GB/T 28545: Evolution and historical versions
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Directives for rehabilitation and performance improvement for hydraulic turbines, storage pumps and pump-turbines
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Guideline for rehabilitation and performance improvement for Hydraulic turbines, storage pumps and pump-turbines
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Basic data | Standard ID | GB/T 28545-2023 (GB/T28545-2023) | | Description (Translated English) | Directives for rehabilitation and performance improvement for hydraulic turbines, storage pumps and pump-turbines | | Sector / Industry | National Standard (Recommended) | | Classification of Chinese Standard | K55 | | Classification of International Standard | 27.140 | | Word Count Estimation | 122,151 | | Date of Issue | 2023-12-28 | | Date of Implementation | 2024-07-01 | | Older Standard (superseded by this standard) | GB/T 28545-2012 | | Issuing agency(ies) | State Administration for Market Regulation, China National Standardization Administration | GB/T 28545-2023: Directives for rehabilitation and performance improvement for hydraulic turbines, storage pumps and pump-turbines
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ICS 27:140
CCSK55
National Standards of People's Republic of China
Replace GB/T 28545-2012
Turbines, storage pumps and pump turbines
Retrofit and Performance Improvement Guidelines
turbines,storagepumpsandpump-turbines
(IEC 62256:2017,Hydraulicturbines,storagepumpsandpump-turbines-
Published on 2023-12-28
2024-07-01 Implementation
State Administration for Market Regulation
Released by the National Standardization Administration Committee
Table of contents
Preface Ⅶ
1 Scope 1
2 Normative references 1
3 Terms and Definitions 1
4 Abbreviations 2
5 Reasons for Renovation 2
5:1 Overview 2
5:2 Improving reliability and availability 4
5:3 Repair performance and extended service life 4
5:4 Performance improvements 4
5:5 Improving power station safety 4
5:6 Environmental, social and management issues 4
5:7 Reduce maintenance and operating costs 5
5:8 Other issues to consider 5
6 Renovation work content 5
6:1 Collection and evaluation of data 5
6:1:1 Data collection 5
6:1:2 Data evaluation 6
6:2 Determination of plan 6
6:2:1 General 6
6:2:2 Determination of the transformation scope of various comparison options 7
6:2:3 Cost determination of comparison options 8
6:2:4 Determination of the schedule of the comparison plan 8
6:2:5 Determination of benefits of comparison options 8
6:2:6 Risk management of comparison options 8
6:2:7 Economic analysis of alternative options 9
6:3 Contract terms 9
6:3:1 Overview 9
6:3:2 Technical specifications 9
6:3:3 Tendering and bid evaluation 9
6:3:4 Contract Award 9
6:4 Project implementation 10
6:4:1 Model test 10
6:4:2 Design, construction, installation and testing10
6:5 Compliance assessment of transformation results and guaranteed values 10
6:5:1 Overview 10
6:5:2 Turbine performance evaluation 11
6:5:3 Generator performance evaluation 11
6:5:4 Assessment of penalties and/or rewards11
6:6 Transformation progress, cost analysis and risk analysis11
6:6:1 Schedule 11
6:6:2 Economic and Financial Analysis 13
6:6:3 Sensitivity analysis 16
6:6:4 Conclusion 16
6:7 Risk Analysis 16
6:7:1 General 16
6:7:2 Risk of not achieving expected performance17
6:7:3 Risks of continuing operation without modification17
6:7:4 Risk of extended downtime17
6:7:5 Financial risk18
6:7:6 Project Scope Risks18
6:7:7 Other risks18
7 Assessment and decision-making of the scope of renovation work 19
7:1 Overview 19
7:2 Assessment of hydropower station site conditions 19
7:2:1 Hydrology 19
7:2:2 Actual power generation 20
7:2:3 Environmental, social and related regulations20
7:3 Turbine evaluation 20
7:3:1 General 20
7:3:2 Overall assessment of turbine 21
7:3:3 Turbine performance evaluation 29
7:4 Evaluation and decision-making of unit-related equipment 41
7:4:1 General 41
7:4:2 Generator and thrust bearing 42
7:4:3 Turbine speed regulator 42
7:4:4 Turbine inlet and outlet valves and pressure relief valves 43
7:4:5 Auxiliary equipment 43
7:4:6 Equipment for installation, disassembly and maintenance 43
7:4:7 Penstock and other water passages 43
7:4:8 Impact of changes in water head of power station 44
7:4:9 Power Grid 44
8 Hydraulic design and performance test 44
8:1 General 44
8:2 Hydraulic design calculation 45
8:2:1 General 45
8:2:2 The role of CFD 45
8:2:3 Steps 46 of the CFD cycle
8:2:4 Accuracy of CFD calculations 46
8:2:5 How to apply CFD in renovation 46
8:2:6 Comparison of CFD and model testing 47
8:3 Model test 48
8:3:1 Overview 48
8:3:2 Similarity of model tests 48
8:3:3 Model test content 48
8:3:4 Application of model testing 49
8:3:5 Model test location 50
8:4 Prototype performance test 51
8:4:1 Overview 51
8:4:2 Prototype performance test accuracy51
8:4:3 Types of prototype performance testing51
8:4:4 Results evaluation 52
Appendix A (Informative) Technical Specifications 53
A:1 Overview 53
A:2 Reference Standard 53
A:3 Information to be provided in the bidding documents54
A:4 Documents to be developed during project execution55
Appendix B (Informative) Project Organization 57
B:1 Overview 57
B:2 Organizational Decision Making 57
B:3 Professional advice required57
B:4 Preliminary study of renovation project 58
Appendix C (Informative) Evaluation Example 59
C:1 General 59
C:2 Runner (applicable to mixed flow type, axial flow type and bucket type) 59
C:2:1 Documentation --- available information 59
C:2:2 Design Review 60
C:2:3 Inspection items 60
C:2:4 Evaluation of inspection results 61
C:2:5 Current situation assessment 63
C:2:6 Scope of work63
C:3 seat ring 64
C:3:1 Documentation --- Available information 64
C:3:2 Design review 65
C:3:3 Inspection items 65
C:3:4 Evaluation of inspection results 66
C:3:5 Current situation assessment 66
C:3:6 Scope of work (possible actions) 67
C:4 Movable guide vanes 67
C:4:1 Information---Available data 67
C:4:2 Review design 68
C:4:3 Inspection items 68
C:4:4 Evaluation of inspection results 69
C:4:5 Current situation assessment70
C:4:6 Scope of work70
C:5 Example: Pelton runner with serious cracks71
C:5:1 Pelton runner data 71
C:5:2 Fatigue analysis 72
C:5:3 Fracture mechanics analysis 73
C:5:4 Analysis results of bucket runner74
Appendix D (informative) Remaining life of components 75
D:1 Overview 75
D:2 Calculation of remaining life (based on current status) 77
D:3 Remaining life evaluation criteria78
D:4 Assessment of current status 79
D:4:1 Inspection level 79
D:4:2 Inspection results 79
D:4:3 Rating of components based on relative importance80
D:4:4 Sorting of inspection results 80
D:5 Influence of operating conditions81
Appendix E (Informative) Checklist for Evaluating Existing Turbines83
Appendix F (informative) Checklist for assessment of relevant equipment 107
Reference 110
Figure 1 Crack danger area A and area B of bucket-type runner bucket 29
Figure 2 Statistical relationship between Francis turbine (model) efficiency and hydraulic loss distribution and specific speed in:200531
Figure 3 Cavitation and abrasion of Francis turbine runner35
Figure 4 Cavitation erosion on the back side of the water inlet side of the bucket type bucket 36
Figure 5 High-pressure side cavitation caused by overtime operation of a Francis pump turbine at very low load36
Figure 6 Severe sediment wear of a certain Francis turbine38
Figure D:1 Bathtub Curve 75
Figure D:2 Remaining life estimation procedure 76
Figure D:3 Schematic diagram of behavior at different stages in the fatigue process77
Figure D:4 Strain gauge signals on the blades of the Francis turbine at start-up and full load 81
Table 1 Life expectancy of hydropower stations and their auxiliary systems before major modification work 2
Table 2 Typical routine inspections22
Table 3 The potential impact of the runner water-stop seal design and condition on Francis turbine efficiency when the runner is newly replaced or repaired
Impact 32
Table 4 Expected efficiency improvement value of Francis turbine runner (including improving airfoil, restoring surface condition and reducing leakage ring loss) 33
Table 5 Potential efficiency improvement of the turbine after retrofitting/replacing other components of the Francis turbine flow path 33
Table D:1 Example of inspection result rating system 80
Table D:2 Typical list examples of Francis and propeller turbine components based on different weighting factors X1~X7 of relative importance80
Table D:3 Examples of ratings for a single component assessment including three assessment criteria81
Table E:1 Evaluation of hydraulic turbine embedded parts---seat ring (suitable for Francis, rotary paddle and fixed propeller turbines) 83
Table E:2 Evaluation of turbine embedded parts—volute or half-volute (suitable for Francis, rotary and fixed-paddle turbines) 84
Table E:3 Evaluation of turbine embedded parts---basic ring (runner chamber) (suitable for Francis, rotary paddle and fixed propeller turbines) 85
Table E:4 Evaluation of turbine embedded parts---draft tube (suitable for Francis, rotary paddle and fixed propeller turbines) 86
Table E:5 Evaluation of non-embedded and non-rotating components of turbines---top cover (suitable for Francis, rotary and fixed propeller turbines) 87
Table E:6 Evaluation of non-embedded and non-rotating parts of hydraulic turbines---support cover and inner top cover (suitable for rotary propeller and fixed propeller turbines) 89
Table E:7 Evaluation of non-embedded and non-rotating components of hydraulic turbines---bottom ring (suitable for Francis, rotary and fixed propeller turbines) 90
Table E:8 Evaluation of non-embedded and non-rotating components of hydraulic turbines---guide vanes (suitable for Francis, rotary and fixed propeller turbines) 92
Table E:9 Evaluation of non-embedded and non-rotating components of hydraulic turbines---guide vane operating mechanism (suitable for Francis type, rotating propeller type and fixed propeller type
water turbine) 94
Table E:10 Evaluation of non-embedded and non-rotating components of hydraulic turbines---control loop (suitable for Francis, rotary and fixed-paddle turbines
turbine) 95
Table E:11 Evaluation of non-embedded and non-rotating components of hydraulic turbines---relays (suitable for Francis, rotary and fixed-paddle turbines
turbine) 95
Table E:12 Evaluation of non-embedded and non-rotating parts of hydraulic turbines---guide bearings (suitable for Francis, rotary and fixed-paddle turbines
turbine) 96
Table E:13 Evaluation of non-embedded and non-rotating parts of hydraulic turbine---hydraulic turbine main shaft seal (mechanical seal or stuffing seal box) (suitable for
Francis, rotary and fixed propeller turbines) 98
Table E:14 Evaluation of non-embedded and non-rotating parts of hydraulic turbine---thrust bearing bracket (suitable for Francis type, rotating propeller type and fixed propeller type
A separate bearing bracket for the turbine or a thrust bracket supported on the top cover of the turbine) 98
Table E:15 Evaluation of non-embedded and non-rotating parts of hydraulic turbines---nozzles (suitable for pelton turbines) 99
Table E:16 Evaluation of non-embedded and non-rotating components of hydraulic turbines--- deflectors and energy dissipation devices (suitable for bucket-type turbines) 99
Table E:17 Evaluation of rotating parts of hydraulic turbines---runners (suitable for Francis, rotary paddle and fixed propeller turbines) 100
Table E:18 Evaluation of rotating parts of hydraulic turbine---runner (suitable for rotary paddle and fixed propeller turbines) 102
Table E:19 Evaluation of turbine rotating parts---runner (suitable for pelton turbines) 103
Table E:20 Evaluation of rotating parts of hydraulic turbine---hydraulic turbine main shaft (suitable for bucket type, mixed flow type, rotary paddle type and fixed propeller type water turbine
turbine) 104
Table E:21 Evaluation of the rotating part of the turbine---oil receiver and oil distribution pipe (suitable for propeller turbines) 105
Table E:22 Evaluation of turbine auxiliary equipment---speed and load adjustment system (speed governor) (suitable for all turbines and water pumps
Water turbine) 105
Table E:23 Evaluation of auxiliary equipment of hydraulic turbines---draft tube air supply system (suitable for bucket type, mixed flow type, rotating propeller type and fixed propeller type
Water turbine) 106
Table E:24 Evaluation of auxiliary equipment of hydraulic turbine---lubrication system (guide vane mechanism) (suitable for mixed-flow, rotary paddle and fixed propeller water turbines
turbine) 106
Table F:1 Evaluation of related equipment---speed regulator 107
Table F:2 Evaluation of related equipment---generators and thrust bearings 107
Table F:3 Evaluation of related equipment---penstock and turbine inlet valve 108
Table F:4 Evaluation of related equipment---Civil Engineering 109
Table F:5 Evaluation of related equipment---cranes and hoisting equipment 109
Foreword
This document complies with the provisions of GB/T 1:1-2020 "Standardization Work Guidelines Part 1: Structure and Drafting Rules of Standardization Documents"
Drafting:
This document replaces GB/T 28545-2012 "Guidelines for the Renovation and Performance Improvement of Water Turbines, Storage Pumps and Water Pump Turbines" and is consistent with
Compared with GB/T 28545-2012, in addition to structural adjustments and editorial changes, the main technical changes are as follows:
a) The scope of application has been changed, and the Pelton turbine has been changed to Pelton turbine (see Chapter 1, Chapter 1 of the:2012 edition);
b) The term “modern technological transformation” is deleted (see 3:4 of the:2012 edition);
c) Added the term "replacement" and its definition (see 3:4);
d) Added abbreviations (see Chapter 4);
e) The reasons for the transformation have been changed, and the 7 main reasons for the transformation have been described in detail (see 5:2~5:8, Chapter 4 of the:2012 edition
chapter);
f) The determination of the plan has been changed, and the options are compared and confirmed from the aspects of transformation scope, cost, schedule, benefit, risk management and economic analysis:
The regulations have been refined (see 6:2:2~6:2:7, 5:2:3:1~5:2:3:6 of the:2012 version);
g) Added a typical routine checklist (see Table 2);
h) Added content for evaluation of temperature, noise, stainless steel galvanic corrosion and scratching (see 7:3:2:2:5~7:3:2:2:7);
i) Increases the impact of the roughness of the flow channel itself and its adjacent components on efficiency (see 7:3:3:3:2);
j) Added the evaluation of the impact of the sealing gap of the anti-leak ring on the hydraulic performance (see Table 3);
k) Increased expected efficiency after replacing the runner of the Francis turbine (including improving the airfoil, restoring the surface condition and reducing the loss of the anti-leak ring)
The improvement value (see Table 4);
l) Increased the potential efficiency improvement of the turbine after modifying/replacing other components of the Francis turbine flow path (see Table 5);
m) The modification plan of extending the blades of the lower ring of the runner into the upper part of the draft tube tapered tube has been deleted (see 6:3:4:5:3 of the:2012 edition);
n) Delete the plan for ultra-long guide vane design (see 6:3:4:5:3 of the:2012 edition);
o) Added assessment of the impact on the power grid (see 7:4:9);
p) The content of the feasibility study of the renovation project has been changed (see B:4, A:1:4 of the:2012 version):
This document is modified to adopt IEC 62256:2017 "Updation and Performance Improvement of Water Turbines, Storage Pumps and Water Pump Turbines":
Compared with IEC 62256:2017, this document has made the following structural adjustments:
---Chapter 4 corresponds to the abbreviation part of Chapter 3 in IEC 62256:2017;
---Chapter 5 corresponds to Chapter 4 in IEC 62256:2017;
---Chapter 6 corresponds to 5:3:4:2~Chapter 6 in IEC 62256:2017;
---7:3:3 corresponds to 7:3:4 in IEC 62256:2017;
---Appendix A corresponds to Chapter 9 of IEC 62256:2017;
---Appendix B corresponds to 5:1, 5:2:1, 5:2:2, 5:3:2, 5:3:3, 5:3:4:1 in IEC 62256:2017;
---Appendix C corresponds to Appendix B in IEC 62256:2017;
---Appendix D corresponds to 7:3:3 in IEC 62256:2017;
---Appendix E corresponds to Appendix A in IEC 62256:2017;
---Appendix F corresponds to Appendix C in IEC 62256:2017:
The technical differences between this document and IEC 62256:2017 and their reasons are as follows:
---Changed the scope of application and deleted diagonal flow units (see Chapter 1);
--- Added normative references to GB/T 2900:45 (see Chapter 3);
---Deleted the terms "upgrade", "expanded overhaul", "modern technological transformation", "reconstruction" and "renovation" (see paragraph 3 in IEC 62256:2017
chapter);
---Deleted the abbreviations "ACG" "ETA" "FMA" "FMECA" "FTA" "HAZOP" "IRR" "PCB" "VAR" (see
Chapter 3 in IEC 62256:2017);
---Changed the reason for the transformation (see Chapter 5);
---Deleted the transformation project logic flow diagram (see Figure 1 in IEC 62256:2017);
--- Added normative references to GB/T 15613 (see 6:4:2);
---Added optimization of operation mode (see 6:6:2:3:3);
---Added the influence of draft tube bulging on turbine status (see 7:3:2:4:1);
---Deleted the figures on the potential efficiency improvement after Francis turbine modification and the efficiency improvement after propeller turbine modification (see
Figure 11 and Figure 12 in IEC 62256:2017);
---Changed the impact of runner improvement on turbine efficiency (see 7:3:3:3:2);
---Changed the impact of improvements in other components of the turbine on turbine efficiency (see 7:3:3:3:3);
---Deleted the modification of the Hoover Dam hydropower station unit in the United States and the No: 3 hydroelectric generator unit of the Outardes Power Station in Canada:
Examples and curves of retrofit projects (7:3:4:2 in IEC 62256:2017);
---Deleted the potential efficiency improvement value after only improving the hydraulic design of the Francis turbine runner and the third stage of La Grande, Quebec, Canada
The power station (LaGrande-3) turbine runner (put into operation in 1982) achieved efficiency improvements by slightly cutting the water outlet edge of the blades:
High conditions and curves (7:3:4:3:2 in IEC 62256:2017):
The following editorial changes have been made to this document:
---Change the name of the standard to "Guidelines for the Renovation and Performance Improvement of Water Turbines, Storage Pumps and Water Pump Turbines";
---Replaced IEC 60193 with the informative reference GB/T 15613 (see 6:5:2, 7:3:2:2:8:2, 8:3:4:2, 8:3:4:3);
---Replaced IEC 60041 with the informative reference GB/T 20043, and used the informative reference GB/T 15469:1,
GB/T 19184 replaces IEC 60193 (see 6:5:2, 8:4:1);
---Replaced IEC 60944 with the informative reference GB/T 17189 (see 7:3:2:2:3, 7:4:1);
---Replaced ISO 7919-5:2005 with the informative reference GB/T 32584, adding installation, operation and maintenance issues (see
7:3:2:2:8:1);
---References changed:
Please note that some content in this document may be subject to patents: The publisher of this document assumes no responsibility for identifying patents:
This document is proposed by the China Electrical Equipment Industry Association:
This document is under the jurisdiction of the National Water Turbine Standardization Technical Committee (SAC/TC175):
This document was drafted by: Harbin Electric Machinery Co:, Ltd:, China Water Conservancy and Hydropower Research Institute, China Water Conservancy and Electric Power External Co:, Ltd:
Company, Dongfang Electric Group Dongfang Electric Co:, Ltd:, China Three Gorges Group Co:, Ltd:, Shanghai Voith Hydropower Equipment Co:, Ltd:, Changjiang
Jiang Survey, Planning, Design and Research Co:, Ltd:, China Yangtze Power Co:, Ltd: Gezhouba Power Plant, Baihetan Power Plant, Ministry of Water Resources
General Institute of Hydropower Planning and Design, Harbin Electric Machinery Research Institute Co:, Ltd:, Chongqing Turbine Factory Co:, Ltd:, China Power Construction Group East China Survey
Survey and Design Research Institute Co:, Ltd:, Power Construction Corporation of China Zhongnan Survey and Design Research Institute Co:, Ltd:, Power Construction Corporation of China Chengdu Survey and Design Research
Research Institute Co:, Ltd:, Huadian Electric Power Research Institute Co:, Ltd:, and Three Gorges International Energy Investment Group Co:, Ltd:
The main drafters of this document: Gong Rangqin, You Chao, Pan Luoping, Wang Lunqi, Li Changyong, Liu Jie, Zhang Peng, Zheng Taoping, Qiu Shaoping, Ma Long,
Wang Jianming, Jing Xianwei, Wu Zhijun, Qin Daqing, Wang Xiangzhi, Li Jinwei, Gao Haijun, Gao Peng, Hu Xiongfeng, Wu Jie, Wang Lei, Wang Xianping, Ding Kuang,
Li Li, Yang Yan:
The previous versions of this document and the documents it replaces are as follows:
---First published as GB/T 28545-2012 in:2012;
---This is the first revision:
Turbines, storage pumps and pump turbines
Retrofit and Performance Improvement Guidelines
1 Scope
This document applies to the following types of turbines, storage pumps and pump turbines:
---Mixed flow type;
---Axial flow type;
---Through-flow type;
---Water bucket type:
This document gives information on other aspects of the power plant building that may affect or be affected by the modification of turbines, storage pumps and water pump turbines:
equipment, but not discussed in detail:
The purpose of this document is to assist in the identification, evaluation and implementation of retrofit and performance improvement projects for turbines, storage pumps and pump turbines:
This operation is applicable to owners, consulting units and suppliers to determine the following matters:
---Demand and economic analysis of renovation and performance improvement;
---The scope of work for renewal and transformation;
---skills requirement;
---effect evaluation:
The purpose of this document is as follows:
--- Provide assistance in the decision-making process;
---Provide information resources for transformation;
---Identify major issues during the transformation process;
---Identify key points in the transformation process:
2 Normative reference documents
The contents of the following documents constitute essential provisions of this document through normative references in the text: Among them, the dated quotations
For undated referenced documents, only the version corresponding to that date applies to this document; for undated referenced documents, the latest version (including all amendments) applies to
this document:
GB/T 2900:45 Electrical Terminology Hydropower Machinery Equipment for Hydropower Stations (GB/T 2900:45-2006, IEC /T R61364:1999,
MOD)
GB/T 15613 Hydraulic turbine, storage pump and water pump turbine model acceptance test (GB/T 15613-2023, IEC 60193:
2019,IDT)
3 Terms and definitions
The terms and definitions defined in GB/T 2900:45 and the following apply to this document:
3:1
Rehabilitation
Restoring the efficiency and/or capacity of the equipment to levels close to that of a new unit or extending the life of the equipment by re-establishing the performance of the entire unit
life:
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