be greater than
2mm. The discrepancy in elevation shall not be greater than 0mm ~ +3mm. Squareness
deviation shall be smaller than L/450.
c) Anchor bolt adopts embedded bar. Welding of screw on it shall conform to the
following requirement:
1) Material quality of embedded bar shall agree with the material quality of anchor
bolt basically;
2) Cross-sectional area of embedded bar shall be greater than that of bolt, and the
embedded bar shall be upright;
3) When the bolt and embedded bar adopts double side welding, the weld length
shall not be smaller than 5 times the diameter of the anchor bolt. When single side
welding is adopted, the weld length shall not be smaller than 10 times the diameter of
anchor bolt.
4.5 Use wedge plate pairs and the overlapping length shall be 2/3 upwards. For the
wedge plate that bears important parts, inspect the contact situation with 0.05mm feeler
gauge. The contact length of each side shall be greater than 70%.
4.6 Install the equipment after the substructure concrete intensity reaches 70% of
the design value. Second term concrete on the floor plate shall be poured and
compacted.
4.7 The coupling surfaces of equipment shall be smooth and burr free. For joint
close clearance, measure with 0.05mm feeler gauge and the gauge shall not pass
through. Partial clearance is allowed. Check with 0.10mm feeler gauge and the depth
shall not exceed 1/3 the width of plane of composition. The total length shall not
exceed 20% of the perimeter. No clearance shall exist around the assembling bolt and
pin bolt.
Generally, fitting surface at the combination slot staggering shall not exceed 0.10
mm.
4.8 Match marks shall be considered during component installation. When a lot of
machines are installed together, each machine shall be assembled with the part marked
with the same series design.
The serial numbering in the installation record of same kind of installation or
survey points for fixed parts shall begin from +Y and be numbered clockwise (begin
from generator end, same for the following context); for rotating installation, begin
from the position of No.1 polar of rotor. Except that the survey point on the jigger is
numbered counterclockwise, others are all numbered clockwise. Attention shall be paid
to the above numbering regulations of the manufacturer.
4.9 For connecting bolt with pre-tightening force requirement, the pre-tightening
force deviation shall not exceed the 10% of the set value. If not specified by the
manufacturer, preliminary tension shall not be smaller than twice the design work
stress and shall not exceed 3/4 of the yield strength of materials.
During the installation of closely-pitched connecting bolt, the screw thread shall
be applied with lubricant. Connecting bolt shall be fastened evenly by many times.
Adopt thermal state screwed bolt. After fastening, spot check the pretension of around
20% bolt.
After each part is installed, drill hinge pin tack hole and fit pin bolt according to
design requirement.
Lock and fasten the bolt, bolt cap, and pin bolt according to design requirements.
4.10 Universality measurement of the unit shall conform to the following
requirements:
a) Check and adjust all measuring tools in the qualified metrological examination
departments.
b) Deviation of X, Y datum line and height point used in the installation of unit
against the data mark of factory building shall not exceed±1mm.
c) Measuring error of the height deviation of each part shall not exceed±0.5mm.
d) Horizontal survey deviation shall not exceed 0.02mm/m.
e) Generally, diameter of the steel wire used by the center is 0.3mm ~ 0.4mm. Its
tension stress shall not be smaller than 1200MPa.
f) No matter which method to take in measuring the center or roundness of the
unit, the measuring error shall not be greater than 0.05mm;
g) Pay attention to the impact on the surveying accuracy by temperature
fluctuation. Amend the measured number according to the changes of temperature
during the measuring.
4.11 In the intensity waterproof test for field manufactured bearing equipment and
bridge pieces, the test pressure is 1.5 times the nominal operating pressure, but the
minimal pressure shall not be smaller than 0.4MPa. Sustain for 10 minutes, no leakage
or crackles, and so on.
During the tightness compression test of equipment and its bridge pieces, the test
pressure is 1.25 times the actual working pressure. Sustain for 30 minutes, no leakage
phenomena. During the leakage test, the test pressure is actual working pressure,
sustain for 8 hours, no leakage phenomena.
Carry out the waterproof test of single cooler according to design requirement. If
not regulated, the test pressure shall be twice the working pressure, but no lower than
0.4Mpa. Sustain for 30min, no leakage phenomena.
4.12 In the kerosene leakage test of vessel, sustain at least 4h. If no leakage
phenomena, do not dismantle the vessel after finishing the leakage test.
4.13 Single keystroke shall coordinate with keystroke for the examination. The
tolerance shall comply with design specification. Keystrokes in-pair shall be checked in
pair. The parallelism shall meet the design requirements.
4.14 Welding of assembling unit and its auxiliary facilities shall comply with the
following requirements:
a) Welders of assembling unit and its auxiliary facilities shall attend special item
training and examination regularly as required by the manufacturer. They must hold
certificate to take the position after they pass examinations and are licensed.
b) All the length and height of the welding seams shall meet the drawing
requirements. Welding quality shall be checked as required by the design drawing.
c) For important components, welding shall proceed according to the welding
process or welding procedure specification specified by the manufacturer after the
qualification of welding procedure.
4.15 Trademark of turbine lubricating used by assembling unit and
speed-regulating system shall comply with the design regulations. See Annex F.
4.16 All monitoring equipment and automation components of the assembling unit
shall be check and qualified according to the ex-factory specifications.
4.17 Assembling and general installation of the water-turbine generator as well as
installation shall all be kept clean. After the installation of assembling unit, clean and
check carefully both inside and outside the unit. No impurities or nastiness shall exist.
4.18 Antisepsis painting of each part of the water-turbine generator set shall
satisfy the following requirements:
a) Each part of the assembling unit shall be pre-treated and painted in the
manufacturing factory according to the design drawing.
b) Installation (including site-welding seams) needs to be painted with final
coating on site shall proceed according to the design requirements. If the color and
factory building ornament do not agree, except for the tube color, colors of other parts
are changeable.
c) During the installation process, if the finish coat is damaged partially, fix it
according to the requirements of original coating.
d) Coating of the site operation shall be homogeneous, bubble free, wrinkle free
and with the same color.
e) Installation that needs to be varnished on site according to contract or required
specially shall comply with regulations.
5 Installation of vertical type reaction turbine
5.1 Installation of built-in fitting
5.1.1 Installation of the steel liner on the nose of the splitter wall of draft pipe
shall comply with the following requirements:
a) Range deviation from the top of nose steel liner to the X-axis of assembling unit
±30mm;
b) Range deviation from the nose steel liner side to Y-axis of assembling
unit±15mm;
c) Discrepancy in elevation from the top of the nose steel liner (or bottom)
±10mm;
d) Squareness deviation of the nose steel liner 10mm.
5.1.2 Permissible deviation of installation of draft tube liner shall conform to the
requirements of Table 1.
8.2.9 Record relation curve of input and output signals (electric current and electric
pressure) of speed detector. Within the scope of ±10% nominal speed, static characteristic
curve shall be rounded as straight line and its speed dead band shall meet the design set value.
Within the scope of ±2% of nominal speed, deviation of the measured amplification coefficient
shall not be greater than ±5% of design value.
8.3 Oil filling adjustment test of speed regulating system
8.3.1 Switch on oscillating current. Examine the oscillating quantity of electrohydraulic
conversion device, which shall meet the design requirements.
8.3.2 Examine the zero deflection and null shift of pressure of electrohydraulic
conversion device. Generally, its zero deflection shall not be greater than 5% of nominal value
of output quantity (electric current, electric pressure); within the working oil pressure scope,
the pressure null shift shall not create overt shift of servomotor.
8.3.3 Record the relationship transfer curve of incoming frequency and the
electricity-liquid or electricity- machine conversion device output. Dead volume and
amplification coefficient shall meet the design requirements.
8.3.4 Determine the relation curve between the output voltage (electric current) of
feedback transducer and servomotor stroke. Within the total excursion range of servomotor, it
shall be linear and its characteristics shall meet the design requirements.
8.3.5 The first oil charge of speed regulating system shall proceed slowly. Generally, oil
charge pressure shall not exceed 50% of the nominal pressure. Servomotor actuates several
times the entire stroke. No abnormal phenomena shall exist.
Operation switching of speed governor between manually, automatically or different
kinds of control modes shall be tested. The actuating mechanism shall be normal. Servomotor
has no evident swing.
Oil pipeline and bearing components shall take proof test as required by 4.11.
8.3.6 Manually operate the opening restriction of wicket gate servomotor; check the
indicated value on the indicator of mechanic cabinet. The indicated value shall be in
compliance with the stroke of wicket gate servomotor and servomotor of runner blade.
Deviation shall not be greater than 1% of the entire stroke of plunger for the former and for the
latter the deviation shall not be greater than 0.5°.
8.3.7 Time for emergency shutdown and opening of guide blade and runner blade as well
as step closure stroke, time and design value of guide blade shall not exceed±5% of the design
value, but ultimately it shall satisfy the requirements of calculation of guaranteed regulation.
Generally, time of shutdown and starting shall adopt twice the needed time for 75% ~ 25%
opening.
8.3.8 Deviation of time and design value of the shutdown of guide blade by accident
regulation valve shall not exceed ±5% of the design value, but ultimately it shall satisfy the
requirements of calculation of guaranteed regulation.
8.3.9 Examine the dead-stroke of reversion mechanism. Generally, the value shall not be
greater than 0.2% of the entire stroke of servomotor.
8.3.10 Plot the relation curve of wicket gate servomotor stroke and guide vane opening
from starting and closing directions. Measure 4~8 guide vane openings for each point. Adopt
the average value. When the guide blade is wide open, measure the opening of all the guide
blades. Generally, the deviation shall not exceed ±2% of the design value.
8.3.11 Plot the relation curve and switch rule of wicket gate servomotor stroke and runner
blade servomotor stroke under different water head on-cam relationship from the starting and
closing directions. It shall meet the design requirements. The inaccuracy of its runner blade
servosystem shall be smaller than 1.5% of the entire stroke.
8.3.12 Setting of the practical open-loop gain of servosystem: time for the switch-on and
closure of servomotor has been adjusted and meet the design requirements. Set amplification
coefficient and lever ratio as the maximum design value. Input step-function signal into
servosystem equivalent to 10% of the entire stroke of servomotor. Observe the movement of
servomotor; the maximal amplification coefficient and lever ratio that can keep the
servosystem stable and not over control are the practical open-loop gain.
8.3.13 Record the static characteristic curve of speed regulating system when permanent
speed droop bp = 6%, static characteristic curve shall be approximated as straight line. Speed
dead band is no greater than 0.04%. For speed regulating system of Kaplan turbine, inaccuracy
of its runner blade servosystem shall not be greater than 1.5%.
8.3.14 When the spiral case is anhydrous, record the pressure of overhead tank of low oil
pressure closedown and drop-out value of oil level.
8.3.15 When the spiral case is anhydrous, measure the minimal operation oil pressure of
guide blade and runner blade operating mechanism. Generally, it shall not be greater than 16%
of the nominal oil pressure.
8.3.16 Speed regulating system of impulse turbine shall take oil charge adjusting test
according to related test items and standards in Article 8.3.
8.4 Simulation test of speed regulating system
8.4.1 Simulate all kinds of malfunctions of speed regulating system. Protective devices
shall be secure. The actuating mechanism and alarm signals are correct.
8.4.2 Carry out the starting, shutting down, and emergency stop simulation test by
manually operation and in automatic mode. The actuating mechanism of speed regulating
system shall be normal. Alarm signal shall be correct.
9 Installation of vertical type hydrogenerator
9.1 Combination of framework
9.1.1After the combination of bracket arms of combined type framework, check the joint
close clearance, which shall meet the requirements of Article 4.7.
Top of bearing framework and combination slots of bracket arms shall be checked with
0.05mm clearance gage. Partial discontiguous length shall not exceed 10% of the total length
of the top.
9.1.2 Combination of welded type framework shall meet the following requirements:
a) After the fastness of the bearing of central body, adjust the level, measure the planeness
on plane of composition, which shall not be greater than 0.04mm/m.
b) After bracket arm is coupled with the central body, check if the following items, which
shall ...
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Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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