Hydraulic Turbines / SECTION 3

Part-02
SECTION 3 - HYDRAULIC TURBINES

TABLE OF CONTENTS

3-01 SCOPE...................................................................................................................1
3-02 TYPE AND DESCRIPTION......................................................................................1
3-03 OPERATING CONDITIONS....................................................................................3
3-04 CAPACITY AND EFFICIENCY..................................................................................6
3-05 SPEED...................................................................................................................6
3-06 RUNNER...............................................................................................................7
3-07 TURBINE SHAFT....................................................................................................8
3-08 COMBINED SHAFT ALIGNMENT.........................................................................10
3-09 GUIDE BEARING AND OIL LUBRICATION SYSTEM..............................................11
3-10 TURBINE SHAFT SEAL.........................................................................................12
3-11 STAY RING..........................................................................................................13
3-12 SPIRAL CASE.......................................................................................................15
3-13 HEAD COVER......................................................................................................18
3-14 BOTTOM RING...................................................................................................19
3-15 DISCHARGE RING...............................................................................................20
3-16 AIR ADMISSION SYSTEM....................................................................................21
3-17 WEARING RINGS, FACING PLATES, GATE SEALS, AND INSPECTION OPENINGS
22
3-18 WICKET GATES AND GATE MECHANISM...........................................................23
3-19 GATE SERVOMOTORS........................................................................................26
3-20 PIT LINER, WALKWAYS AND STAIRWAYS, AND HOIST.......................................27

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3-21 DRAFT TUBE AND LINER....................................................................................29

3-22 TURBINE PIT DRAIN............................................................................................32
3-23 TURBINE FLOW MEASUREMENT SYSTEM.........................................................32
3-24 INSTRUMENTS, CONTROL EQUIPMENT, INSTRUMENT CUBICLE, ................AND
TERMINAL BOX..............................................................................................................34
3-25 SPARE PARTS......................................................................................................41
3-26 SPECIAL TOOLS AND MAINTENANCE EQUIPMENT............................................41
3-27 SHOP ASSEMBLY AND TESTS.............................................................................42
3-28 MODEL TESTS (OPTIONAL BID ITEM).................................................................43
3-29 HANDLING OF COMPONENTS............................................................................54
3-30 LIQUIDATED DAMAGES FOR SHORTFALL OF OUTPUT AND ...............EFFICIENCY
56

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SECTION 3 - HYDRAULIC TURBINES

3-01 SCOPE

A. This Section covers the detailed requirements for the design, manufacture, shop
assembly and shop testing and optional model testing of nine, Francis type hydraulic
turbines and appurtenances to be furnished complete in accordance with these
Specifications.

The following paragraphs written in singular form for one turbine shall apply equally to
all turbines furnished, except where specifically indicated otherwise.

The basic materials and methods shall be in accordance with part-02 Section 1 General
Technical Requirements. The governing systems shall be in accordance with part-02
Section 5 Governing Systems; the inlet valves shall be in accordance with part-02 Section
4 Inlet Valves. Packing and shipping of the turbines to the project site shall be in
accordance with part-02 Section 1, General Technical Requirements (Section 1-11
Shipping and Packaging Requirements). The turbines shall be received, stored,
maintained during storage, installed, commissioned and field-tested in accordance with
part-02 Section 11, Installation and Field Testing.

3-02 TYPE AND DESCRIPTION

The turbine shall be of the vertical-shaft, single runner Francis type with spiral case and
elbow type draft tube. Rotation as viewed from above shall be clockwise. The turbine
shall be designed and constructed to meet the following requirements:
The turbine shall be designed for direct coupling to 276.47 MVA (rated capacity) and
305.0 MVA (maximum capacity), 0.85 power factor (lagging) 50-Hz alternating-current

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vertical shaft generator, which is specified in part-02 Section 6, Generators. The thrust
bearing will be mounted on a lower bracket, and both the bracket and the thrust
bearing will be furnished with the generator.
The prototype turbine hydraulic design and guaranteed performance values shall be
based upon a geometrically homologous scale model that shall be tested and witnessed,
in accordance with international standards. The prototype turbine runner and water
passages shall be homologous to this model to the maximum extent possible within the
limitation of the water passages required for this Contract. The Supplier may include.
a geometrically homologous scale model test in their proposal, if they can demonstrate
that this would provide benefit for the project and that it wouldn't cause a delay in the
specified project completion date. The Supplier is required to include a geometrically
homologous scale model test in their proposal, if this is not included in their previous
experience.

The Rufiji Hydropower Project is located on the Rufiji River in the southeast of the
United Republic of Tanzania. The Project is about 350km (in highway mileage) from the
coastal city of Dar es Salaam, Tanzania's largest city.
The Rufiji River is the longest river in Tanzania, with a total catchment area of 184,000
km². The controlled catchment area upstream of the Dam site of the Rufiji Hydropower
Project is 158,000 km². The mean annual flow and runoff of the Dam site are 896 m3/s
and 28.23 billion m3 respectively. The turbine may be expected to operate under
sand/silt concentrations of 2000 to 3000 ppm. The Turbine Supplier is advised that the
water going through the turbines will certainly contain considerable quantities of
harmful, hard and coarse quartz sand/silt (including particles 0.30 mm and greater)
particularly during peak river flow periods. All turbine components exposed to river
water shall be designed to minimize damage and wear caused by sand/silt erosion.

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A petrographic analysis of the properties of the sand/silt expected in the river water and
a chemical analysis of the river water is included in Volume 9 Reference Documents for
the Suppliers information and use in the preparation of their turbine design. The
Supplier shall critically study the sand/silt data and chemical analysis of water and take
the same into account in designing the turbine and auxiliary equipment susceptible to
abrasive effect of sand/silt, making all such specific provisions and measure including
selection of materials, coatings and paintings which will help to resist sand/silt abrasion
and enable easy and quick maintenance / replacement of worn out components.
Subject to the conclusive studies as done by the Suppliers these provisions shall cover
but not limited to: -

Use of special abrasion resistant materials for sand/silt susceptible components

Use of feasible hard abrasive resistant facings, coatings etc. on susceptible components

Easy and quick replacement and maintenance of affected components

Suppliers shall furnish the details of the specific provisions proposed and offered by
them, in their offers along with past cases and experience of the same along with the
offer.

The turbine shall be designed and constructed to provide sufficient clearances for axial
movement of the rotating parts sufficient for disconnecting the main shaft coupling and
clearing the centering portions of the coupling and for inspection, adjusting, and
dismantling of the thrust bearing.

The components of the turbine shall be designed to withstand, without excessive

deflections or vibrations and without plastic deformations or fatigue failure, the static

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and dynamic loads resulting from continuous operation within the range of guaranteed
heads and outputs and to safely withstand operation at maximum runaway speed for at
least 30 minutes.

The structure and components of the turbine shall be designed for convenient and
economical maintenance, erection, and dismantling. The height of the space from
walkways around the turbine pit interior to the generator lower bracket shall be
coordinated with the Generator Manufacturer. The major parts shall be suitable for
shipping, hauling, and land transport to the site. Removable parts shall be designed and
constructed to pass through the stator bore of the generator and through the finished
circular opening in the concrete foundation underneath it, using the lifting devices
furnished with the turbine for lifting by the powerhouse crane.

The turbine design shall permit the removal of the runner and wicket gates without
disturbing the generator and all required tools and equipment for the removal shall be
furnished to the Purchaser at Unit Delivery.

The main components of wicket gate mechanism shall be interchangeable among the
turbines furnished.

A coordinated and adequate design fulfilling the requirements and intent of the
Contract and conforming to established good Purchaser and manufacturing practice
shall be provided. Any element or device not specifically called for in the Contract but
which is necessary or desirable to provide a complete, satisfactory, and dependably
operating unit shall be included.

3-03 OPERATING CONDITIONS

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The station is with water head range of 82m ～ 118m and installed capacity of
2115MW. According to the suitable water head range of various models of
turbines, Francis turbine can be chosen for the station. The turbine shall be of
the vertical shaft; direction of rotation shall be clockwise when viewing from
above.

The main components of turbine including runner, main shaft, guide bearing,
head cover, wicket gate, spiral case, draft tube, etc.

According to the Employer’s Requirements, the turbine shall be dimensioned for

an overload of 7% in continuous operation condition.

Turbine Operating Levels and Net Heads:

Name Unit Parameter

Intake maximum normal operating water level m 184.00
Intake minimum normal operating water level m 163
Installed capacity MW 2115
Installed annual occupation hours h 2982
Annual generated energy GW·h 6307
Firm capacity MW 517
Gross head m 118
Rated Net head m 111
Minimum head m 81.33

Turbine Operating Levels and Net Heads: The Nine generating units will be supplied by a
Dam reservoir with a storage capacity of 30.67x10^9 m3 formed by variation of water

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level from full reservoir level to minimum drawdown level, a long power tunnel, surge
tank, penstocks, and draft tubes.

The turbine shall operate satisfactorily and shall deliver the specified outputs under the
following conditions of headwater and tail water levels and net heads.
maximum normal operating water level condition
water level（m）
Number of units ∆h（m） net head（m）
U/S D/S
1×1 184.00 66.66 5.27 112.07
1×2 184.00 68.22 6.30 109.48
1×3 184.00 69.44 8.01 106.55
2×1 184.00 68.22 5.27 110.51
2×2 184.00 70.42 6.30 107.28
2×3 184.00 71.90 8.01 104.09
3×1 184.00 69.44 5.27 109.29
3×2 184.00 71.90 6.30 105.80
3×3 184.00 73.66 8.01 102.33
minimum normal operating water level condition
water level（m）
Number of units ∆h（m） net head（m）
U/S D/S
1×1 163.00 66.66 5.27 91.07
1×2 163.00 68.22 6.30 88.48
1×3 163.00 69.44 8.01 85.55
2×1 163.00 68.22 5.27 89.51
2×2 163.00 70.42 6.30 86.28
2×3 163.00 71.90 8.01 83.09
3×1 163.00 69.44 5.27 88.29
3×2 163.00 71.90 6.30 84.80
3×3 163.00 73.66 8.01 81.33

Note: All elevations are in meters above mean sea level.

Maximum permissible pressure rise shall be 30% of the maximum static head and speed
rise shall not be more than 45% of the rated speed.

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Table 2.2-1 Stage/discharge relations at Mpeko I after extension

(Stage in m, and discharge in m3/s)
stage discharge stage discharge stage discharge stage discharge
65 127 73.5 2217 82 8150 90.5 17653
65.5 157 74 2450 82.5 8638 91 18302
66 202 74.5 2700 83 9130 91.5 18962
66.5 262 75 2966 83.5 9658 92 19632
67 332 75.5 3245 84 10202 92.5 20309
67.5 412 76 3548 84.5 10746 93 20996
68 498 76.5 3860 85 11266 93.5 21692
68.5 593 77 4188 85.5 11803 94 22398
69 694 77.5 4529 86 12257 94.5 23109
69.5 805 78 4888 86.5 12818 95 23829
70 930 78.5 5249 87 13388 95.5 24539
70.5 1072 79 5629 87.5 13968 96 25259
71 1235 79.5 6013 88 14557 96.5 25984
71.5 1407 80 6417 88.5 15156 97 26721
72 1599 80.5 6833 89 15765 97.5 27473
72.5 1798 81 7259 89.5 16384 98 28236
73 1997 81.5 7698 90 17013
Note: Left bank: X=373808.507 Y=9138016.230 Right bank: X=373834.502 Y=9137607.717

Tailrace maximum normal water level 9 units at full load m 73.66

Tailrace maximum normal water level 3 units at full load m 69.44
Tailrace maximum normal water level 2 units at full load m 68.22
Tailrace maximum normal water level 1 unit at full load m 66.66
Sill elevation of tailrace channel outlet m 66.00

Turbine Setting Elevation:

The centerline elevation of the turbine distributor shall be set at … … … El 61.0 m,

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providing for a submergence of not less than 4.0 meters with one unit operating at full
load.

Principal design features

Number of units 9
According to the Contract the turbine power output will be:
Q(m3/h) H(m) η(%) *N(MW)
200 81.33 94 149
235.6 111 93.6 238.6
249 111 93.4 251.45(1)
235.6 112.07 93.5 240.7

*N= ρ

Where: ρ=997(kgf/m3), g=9.78(m/s2)

(1)According to the Employer’s Requirements each turbine shall be
suitable for a seven percent (7%) overload operation above the
guaranteed output (235MW) at the Maximum Net Head, (111
m).Therefore 1.07x235=251.45MW

Rated synchronous speed 150 rpm

Setting elevation of guide center 61.0 m asl
Turbine design pressure 2.1 MPa
Particular requirements
Turbine model tests

The turbine model tests shall be carried out to ensure the satisfactory design and
manufacture of the supply. The Contractor of units shall perform tests on a model
turbine that is homologous to the prototype turbine. The main purpose of the model
test will be to demonstrate that the prototype turbine performance predicted by the
model tests satisfies the performance guarantees, to obtain the model's complete
performance and cavitation characteristics, and to allow investigation of pressure

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pulsations at the turbine in order to ensure that their amplitudes do not lead to
resonance problems. The model tests shall be performed in accordance with the relevant IEC
codes

3-04 CAPACITY AND EFFICIENCY

Turbine Capacity:

The turbine shall be capable of continuous, safe operation over the specified range of
net heads and operating conditions and shall be guaranteed for the following outputs at
the shaft coupling at the rated speed of 150.0 rpm and at suitable wicket gate openings:

Rated output not less than 238.6 MW at the rated net head of 111.00 mtrs and
discharge 235.6 m3/h (this output should occur at the turbine best efficiency point at
the rated net head and discharge).
The Maximum continuous output shall not be less than 251.45 MW at the rated net
head of 111.0m & at discharge of 249.0 m3/h. The limiting max. Turbine output at
minimum net head of 81.33 m shall be 149.0 MW at 200 m3/h discharge. The turbine
shall also be capable of delivering the guaranteed outputs. Turbine output at rated
discharge and net head 112.07 m should not less than 240.7 MW.

Turbine Efficiency:

The minimum, guaranteed, turbine weighted average efficiency shall be not less than
95.0%. The Supplier has to guarantee the weighted prototype efficiency which is built
by weighting the up-scaled model efficiencies. The up-scaling of the measured model
efficiencies shall be calculated according to IEC 60995, latest edition. The guarantees
shall be given for water temperature of 30 °C. Mechanical losses attributable to the
turbine (e.g. guide bearing and blades losses) shall be included in the prototype
efficiency. The weight factors with the corresponding operating points are specified in

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the bellow table and repeated in the corresponding data sheet. The guaranteed
weighted prototype efficiency is subject to penalties.
(2) Guaranteed Efficiency

The Supplier is required to guarantee efficiencies from 50 to 100 % of the power

output from the maximum to the minimum net head.

The guaranteed turbine efficiencies (ɳ) shall be checked at Site on three units only
selected by the Purchaser (one for each penstock). Liquidated damages for
efficiency default are applicable on the basis of the difference between the
weighted average efficiency, measured at the heads during the test and corrected
to one of the three guaranteed heads in accordance with IEC 41 Standard, and the
guaranteed value.

The average efficiency ŋwi shall be calculated according to the following formula:

Where ŋij is the efficiency in the iJ conditions and Wij is the relevant weight
according to the following table:

Capacity Weight factors at the following

fractions of capacity

J=1 J=2 J=3 J=4

Net heads i (MW) 10/10 8.5/10 7/10 5/10

Rated net head 1 238.6 25% 40% 25% 10%

Minimum net head 2 149.0 25% 40% 25% 10%

3-05 SPEED

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Rated Speed: The turbine rated speed shall be 150 rpm.

Runaway Speed:

The maximum runaway speed under the maximum net head with neither load nor
excitation on the generator shall be less than or equal to 275.0 rpm. All turbine parts
shall be designed and constructed to safely withstand the stresses, temperatures,
vibrations, and wear resulting from operation at the maximum runaway speed for at
least 30 minutes.

The Supplier, in accordance with the turbine and generator manufacturers shall,
define the maximum steady state runaway speed.

Over speed:

The guaranteed over speed during sudden load rejection from full opening under the
most unfavorable head and opening conditions shall be less than 145% of the rated
speed.

The guaranteed maximum steady state runaway speed occurring under the most
unfavorable head and opening conditions, without governor intervention, shall be
determined on the basis of the turbine model test and the generating units will be
designed accordingly.

Moreover, the turbine shall safely withstand the stress rising from the operation
of the unit at the maximum steady runaway speed for 15 (fifteen) minutes without
permanent damages.

3-06 RUNNER

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Design and Construction:

The runner shall be delivered in one piece, with blades, crown, and band either
integrally cast or made of a combination of plate steel and cast components accurately
assembled and welded together in the shop. The runner surface finish shall be in
accordance with 1-09.1, Surface Finish of Equipment Parts and Welds. The runner shall
have sufficient strength to withstand forces due to maximum runaway speed and to
support its weight and the weight of the turbine shaft when the latter is disconnected
from the generator and the runner is resting on a seating surface provided for that
purpose in a stationary part of the turbine. The design and construction shall provide
clearances for axial movement of the runner as specified under 3-2, Type and
Description. A runner cone shall be attached to the underside of the runner crown or
hub to serve as an extension for guiding the water from the runner. Provisions shall be
made to relieve water pressure under the head cover. The runner crown shall have a
bolted flange connection for attaching to the turbine shaft. The design for the
connection between the runner and the turbine shaft shall use fitted bolts, dowel pins,
keys, or similar approved method.

Materials:

The runner shall be made of stainless steel ASTM A487 Class A, Grade CA-6NM castings
or plates containing not less than 4% nickel and 13% chromium to protect against
cavitation erosion and to provide excellent weldability. Alternatively, the runner
material shall be of welded construction having all cast components of ASTM A743
CA6NM (13/4 Cr. Ni steel). The weld filler metal used in the manufacturing of the
runner shall have similar properties as those of the parent materials. After completion
of welding, the entire runner shall be subjected to post weld heat treatment to relieve

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stresses prior to machining. The runner shall be guaranteed against excessive pitting
caused by cavitation.

Wearing Rings:

The runner shall be equipped with integral wearing rings on the periphery of the runner
crown and band. These wearing rings shall be designed to work together with the
stationary wearing rings specified under Section 3-17, Wearing Rings, Facing Plates, Gate
Seals, and Inspection Openings.
Alternatively, wearing rings can be replaceable type for ease in maintenance but with
proper locking device so that the wearing ring will not come out.

Balancing:

The finished runner with wearing rings attached shall be statically balanced in the shop.

Templates and Homology Check:

The prototype runner water passages shall be homologous to the previously tested
model runner and shall be verified by precision measuring instruments, templates, or
other shop control devices. Not less than 4 horizontal templates spaced along the
vertical height of the blades to check the blade profile, inclination, and blade thickness
shall be furnished. Not less than 4 templates shall be furnished to check the profile of
the bottom of the suction side of the runner blades near the runner blade and band
juncture. Precision means shall be used for measurement of the runner inlet and
discharge openings and edges and the blade pitch. A detailed procedure shall be
submitted for the Purchaser’s review for checking the runner, defining the templates,
tools, method of measurements, and tolerance to be applied. The runner shop
homology test after finishing of manufacture will be witnessed by the Purchaser’s

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representatives. One complete set of templates shall be furnished to check the

homology during weld repairs of cavitation damage.

3-07 TURBINE SHAFT

General:

The shaft shall be made from forged, vacuum-degassed, open-hearth carbon or alloy
steel properly heat treated. It shall be of ample size and strength to operate safely in
combination with the generator shafts at any speed up to the maximum runaway speed
without harmful vibration or distortion. It shall be able to operate at the rated speed
with the guaranteed maximum turbine output without exceeding the maximum
allowable stresses for normal operation specified in 1-06, Allowable Stresses, except
that stresses may be increased as allowed therein for temporary overloads. Under the
generator unbalanced conditions, such as short circuits of one-half of the field windings,
stresses may be increased as allowed therein for generator maximum unbalanced
transient forces. The critical speed of the combined rotating parts of the turbine and
generator shall be verified by both the Turbine and Generator Manufacturers. The first
critical speed shall be at least 25% above the maximum runaway speed. The Turbine
Manufacturer shall coordinate with and provide the Generator Manufacturer with
Drawings and all details relative to the turbine guide bearing and rotating parts for use
in the critical speed calculation.

Analysis of Unit Rotating System:

The dynamic stability, rigidity, and critical speeds of the unit shaft system, complete
with its bearings and including all superimposed loads, shall be analyzed. The analysis
shall demonstrate that the bearings, their supports, and established oil films are
adequate for both normal operation and transient operating conditions without

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damage. An analysis shall also be made to verify that the dynamic loads, hydrodynamic
pressure pulsation inherent with the turbine, pressure surges in the water passages,
frequency of von Karman vortices, frequency of the electrical grid, and the natural
frequencies of the unit components are sufficiently separated to avoid resonance. A
detailed report, accompanied with related calculations and data, shall be submitted for
review.

Shaft Length:

The diameter of the turbine shaft shall be coordinated with the generator main shaft
diameter. The turbine shaft shall be of proper length and shall have coupling flanges at
both ends, one for connection to the generator main shaft and the other for connection
to the runner. The shaft coupling for connection to the generator main shaft shall be
designed to provide a precision fit between the 2 coupling halves. The coupling
dimensions and corresponding internal and external shaft diameters shall conform to
ANSI/IEEE 810, "Standard for Hydraulic Turbine and Generator Integrally Forged Shaft
Couplings and Shaft Runout Tolerances." All bolts, nuts, nut or bolt guards, keys for the
coupling, and all tools and devices for fit-up of the coupling and tightening the bolts
shall be furnished by the manufacturer responsible for the combined shaft alignment.
The tools and devices required to connect and disconnect the coupling will become the
property of the Purchaser.

Shaft Sleeve:

The shaft shall be provided with a removable and replaceable sleeve where it passes
through the shaft seal in the head cover. The sleeve shall be made of corrosion and
abrasion-resistant stainless steel, accurately machined and polished, split, and securely
fastened to the shaft. Effective means for preventing shaft corrosion under the sleeve

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shall be adopted. Suitable oil and water deflectors shall be provided between the shaft
seal and guide bearing.

Machining and Run out Tolerances:

The turbine shaft shall be accurately machined and finished throughout to obtain a
smooth finish and shall be polished at guide bearing surfaces, shaft sleeve, and at bands
provided at suitable and accessible locations for shaft runout verification. If the shaft is
made of solid forgings, it shall have a concentric hole at least 300 mm in diameter bored
axially throughout its entire length, machined sufficiently smooth to permit visual
inspection of the metal in the shaft interior, or the interior material shall be inspected
by other suitable means subject to review. The entire shaft shall be subjected to
ultrasonic examination as specified in 1-10.3, Nondestructive Testing. A circumferential
line shall be inscribed on the shaft immediately above the guide bearing housing to
provide means for verifying the vertical position of the shaft relative to a fixed pointer
installed on the bearing housing opposite this line. The amount of shaft runout shall be
verified in the shop by rotating the finished shaft in a lathe or in an aligning device, and
it shall not exceed the tolerances recommended for turbine shafts in ANSI/IEEE 810,
"Standard for Hydraulic Turbine and Generator Integrally Forged Shaft Couplings and
Shaft Runout Tolerances," Paragraph 4, "Shaft Runout Tolerances-Factory Check."

Runner Connection:

Fitted bolts or torque keys shall be provided in the runner to turbine shaft flange
connection and in the turbine shaft to generator shaft flange connection (torque
transfer by friction coupling is also acceptable). However, type of coupling shall be
subject to Purchaser’s review and approval. The bolt holes in the coupling flange at the
runner side of the shaft shall be finished in the shop to assure proper fit in the field. The

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connection and disconnection between the shaft and the runner in the turbine pit shall
be designed so as to be able lift them separately during erection and overhaul. All bolts,
nuts, nut or bolt guards, keys for the connection, and all tools and devices for fit-up of
the connection and tightening the bolts shall be furnished. The tools and devices
required to connect and disconnect the connection will become the property of the
Purchaser.

3-08 COMBINED SHAFT ALIGNMENT

General:

The fitting and aligning of the combined turbine and generator main shafts shall be
performed in the turbine Manufacturer’s factory or in the generator Manufacturer's
factory at the option of The Supplier.

Method of Alignment:

The manufacturer shall match the shafts in a way to obtain the best combined
alignment, match-ream the coupling bolt holes, fit the bolts in the coupling, bolt the
shafts together, check the alignment, fit the coupling guards, match mark the couplings,
disassemble the shafts, pack the shafts for shipment, and ship them to the site. The
shop alignment check of the combined shafts shall conform to ANSI/IEEE 810. The shop
alignment check will be witnessed by the Purchaser and shall be documented and
certified in writing by the manufacturer. Any necessary corrections to either of the
shafts for proper alignment shall be made immediately; the manufacturer shall
cooperate to effect this so as to minimize any delays and to adhere to the shipping
schedules.

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3-09 GUIDE BEARING AND OIL LUBRICATION SYSTEM

General Design:

The turbine guide bearing shall be of the segmented type, with multiple shoes lined with
babbitt bearing material and oil lubricated. Alternatively, pad type or Shell type Babbitt
lined with rotating sump self-lubricated and self-cooled design of turbine guide bearing
can also be offered. The bearing shall consist of screw adjustable and removable
bearing shoes, bearing shoe support structure, housing with oil reservoir, covers and
accessories. It shall be located as close to the runner as possible and shall permit access
to the shaft seal for seal maintenance and replacement without removing parts of the
guide bearing. The guide bearing shall also permit vertical shaft movement as required
for uncoupling the shaft for adjustment or dismantling the thrust bearing. The bearing
components shall accommodate the instruments and control devices specified for the
bearing under 3-24, Instruments, Control Equipment, Instrument Cubicle, and Terminal
Box. The design of the guide bearing shall prevent water from entering the lubrication
system and to prevent any appreciable oil loss by leakage, creepage up the shaft, or
overflow from any part of the oil system. Suitable lifting eyes and back-out bolts,
dowels, or fitted bolts shall be provided for the removal and mounting of the bearing
components.

Bearing Housing:

The bearing housing shall be designed to support rigidly the bearing elements and
transmit the maximum side thrust of the unit rotating parts to the head cover. The
housing shall be a separate component bolted to the head cover. It shall be split
vertically, rigidly bolted together, and provided with reinforcements or other suitable

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means to prevent movement due to side thrust. The bearing housing shall be provided
with a cover to prevent dirt or foreign material from entering the bearing. The bearing
housing cover shall have inspection openings provided with transparent covers.
Provisions shall be made to prevent oil from escaping from the housing and creeping up
the shaft.

Bearing Shoes:

The bearing shoes shall be lined with high-grade bearing babbitt metal and shall be
provided with oil grooves for lubrication. The babbitt metal lining shall be securely
attached to the base of the shoe and shall be trial-fitted and adjusted to the shaft. The
babbitt metal shall be given complete (100%) ultrasonic examination to assure firm and
complete bonding to the bearing shoe base metal and shall be inspected by dye
penetrant to verify the absence of surface defects.

Bearing Lubrication:

Oil shall be circulated through the bearing by action of rotation of the shaft. An oil
reservoir of sufficient capacity to contain all the oil required by the bearing lubrication
system shall be provided around the bearing. All circulating devices, strainers, and
other accessories required for a complete lubrication system shall be provided. The
cooling system shall be designed to maintain the metal temperature safely below the
critical wiping temperature of the babbitt bearing material during continuous operation
at maximum runaway speed for at least 30 minutes. A motor driven rotary type oil
pump complete with shut-off-valve, relief valve, and all piping and controls to be
installed in the pit shall be furnished to transfer oil from the bearing reservoir to empty
storage barrels located in the service bay at El. 816.5.

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Oil Cooler:

The lubrication system shall be designed so that the temperature of the bearing and oil
will not exceed 60°C under continuous normal operation. The heat exchangers shall be
designed so that they can be removed without dismantling the turbine. The bearing
shall be capable of normal operation, without injury, with no cooling water supply to the
oil lubrication system for 15 minutes. The heat exchanger coils shall be of stainless steel.
The heat exchangers shall be designed to prevent the accumulation of sediments and to
facilitate cleaning and replacement of coils. The heat exchangers may be of the internal
type consisting of cooling coils mounted in the oil reservoir inside the bearing housing.
The cooling water operating pressure shall be as stated in 1-07.9 Station Service
Compressed Air and Water Supply, and heat exchangers shall be able to withstand 1.5
times maximum operating pressure as test pressure.

Oil Leakage Collector:

Metal trays shall be provided to collect any oil that might leak from the turbine guide
bearing, complete with piping routed to the leakage oil tank specified under 3-19 Gate
Servomotors.

3-10 TURBINE SHAFT SEAL

General Design:

A shaft seal shall be provided where the turbine shaft passes through the head cover. It
shall be designed in such a way that the components of the seal can be inspected,
adjusted, and replaced without unwatering the unit and without disturbing the turbine
guide bearing. The sealing elements shall compensate automatically for wear during
their full service life. An inflatable auxiliary seal shall also be provided to permit the
replacement of the main seal components without unwatering the water passages of
the turbine. The inflatable seal shall be provided with a pressure switch, to prevent unit

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start up with the seal inflated, and suitable pipes and hoses for connection to the station
service compressed air supply. The shaft seal components shall accommodate the
instruments specified under 3-24, Instruments, Control Equipment, Instrument Cubicle,
and Terminal Box.

Seal Lubrication and Cooling:

The seal housing shall be provided with 2 or more connections around its periphery in
suitable locations for water lubrication, cooling, and flushing the seal using unit cooling
water specified in 1-07.9, Station-Service Compressed Air and Water Supply. Two
cartridge filters suitable for obtaining the water purity required for the shaft seal shall
be furnished, and both sides of the filter shall be equipped with pressure gauges. The
filters shall be installed in the turbine pit and all piping and accessories shall be
furnished.

3-11 STAY RING

General Design:

The stay ring shall consist of top and bottom ring-shaped members rigidly connected
together by the stay vanes. The stay vanes shall be shaped and positioned to guide the
water properly to the wicket gates. The stay ring shall be fabricated of tear resistant
steel plates welded together. All structures welded in the shop shall be stress relieved
by heat treatment before final machining. It shall be designed to carry the vertical
superimposed loads acting on the stay ring originated by structures and machinery,
including the weight of the generator and the upper parts of the turbine with spiral case
being empty. The diameter of the stay ring shall be large enough to accommodate the
concrete pedestals required to support the vertical load underneath the stay ring. It
shall also safely resist the tension due to the maximum pressure inside the spiral case

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without any superimposed load. The stay vane design shall consider the effect of
buckling and eccentricity between the acting axial loads and the center of gravity of the
stay vane cross section. The trailing edge of the vanes shall be shaped to minimize
vortex trails and ensure that the forcing frequency of the von Karman vortices is
separated by a substantial margin from the natural frequencies of the stay vane
submerged in water.

Sectionalization:

The stay ring shall be delivered in the least number of sections practicable for shipment
and handling preferably with the spiral case plates shop welded to it, consistent with
the type of spiral case construction employed. The sections shall have machined flanges
drilled for bolting together. The flanges shall be prepared for field seal-welding on the
interior and exterior of the spiral case. The stay ring sections shall be welded to the
spiral case sections specified under 3-12, Spiral Case.

Jack Pads and Connections:

The stay ring shall be provided with a suitable number of machined pads and
connections for the application of jacks and hold down bolts during field erection, as
specified under 1-07.5, Foundation Materials.

Drainage Provisions:

The stay ring shall have means for draining leakage water from the turbine pit through 2
or more stay vanes, or other suitable means, as specified under 3-22, Turbine Pit Drain.
The lower ends of drain piping shall be manifolded into a single header which shall
terminate below the stay ring as required for connection to the station drainage piping.

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Spider Braces:

One set of rigid steel radial spiders (minimum of 3 spiders per set) shall be provided to
maintain the circular shape of the stay ring during erection or placing of concrete. The
spider set shall have provisions for mounting instruments or devices necessary for
controlling the level, alignment, and concentricity.

Grout and Vent Connections:

The bottom flange shall have a sufficient number of holes tapped for pipe connections
for pressure grouting under the stay ring, suitably located to permit grouting and
venting all voids after placement of concrete. Threaded steel pipe plugs shall be
provided to plug the grouting and venting holes. They shall be seal-welded and ground
flush after the grouting operation has been completed.

Holes for Concrete Vibrators:

Holes of 125 mm in diameter shall be provided on the bottom flange of the stay ring to
facilitate concrete placement and the insertion of vibrators. The holes shall be located
to provide access to each area enclosed by reinforcement under the bottom flange of
the stay ring, so as to permit access to the space below the stay ring. The holes shall be
provided with circular steel cover plates beveled on the edges to be placed and welded
at the site after concreting.

Pressure Taps:

The top flange shall be provided with stainless steel pressure taps for use in
combination with additional taps provided in the spiral case for relative flow
measurements using the Winter-Kennedy method. The taps shall be properly designed,

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and their location shall be determined based on the previously performed turbine
model tests. The necessary piezometer piping shall be furnished. The piezometer piping
shall be 3/4" stainless steel and shall be furnished complete with stainless steel valves
and fittings. Provisions shall be made for connection of a pressure gauge or manometer,
pressure transducers, air venting and a connection for blowing out piezometer lines
with compressed air.

Provisions for Adjusting Alignment:

The design of the stay ring and/or mating parts shall include suitable provisions for
adjustment of level, alignment, and concentricity, to compensate for distortions or
misalignment due to field welding or concrete embedding operations.

3-12 SPIRAL CASE

General:

The casing shall be of spiral outline, with substantially circular radial cross-sections of
the water passages surrounding the stay ring to minimize deformation under pressure.
It shall be of welded plate steel construction and shall be designed to withstand,
without any external support from the concrete, the maximum internal water pressure
head at the distributor centerline resulting from the maximum static head, including a
thirty percent (30%) water hammer pressure rise, with stresses not exceeding the
maximum allowable specified for normal operation under 1-06 Allowable Stresses,
based on 100% joint efficiency. The spiral case shall be given a hydrostatic pressure test
of 150% of the design pressure for a period of one hour and shall be embedded under
pressure equal to 50% of the design pressure.

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Design and Fabrication:

The spiral case shall be made of intermediate strength carbon plate steel. The spiral
case shall be designed for fabrication in radial sections and shall be shop-fabricated to
the greatest practicable degree, with field joints as necessary only to meet handling and
shipping limitations. Longitudinal joints shall be staggered to avoid cruciform junctions
between circumferential and longitudinal weld seams. Joints shall be welded and tested
in the shop wherever practicable. The remaining field welded joints between the
shipping sections shall be properly prepared. The spiral case plates shall be accurately
formed and fitted so that edges of adjoining inside surfaces match within the tolerance
specified under 1-09.1, Surface Finish of Equipment Parts and Welds. Field-welded joints
shall, insofar as practicable, be designed for down-hand welding. The use of longitudinal
field joints between spiral case plates shall be avoided insofar as practical and will be
allowed only when necessitated by shipping limitations; where longitudinal field joints
are necessary, their locations shall be carefully selected to facilitate field welding and
weld examination. The joints between the stay ring sections and spiral case plates shall
be shop welded, to the extent possible within shipping limitations. Proper weld
procedures shall be used for the welding of the spiral case and stay ring. All principal
welds shall be full penetration type welds, with back gouging and thorough
nondestructive examination during and after the welding process. Complete
documentation shall be maintained of the welding and nondestructive examination
process, and all weld lengths shall be identified and shall be traceable to the welder that
performed the weld. After completion of welding at the shop, all shop welded seams
joining the spiral case sections and welded seams joining the spiral case to the stay ring
shall be stress relieved and shall be radiographed 100% at T joints & 100% Ultrasonic
Tests throughout their entire length, subject to the Purchaser’s approval, to confirm
that there are no voids, slag inclusions, lack of fusion or penetration, cracks, undercuts,
etc. Nondestructive examination of welds shall be in accordance with 1-10.3,

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Nondestructive Testing. After successful radiographic examination and repairs, all

welded seams on the spiral case and stay ring shall receive magnetic particle or liquid
penetrant examination throughout their entire length. All defects shall be repaired
(stress relieved if necessary) and retested in accordance with the requirements of 1-
08.2, Welding, and 1-10.3, Nondestructive Testing.

Connection to Turbine Inlet Valve:

The spiral case shall be furnished with an inlet extension arranged for a field weld
connection to the downstream extension of the inlet valve.

Accessories:

The spiral case shall be supplied complete including.

Man door:

A watertight mandoor with a clear circular opening of at least 800 mm in diameter. for
convenient access to the interior of the spiral case, located in the spiral case extension.
Mandoor size to be reviewed during detailed engineering. The mandoor shall have a
hinged inward-opening door, with a handle, stainless steel hinge pins, and corrosion-
resistant steel bolts, gasket, washers, backing out screws and a hydraulic cylinder with
hand pump for opening/closing the door. The inner surface of the mandoor shall
conform to the contour of the spiral case interior. A stainless steel test cock shall be
provided on the bottom part of the door and not less than two limit switches, to provide
remote indication of door position (open or closed), shall be provided.

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Spiral Case Drain Connection:

A drain connection on the spiral case will not be required, as the spiral case will be
drained through the inlet valve extension.

Piezometer Connections:

Stainless steel pressure taps complete with 3/4" stainless steel tubing, valves and fittings
(including compressed air blowout connections, air vents and pressure measuring device
connections) shall be furnished and installed as follows.

Net Head Piezometer:

Four pressure taps on the inlet section of the spiral case, located and arranged in
accordance with the recommendations of the "International Code for the Field
Acceptance Tests of Hydraulic Turbines," IEC Publication 41, Chapter IX, Paragraphs 3.1
to 3.4, for precise measurements of turbine inlet pressure head and for connection to
the spiral case pressure gauge to be mounted in the turbine pit as specified under 3-24,
Instruments, Control Equipment, Instrument Cubicle, and Terminal Box.

Winter-Kennedy Piezometers:

Two sets of pressure taps at points where conditions are most favorable for accurate
measurement of relative turbine flow. The type, number, construction, and locations
shall be determined in cooperation with the Purchaser so as to meet the requirements
of the Winter-Kennedy method for relative flow measurement.

Stiffener Rings, Jack Pads, and Connections:

All necessary stiffener rings, pads or brackets, and connections for the application of
jacks and tie rods during field erection, as specified under 1-07.5, Foundation Materials.
These appendages shall be designed to support and position the spiral case and

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extension during all conditions of installation, with maximum local stresses not
exceeding 60% of the yield point.

Bracing and Spiders:

All spiders or bracing required to prevent distortion of the spiral case sections during
transporting and during concrete embedment. Each section of the spiral case shall be
provided with reinforcement supports to prevent deformation during transportation
and handling. The spiral case shall also be provided with sufficient supports,
turnbuckles, and pipe jacks to prevent deformation and movement during placement of
concrete.

Cooling Water Supply Intake:

A cooling water intake on the spiral case will not be required. Cooling water shall be
tapped off the draft tube downstream of the lined portion.

3-13 HEAD COVER

General Design:

The head cover shall be made of welded steel plate and shall be stress relieved prior to
final machining. The head cover shall be sectionalized as necessary to facilitate
shipment, installation, and dismantling. The design of the head cover shall ensure ample
rigidity of all parts and connections of the head cover to minimize vibrations in the
entire range of unit operation, including continuous operation at the maximum runaway
speed. The portions of the head cover outside of the gate circle shall be designed for the
maximum internal pressure head established for the spiral case design. The portion of

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the head cover between the gate circle and the runner seals shall be designed for not
less than 70% of this pressure. The head cover shall be flanged for bolting to the upper
flange of the stay ring and for support of the turbine guide bearing and turbine shaft
seal. Provisions shall be made for lowering and lifting the head cover in or out of the pit
in one-piece by the powerhouse crane. The underside of the head cover shall be
designed to minimize hydraulic friction losses in the space between the head cover and
the runner. This space shall be adequately drained of leakage from the runner seals so
as to relieve water pressure under the head cover and to minimize hydraulic thrust on
the runner. The head cover shall have a radial clearance in the stay ring or other
provisions to permit adjustment for precise centering.

Wearing Ring, Facing Plates, Gate Seals, and Inspection Openings:

The head cover shall have a renewable wearing ring, facing plates, gate seals, and seal
ring clearance inspection openings, all as specified under 3-17, Wearing Rings, Facing
Plates, Gate Seals, and Inspection Openings.

Wicket Gate Upper Stem Bearings and Seals:

The head cover shall contain self-lubricated bushings and seals for the upper stems of
the wicket gates. The wicket gate upper stem bearing bores and the lower stem bearing
bores in the bottom ring shall be line reamed, jig bored, or finished by other methods
that will assure proper alignment. All portions of the wicket gate upper stem bearing
bores subject to contact with river water shall be of stainless steel. Suitable drainage
passages shall be provided in the head cover for conveying leakage water from the seals
to the drainage system specified under 3-21, Turbine Pit Drain, to prevent water
accumulation in the spaces between head cover ribs. The gate stem seals shall be of the
pressure-actuated type.

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Wicket Gate Stops:

The head cover shall be provided with the wicket gate stops specified under 3-18,
Wicket Gates and Gate Mechanism.

Air Connections:

The head cover shall be provided with pipe connections and passages for the air
admission system specified under 3-16, Air Admission System.

Gauge Connections:

The head cover shall be provided with at least 2 stainless steel taps with pipe plugs to
permit installing pressure gauges or transducers for measuring pressure in the space
above the runner. The number and location of these connections shall be determined in
cooperation with the Purchaser.

Control and Protective Devices:

The head cover shall accommodate the control and protective devices specified under
3-24, Instruments, Control Equipment, Instrument Cubicle, and Terminal Box.

3-14 BOTTOM RING

General Design.

The bottom ring shall be furnished as a separate part removable from the stay ring and
discharge ring and shall be made of cast steel or welded steel plate, stress relieved and
sectionalized as required to facilitate removal and shipping. The bottom ring shall
contain self-lubricated bushings for the lower stems of the wicket gates. If the bottom

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ring is a casting or a cast-weld fabrication, cast bosses for the lower gate stems shall be
hydrostatically tested to prove they are free of leakage before insertion of the lower
gate stem bushings. The lower gate stem bushing bores shall be line reamed, jig bored,
or finished by other methods that will assure proper alignment with the upper stem
bushing bores in the head cover. All portions of the wicket gate lower stem bosses
subject to contact with river water shall be of stainless steel. The bottom ring shall be of
a robust design, and shall be stiffened externally to prevent distortion and to transfer
the forces to which it will be subjected, to the stay ring and to the discharge ring.

Facing Plates and Gate Seals:

Removable and renewable facing plate and wicket gate seals shall be provided on the
bottom ring as specified under 3-17, Wearing Rings, Facing Plates, Gate Seals, and
Inspection Openings.

Grout and Vent Connections:

Unless the runner removal is through the draft tube, the bottom ring shall be provided
with a sufficient number of tapped holes to facilitate grouting, conveniently located for
connecting grouting tubes, and for venting air at locations where air can be entrapped
during the placement of concrete. Threaded plugs shall be provided to close the holes.
After the grouting has been completed, the plugs shall be seal-welded and ground flush.

DISCHARGE RING

General Design:

The discharge ring shall be furnished as a separate part removable from the stay ring
and bottom ring and shall be made of cast steel or welded steel plate, stress relieved

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and sectionalized as required to facilitate shipping and handling. Unless the runner
removal is through the draft tube, the discharge ring shall be designed to be
permanently set in the concrete structure and shall be stiffened externally to prevent
distortion and for anchoring adequately to the concrete. The discharge ring shall include
anchor rods, and provisions for attaching them, to transfer the uplift and downpull
forces, to which it will be subjected, into the surrounding mass concrete. If the runner
removal is through the draft tube, the discharge ring shall be of a robust design, and
shall be stiffened externally to prevent distortion and to transfer the forces acting upon
it to the bottom ring and to the draft tube. The discharge ring shall provide a seating
surface under the runner for supporting it and the turbine shaft when the latter is
disconnected from the generator shaft. The clearance between this surface and the
runner shall allow sufficient axial movement. The lower end of the discharge ring shall
have a suitable connection for attaching it to the top of the draft tube liner by welding.

Stainless Steel Throat Liner:

The water passage surfaces directly below the runner extending for a distance of at least
500 mm shall be protected by a stainless steel throat liner mounted in the discharge ring
or by a stainless steel 5-mm thick welded overlay in the upper portion of the draft tube
liner, which shall be applied in at least 2 passes or in an approved alternative manner.

Grout and Vent Connections:

Unless the runner removal is through the draft tube, the discharge ring shall be provided
with a sufficient number of tapped holes to facilitate grouting, conveniently located for
connecting grouting tubes, and for venting air at locations where air can be entrapped
during the placement of concrete. Threaded plugs shall be provided to close the grout

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and vent holes. After the grouting has been completed, the plugs will be seal-welded
and ground flush.

Wearing Ring:

The discharge ring shall have a wearing ring as specified under 3-17, Wearing Rings,
Facing Plates, Gate Seals, and Inspection Openings.

Gauge Connection:

A stainless steel tap of suitable size shall be provided in the discharge ring, with
connecting stainless steel piping terminating at an accessible location for mounting a
pressure gauge or transducer, to permit measuring pressure in the space between the
runner band and the discharge ring. The pipe end shall be provided with a stainless
steel valve and pipe plug.

3-15 AIR ADMISSION SYSTEM

General Design.

Means shall be provided for admitting atmospheric and/or compressed air through
connections on the head cover and for admitting compressed air through connections
on the draft tube immediately below the runner or at another location on the turbine as
may be required for smoothing part-gate operation and to prevent excessive reduction
of pressure in the draft tube. The turbine shall be designed to minimize or eliminate, if
practicable, any requirement for compressed air for smoothing operation and also to
eliminate any need for air admission at rates that would significantly reduce efficiency.

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Aeration pipes mounted in the draft tube water passage below the runner will not be
accepted.

Details.

An air admission system arranged for quick automatic opening of an air admission
control valve, cam-operated through adjustable connections to the wicket gate
mechanism, or other means, shall be provided for the admission of atmospheric and/or
compressed air to the turbine at the required gate opening. A check valve shall be
provided in the air supply line to prevent reverse flow. A shut-off valve shall be provided
to permit removal of the air admission valve or check valve without unwatering the unit.
Provisions for automatically draining any water accumulated in the air admission piping
shall be included in the system. All parts of the valve and piping exposed to water shall
be of stainless steel.

Compressed Air System for Smoothing Air.

If it is determined that compressed air for smoothing part gate operation is required,
then The Supplier shall furnish 2 air compressors complete with controls, accessories,
air receivers, interconnecting piping, and anything else required for a complete system,
to automatically admit compressed air into the turbine when is required. The system
shall comply with the requirements specified in Volume 5 Section 5-15 Governor and
Inlet Valve Compressed Air System, except that the air compressor capacity and
pressure and air receiver volume shall be modified to suit the requirements of the
smoothing air system.

3-16 WEARING RINGS, FACING PLATES, GATE SEALS, AND INSPECTION OPENINGS

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General:

Wearing rings for the runner seals and distributor facing plates for the head cover and
bottom ring throat surfaces adjacent to the wicket gates shall be made of suitable type
stainless steel with difference in hardness in the stationary and moving parts so as to
prevent galling or tearing of the metal in case of accidental rubbing. The characteristics
and degree of hardness of the wearing rings and facing plates shall be determined to
suit the conditions. The difference in hardness of the rotating and stationary wearing
rings shall be not less than 40 points Brinell.

Wearing Rings:

Removable and renewable stationary wearing rings shall be provided at the runner seals
where there are small clearances between the runner and adjacent stationary parts. Not
more than 2 sets of runner seals shall be provided, one in the upper and one in the
lower part of the runner. The upper and lower stationary wearing rings shall be
sectionalized. The wearing rings shall be securely fastened, and upper wearing rings
shall be so located that the clearances may be readily measured, with the turbine
assembled, through the seal clearance inspection openings specified below.

Facing Plates:

Removable and renewable distributor facing plates shall be provided on the head cover
and bottom ring, adjacent to the ends of the wicket gates. The facing plates shall be
sectionalized to facilitate handling and replacement. They shall be attached by corrosion
resistant metal screws which shall be flush with the facing plates and adequately
secured in place to prevent loosening during operation.

Gate Seals:

Removable and renewable metal wicket gate seals shall be provided in the head cover
and bottom ring to minimize the leakage through the clearance spaces at the tops and

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bottoms of the wicket gates. The metal seals shall be placed over rubber or other
resilient and precompressed material to ensure contact with the wicket gate ends. The
seal shall extend to the gate stem, completely sealing the clearance between the ends
of the gates. Wicket gate leakage shall be guaranteed as stated in Volume 3 Section 1
Bid Forms, Attachment-13, Guaranteed Characteristics, and will be measured within the
guarantee period. The wicket gate leakage shall not exceed 0.1% of full gate discharge at
static head.

Seal Clearance Inspection Openings:

Adequate inspection openings with watertight cover plates or plugs shall be provided to
permit checking the radial clearance between the upper stationary wearing rings in the
upper parts of the runner at 4 approximately equally spaced points around the upper
wearing rings.

3-17 WICKET GATES AND GATE MECHANISM

General Arrangement:

An adequate number of wicket gates shall be provided, with stems supported in

bushings in the head cover and bottom ring, to control and guide water to the runner.
The turbine may be idle for an extended period of time with full hydrostatic pressure
against the wicket gates, and provisions shall be made to reduce gate leakage to a
minimum and to use materials which will resist erosion. The number of the wicket gates,
stay vanes, and runner blades shall be coordinated so as not to cause flow-induced
vibrations in operation of the turbine. The wicket gate design shall be such that in the
event of shear pin breakage and failure of the gate stops, no wicket gate can contact the
runner.

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 Hydraulic Turbines / SECTION 3

Gate Design:

The wicket gate bodies shall be made of cast stainless steel containing not less than 4%
nickel and 13% chromium with integral stems. The critical areas of the wicket gates
where the stem joins the body shall be designed to minimize stress concentrations. Each
gate shall be supported in 3 amply proportioned self-lubricated guide bearings of
proven design, one located in the bottom ring and 2 in the head cover. Each upper gate
stem shall also be provided with an adjustable self-lubricated thrust bearing, amply
proportioned to carry the weight of the gate and resist any upward and downward
hydraulic thrust on the gate. Suitable means shall be provided for readily adjusting and
maintaining the adjustment of each gate in the correct position between the head cover
and bottom ring.

Hydraulic Balance:

The wicket gates shall be designed so that the hydraulic moment has a closing tendency
in the range from full gate opening to approximately the speed-no-load position.

Machining:

The gate shall be accurately machined and finished including the stems, the top and
bottom of the gate bodies, and along the contact lines between adjacent gates when
the gates are closed. Adequate machining method shall be employed to assure that all
gates have the same height and that the upper and lower ends are parallel to each other
and perpendicular to the vertical axis of the gates. The gate surfaces shall be finished
smooth within the surface finish tolerances specified in Volume 5, Section 1-09.1,
Surface Finish of Equipment Parts and Welds. The gate surfaces in contact when the
gates are closed shall be adjusted with precision to minimize leakage. The areas at the

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contact lines shall be machined in such a way that the surface pressure between the
contact surfaces remains constant for the entire height of the gates when gate squeeze
is applied and the gates are closed under the specified maximum head.

Self-Lubricating Bushings:

The wicket gate stems and other components of the gate operating mechanism shall be
guided and supported by bushings or pads made of self-lubricating material, and the
mating parts shall be fabricated from or lined with corrosion resistant steel having
substantially higher hardness value than the self lubricating material.

Gate Mechanism:

The gate mechanism shall consist of all elements for connecting the wicket gates to the
gate servomotors, including gate levers, links, gate operating ring, servomotor
connecting rods, self-lubricating bushings, and pins. The components of the gate
mechanism shall have ample strength to withstand the maximum load that can be
imposed on them by the most severe operating conditions. Parts having relative motion
and contact shall be self-lubricating type. Means shall be provided for adjusting the
position of any individual gate independently of the others, to assure its contact with
adjacent gates in the closed position and essentially equal opening in simultaneous
openings of all gates. Ample adjustment shall be available to compensate for future
wear and distortion. Each gate shall be individually connected to the gate operating ring
through a steel lever keyed to the gate stem and through a shear lever and link. The
entire operating mechanism shall be readily accessible for inspection, adjustment, and
repair.

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Gate Operating Ring:

The gate operating ring shall be designed to distribute servomotor forces and moments
simultaneously to all wicket gates. It may be located inside or outside the gate circle and
shall be arranged to allow convenient access to the turbine guide bearing and shaft seal.
The ring shall be made of steel, stress relieved after welding, and of rigid design
supported on renewable elements lined with self lubricating material. The structure
supporting the operating ring shall be of adequate strength and stiffness to prevent
excessive deflections of the structure when the gate operating ring is subjected to
unbalanced thrust of one servomotor with the other servomotor blocked. The gate
operating ring shall be designed for connection of the gate servomotor connecting rods
and all of the gate links and pins.

Connecting Rods:

The connecting rods between the gate servomotor piston rods and gate operating ring
shall be stiff and of steel with self-lubricating bushings.

Shear Pins:

A replaceable shear pin, made of suitable material proven in practice, shall be provided
in the operating linkage of each gate. The pin shall have sufficient strength to withstand
the maximum normal operating forces, but it shall break from forces in both the
opening and closing direction to protect the remainder of the gate mechanism from
damage if one or more gates become blocked. The shear pin shall break smooth and not
deform. The operating linkage shall be designed so that when a shear pin fails the gate
operating lever and its linkage remain pin-connected to the gate operating ring. The
failure of one shear pin shall not cause progressive failure of the others.

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Gate Restraining Device:

A gate restraining device shall be provided on each gate, by friction or other means, and
shall prevent the flailing or erratic movement of the wicket gate following shear pin
failure. The device shall allow the gate operating ring to move in both opening and
closing direction if there is an obstruction between any pair of gates.

Shear Pin Failure Annunciation:

The wicket gate shear pins shall be equipped with a shear pin failure detection system,
to provide an electrical signal for indication and annunciation when a shear pin fails. The
system shall specifically identify which shear pin or pins have failed. All necessary
contacts and wiring within the turbine pit shall be furnished. The signal wiring shall be
brought to the turbine terminal box.

Gate Stops:

Rugged gate stops designed for the maximum hydraulic moment and impact that can be
exerted on the stops under the most adverse operating conditions shall be provided for
each gate. The stops shall be provided between the gate lever and head cover and shall
limit the angular movement of a gate, in the event of breaking of a shear pin, to prevent
interference of a loose gate with the movement of adjacent gates or parts. The gate
stops shall be protected by shock-absorbent pads.

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Gate Lever Aligning Tool:

One gate lever aligning tool shall be provided for all three units for safely pulling any
gate into position for shear pin replacement under unit operating conditions.

3-18 GATE SERVOMOTORS

General:

The turbine shall be provided with 2 oil-pressure-operated, double-acting, hydraulic-

cylinder type servomotors to operate the wicket gates through the wicket gate
operating mechanism. The servomotors shall be located in alcoves in the pit liner wall
supported on suitable machined pads forming an integral part of the turbine pit liner
and shall be designed to withstand the maximum reactions in both directions. Oil for
operating the servomotors shall be supplied under pressure from the governor oil
pressure system under the control of the governor actuator. The operating pressure
shall be selected in cooperation with the governor manufacturer and shall conform to
the description under 5-02, Basic Parameters and Other Pertinent Data. The servomotor
components shall be designed for the maximum governor oil operating pressure. The
gate servomotors shall be designed with a slight overtravel in the closing direction to
apply a squeezing force on the closed gates.

Servomotor Capacity:

The turbine servomotors shall have a combined capacity sufficient to operate and
control the rate of movement of the wicket gates under all head, output, and transient
conditions and to move the gates through the full opening or closing stroke of the
servomotors with precision control within the gate movement times specified under 5-

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02, Basic Parameters and Other Pertinent Data, with minimum oil pressure in the
servomotor cylinders corresponding to a minimum operating pressure in the governor
oil pressure tank reduced by piping losses.

Servomotor Details:

The servomotor cylinders and heads shall be made of steel and shall be provided with
flanged connections for piping, packing boxes, or seals to prevent leakage of oil in any
position of the piston. An outboard piston rod guide bearing shall be provided beyond
the packing box or seal, to prevent lateral loads on the packing boxes or seals. Means
shall be provided to assure adequate lubrication to the seal packing. The piston shall be
of cast steel and shall be fitted with piston seals and glydrings and one wiper ring
suitably shaped to obtain uniform pressure on the cylinder wall and to prevent leakage
of oil past the piston. Suitable drain valves and piping shall be furnished for draining oil
from each end of the servomotor and for bleeding entrapped air. Pressure gauge
connections with stopcocks shall be provided at both ends of each cylinder.

Slow-Closing Device:

The servomotor shall be equipped with adjustable slow-closing devices to retard the
rate of closure between the approximate speed-no-load position and the closed position
so as to minimize shock loads in the gate mechanism when the gate bodies contact each
other.

Manual Locking Device and Stroke Limiter:

The servomotors shall be provided with combination screw type mechanical

locking/stroke limiting devices to securely hold the wicket gates in the open or closed

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position or limit the gate opening against maximum governor oil pressure and maximum
hydraulic torque acting on the wicket gates. The combination locking device and stroke
limiter shall be designed for easy manual operation and shall be designed to positively
limit the gate opening and to prevent accidental position change. A suitable scale
affixed to each device shall show the limit for which the gate-limit device is set. Actual
gate opening shall be accurately indicated on a suitable scale with pointer affixed to one
servomotor or to the gate operating ring:

Oil Leakage Collector:

Metal trays shall be provided to collect any oil that might leak from the servomotors.
The trays shall be located in the turbine pit and shall be connected by piping to a
leakage oil tank located outside of the turbine pit. The leakage oil tank shall be provided
with a flanged cover, a breather filter, oil level sight gauge, and provisions for
transferring the leakage oil into a portable container, provided by others, for disposal.
The leakage oil collectors, piping, and oil tank shall be furnished as a complete system.

3-19 PIT LINER, WALKWAYS AND STAIRWAYS, AND HOIST

Pit Liner:

The turbine shall be provided with a welded steel pit liner of not less than 12-mm thick
plate which shall extend from the stay ring, the full height of the turbine pit, to the
bottom of the generator thrust bearing bracket. The pit liner shall be fabricated in the
least number of sections to meet shipping limitations, and the sections shall be joined
together and to the stay ring by field welding. Shop and field welds on the pit liner may
be welded without stress relieving. The inside diameter of the pit liner shall be ample to

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provide at least 150-mm radial (300-mm diametral) clearance, during head cover
removal, between the periphery of the head cover and any instrument, auxiliary
equipment, and piping mounted on the pit liner. The pit liner shall be provided with
reinforcing ribs to maintain its shape during embedding and anchors to secure it firmly
to the concrete and to transmit a portion of the load from the structure above the spiral
case to the stay ring. The pit liner shall be provided with recesses for the installation of
valves, and other accessories. The pit liner shall have provisions to collect and dispose of
any water seeping up between the concrete and the liner and to prevent external
pressure on the liner. A drain consisting of perforated channels shall be welded to the
outside of the upper part of the pit liner and along the top of the steel liner access
stairway to intercept any water seeping up between the concrete and liner. Drain piping
shall be provided to dispose of such leakage to the turbine pit drainage system.

Walkways, Platforms, Stairways, and Railings:

Working, operating, and inspecting walkways and platforms complete with non-slip type
floor plates or gratings, stairs, ladders, and hand railings shall be furnished where
necessary or desirable in the turbine pit, to provide convenient access to all equipment
and components located in the pit. All walkways, platforms, stairways, and equipment
located in the pit shall be designed for easy removal as necessary for dismantling the
turbine. Individual floor plate sections shall be not heavier than 30 kg. An entrance
opening, 1.8 m width minimum with steel stairway and liner forming a part of the pit
liner and extending from the pit walkway up to the turbine floor elevation, shall be
provided for convenient access to pit.

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Monorail Hoist:

For convenience in handling, removing and installing parts during inspection and
maintenance, the turbine pit shall be provided with one electric monorail hoist, and a
monorail which runs on a rotating bridge. The capacity of the hoist shall be as required
for the replacement of guide bearing parts, servomotor parts, gate operating
mechanism parts, the monorail and other equipment located in the turbine pit. The
crane rail which carries the rotating bridge shall be circular within the pit. The monorail
shall extend to the pit access passage and sufficiently far out into the gallery to pick up
turbine parts placed under the monorail in the gallery. The hoisting system shall include
the rotating hoist bridge spanning the pit and straddling the turbine shaft, arranged to
rotate on the circular rail to permit traversing the entire pit area with the hoist. A drive
mechanism shall be provided for the movement of the rotating bridge and the trolley.
All rail supports, rail switches, mechanical interlock permitting the hoist to travel onto
the monorail in the turbine pit access only after alignment with the rotating monorail,
suitable hoist with pendant controls, and all other items necessary for the complete
hoisting system shall be provided. The circular rail supports shall be located on the face
of the concrete opening immediately above the pit liner. A circular 3-phase, 4 wire, 415
V, 50 Hz feed rail and collector shall be provided and protected by a suitable 3 pole
molded case air circuit breaker.

Pit Lighting System:

A complete lighting system shall be designed and provided inside the turbine pit. The
lighting system shall consist of an adequate number of flush mounted fluorescent or
incandescent lighting fixtures with guards arranged to provide lighting in the turbine pit
and in the turbine pit access way. The fixtures shall operate at 230 V ac and shall provide
a minimum illumination of 150 lux on vertical and horizontal working surfaces inside the

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pit. Duplex receptacles and lighting switches shall be arranged at appropriate locations.
Wiring shall be routed in conduit and terminated in the turbine terminal box. The
Supplier shall provide a 230 V ac, 1-phase, power supply for the lighting system to the
turbine terminal box. Wire and conduit from the turbine terminal box to lighting fixtures
shall be furnished as part of the lighting system. The lighting fixture, guards, receptacles,
and switches shall be of heat-resistance and vibration-proof type.

3-20 DRAFT TUBE AND LINER

General:

The draft tube shall be of the elbow type with no center pier as shown on the Drawings.
The draft tube shall be provided with a steel liner extending from the discharge ring
through the vertical conical portion and draft tube bend upto the end of the power
station (upto draft tube gate). Part of the draft tube liner shall be removable if the
turbine is designed for bottom removal of the runner.

Design and Fabrication of Steel Liner:

The draft tube liner shall be fabricated of plate steel in the least number of sections
practicable for shipment and handling and with joints properly prepared for field
welding. The liner thickness shall be determined by the Supplier, subject to approval of
the Supplier’s calculation by the Engineer-In-Charge. The liner shall be not less than 16
mm thick with the adequate no. of ribs. This thickness is with respect to every section of
draft tube liner. The interior surfaces of the liner shall be hydraulically smooth and free
of waviness, projections, depressions, and other surface irregularities. Plates shall be
fitted so that edges of adjoining interior surfaces match within the tolerances specified

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under Volume 5 Section 1-09.1, Surface Finish of Equipment Parts and Welds. The liner
shall be adequately stiffened with external ribs and shall be provided with adequate
means for maintaining the alignment during placing of concrete and for securely
anchoring the liner in concrete for the service life of the machine. Embedded parts of
the liner and anchorage shall be designed for the external hydrostatic pressure from
water seepage equivalent to the maximum design flood tailwater elevation with an
absolute pressure of one-half atmosphere on the interior of the draft tube liner.

Jack Pads and Connections:

The draft tube liner shall have a suitable number of pads and connections for the
application of jacks or leveling screws and tie rods during field erection. Anchors for
securing the liner to the concrete shall be attached to the external ribs to minimize
stress concentrations in the liner.

Draft Tube Man door:

The draft tube liner shall have a watertight and airtight man door with a clear opening
not less than 750 mm wide by 1000 mm high, located approximately as shown on the
Bid Drawings at an elevation suitable for convenient access from a passageway in the
powerhouse substructure to the underside of the runner and for installing the
maintenance platform specified herein. However, the size can be discussed during
detail engineering. The man door shall have a frame, hinged inward-opening door with a
handle, stainless steel hinge pins and corrosion-resisting steel bolts and backing-out
screws, washers, and gasket. The inner surface of the door shall conform to the interior
contour of the draft tube liner. A stainless steel test cock shall be provided below the sill
of the door and not less than two limit switches, to provide remote indication of door
position (open or closed), shall be provided. The portion of the liner exposed in the

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access passageway shall be reinforced by stiffener ribs to reduce the effects of

secondary stresses and vibration. The liner around the access gallery shall be provided
with a water collector to intercept water leaking between the concrete and liner. The
leakage water shall be routed through a stainless steel pipe, not less than 50 mm in
diameter, to be discharged to the nearest floor drain or gutter.

Grout and Vent Connections:

The draft tube liner shall be provided with tapped holes for pipe connections to
facilitate pressure grouting and for venting air after the concrete has been placed and
cured. Threaded plugs shall be provided to close the holes. After the grouting has been
completed, the plugs shall be seal-welded and ground flush.

Pipe Connections:

The draft tube shall be provided with the following pipe connections:

Pressure Gage Connection:

A 1/2-in. threaded stainless steel pipe tap shall be located in the upper part of the liner
complete with 3/4" stainless steel tubing, stopcock, and fittings for connection to the
draft tube pressure/vacuum gage supplied for mounting near the draft tube mandoor.

Compressed Air Admission Connections:

Suitable stainless steel pipe connections shall be located in the area immediately below
the runner, piped to accessible locations near the passageway and valved and plugged,
for the compressed air provisions specified under 3-16, Air Admission System, if air

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admission through the upper part of the draft tube liner is best suited to the turbine
design. All piping, fittings, and valves shall be stainless steel.

Pressure Tap Connections:

Not less than 8 stainless steel pressure taps complete with 3/4" stainless steel tubing,
valves, and fittings (including compressed air blowout connections, air vents and
pressure measuring device connections) shall be located in the draft tube, 4 located in
the top section of the draft tube liner for measuring pressure pulsations and 4 built into
plates suitable for embedment into the wall of the concrete portion of the draft tube
near the draft tube exit. The 4 pressure taps on the outlet section of the draft tube shall
be located and arranged in accordance with recommendation of the “International Code
for the Field Acceptance Tests of Hydraulic Turbines,” IEC Publication 41, Chapter IX,
Paragraphs 3.1 to 3.4, for precise measurements of turbine outlet pressure head and for
connection to the pressure transducer specified under 3-24, Instruments, Control
Equipment, Instrument Cubicle, and Terminal Box.

Maintenance Platform:

One maintenance platform shall be furnished, to be used for all three units, to facilitate
inspection and maintenance of the runner from the draft tube without dismantling the
unit. The platform shall extend over the entire cross-sectional area of the draft tube
where it is installed. It shall be made of alloy aluminum beams and corrugated alloy
aluminum sheets or plates and shall be sectionalized for easy transport, assembly, and
disassembly through the access gallery and draft tube mandoor shown on the Drawings.
Circular pockets or removable brackets, or both, shall be provided on the draft tube
liner to support the main members of the platform if there is no removable draft tube
liner section provided. The support pockets and bolt holes for the brackets provided in

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the draft tube liner shall be made from stainless steel, ground flush with the liner, and
shall be covered with removable stainless steel covers or plugs. The platform shall be
complete with all accessories required for its installation, and it shall be designed for a
live load of at least 500 kg/m2. All parts shall be properly identified for easy assembly.

3-21 TURBINE PIT DRAIN

An adequate drainage system shall be provided for collecting leakage water from the
gate stem seals, turbine shaft seal, and other sources subject to leakage and for
removing it from the turbine pit. Gravity drainage within the pit is desired. Piping shall
be provided within the pit as necessary to connect through the stay vanes or pit liner
with powerhouse drainage piping for disposal of the drainage water to the station
drainage system (including oil separator). If an automatic drainage system operated by
an electric motor driven pump is needed for removal of the leakage water, two ac
electric motor driven pump shall be provided complete with all necessary float switches,
combination circuit breaker and motor starter, alarm, piping, and valves. All related
piping, fittings, valves, and other equipment shall be made from stainless steel.

3-22 TURBINE FLOW MEASUREMENT SYSTEM

General:

One complete turbine flow measurement system shall be furnished for each turbine.
The system shall perform flow measurement, display, totalization, recording, and
remote indication during unit operation or while conducting a turbine efficiency or index
text. The system shall operate based on the propagation of time difference of the
ultrasonic waves which cross a sloped path with respect to the center line of the water

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conduit in relation to the velocity of the water in such conduit. The system shall be an
Accusonic 7500 Series Multiple Path Acoustic Flowmeter System, as manufactured by
Accusonic Technologies, Division of ADS LLC; 28 Patterson Brook Road Unit 1; W.
Wareham, MA 02576, U.S.A.; phone 508-273-9600; or equivalent. The instruments and
other components of the system shall be designed for successful and highly-reliable
operation in a wet environment, with temperatures between 0°C and 40°C. The system
shall be capable of measuring flows, from 25 up to 110% of the maximum discharge of
each turbine, with an accuracy not less than 0.5 % regardless of water friction
coefficient in the conduit, water temperature and composition, and of any other factor
affecting the speed of sound in the water. The calibration of the system shall be verified
and adjusted by the representative of the flowmeter supplier during the first phase of
the turbine performance measurement tests specified in Volume 5 Section 11,
Installation and Field Testing of Turbines, Inlet Valves and Governors. All data shall be
displayed in metric units. The display shall be digital, LED in-line type, with digits not less
than 12 mm high, and with sufficient contrast to be legible in an illuminated
environment. The initial zeros to the left of the first figure displayed shall be omitted.
The electric power available for the system consists of 230 V, 50 Hz ac and 110 V dc. A
complete system shall be furnished, including cables, conduits, piping, connectors, all
mounting hardware, splicing boxes, cubicles and cabinets, instruments, and other
accessories and materials required.

Water Velocity Sensors:

Two complete sets of water velocity sensors shall be furnished with the turbine flow
measurement system. A complete set of water velocity sensors shall consist of 4
acoustical steps at one cross plane of 45 degrees grade from the center line of the
straight section of the penstock of each unit. The acoustical transducers (8 per unit)

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shall be installed in the penstock. The turbine flow measurement system supplier will be
responsible to provide all necessary information for drilling holes in the penstock to the
penstock supplier prior to the installation of the transducers. Installation of the
transducers shall be supervised by the representative of the flow measurement system
supplier. Each transducer shall be provided with cable and connector, both suitable for
use in water. The transducer cables shall end in a splicing box. All bolting, adjusting, and
sealing material for the transducer assemblies and their bases shall be furnished. The
system shall utilize instrumentation cable, as specified in 1-07.3, Electrical Accessories,
for interconnections between the splicing boxes and the turbine flowmeter.

Computing, Display, and Control Components:

General.

The turbine flow measurement system shall include all main components specified
below, with interfaces and other accessories.

Flowmeter:

One electronic digital processor shall be furnished which shall receive, verify, average,
process, or reject the signals received from the 4 acoustical steps and shall integrate the
input data in order to determine the turbine flow. The processor shall evaluate each
incoming acoustical signal and reject signals distorted by reflection of reverberating
signals or whose amplitudes are below the minimum acceptable value. Each input
signal shall also be checked to ensure that the travel time of the ultrasonic wave and the
corresponding calculated velocity, flow, and flow change are within the limits of the
system. The system limits shall be selected at the site by The Supplier after consultation
with the Purchaser. The meter shall be provided with a keyboard for access to the
system at the site and for adjustment of conduit parameters and test constants, in order

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to use the diagnostic procedure or to display the transient test values, including
individual velocities of each acoustical step connected to the meter. The system shall be
capable of "self-diagnosing" in order to have a continuous check-up of input data,
computation accuracy, and meter output data. Rejected data shall not be used in flow
determination, and if the fault continues beyond the user preset time limit, the output
data shall reset to zero, and the meter shall indicate the position and cause of the fault.
In case of failure of one of the transducers, the system shall be capable of operating
without receiving signals from 1 of the 8 acoustical steps, using the historical data
stored in the processor to simulate the inactive step, and displaying such incomplete
operation. The meter shall be capable of diagnosing a total or partial failure in the flow
measuring system and of delivering an output signal indicating the failure into the
remote I/O modules of the computer control system provided by The Supplier under
Section 6. The meter shall show a 4-digit display of the turbine flow, in cubic meters per
second, and at least 6 digits for total accumulated volume of the turbine, in cubic
meters x e10. A dc current signal proportional to turbine flow shall be provided. The
signal shall have a rating of 4 to 20 mA full scale and shall be suitable for termination in
a load resistance up to 750 Ω. The signal will be connected to the remote I/O modules of
the computer control system. The cables for interconnection of remote I/O modules
with the flowmeter shall be furnished by The Supplier under Section 6. The flowmeter
shall be located in a separate NEMA Type 4 enclosure, located near, or rack mounted in,
the governor electrical cubicle.

3-23 INSTRUMENTS, CONTROL EQUIPMENT, INSTRUMENT CUBICLE, AND

TERMINAL BOX

List of Instruments and Control Equipment:

The turbine shall be provided with instruments, control equipment, and switches as
necessary for complete operation with high degree of safety, reliability, and continuity

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in service. All necessary electrical wiring, wiring materials, piping, and piping materials
and accessories within the turbine pit and governing system shall be furnished. The
following equipment, numbered 1 to 24, shall be included and furnished at the locations
indicated for each turbine. Additionally, any other instrument or control equipment
required by the turbine design shall be furnished, even if it is not included in the list.

No. Nameplate Designation Instrument Location Quantity

1 Spiral case pressure Pressure gauge Turbine pit 1
2 Draft tube pressure and Compound Draft tube 1
vacuum pressure and access
vacuum gauge passageway
3 Guide bearing oil cooler water Pressure gauge Turbine pit 1
pressure
4 Turbine shaft seal water Flow indicating Turbine pit 1
transmitter
5 Guide bearing metal Resistance Turbine pit 2
temperature temperature
detector
6 Guide bearing metal Thermometer Instrument 1
temperature cubicle
7 Guide bearing oil temperature Resistance Turbine pit 2
temperature
detector
8 Guide bearing oil temperature Thermometer Instrument 1
cubicle

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No. Nameplate Designation Instrument Location Quantity

9 Guide bearing oil cooler water Resistance Turbine pit 1
temperature at exit temperature
detector
10 Guide bearing oil transfer Combination Turbine pit 1
pump power supply magnetic starter
11 Guide bearing oil transfer Pushbutton station Turbine pit 1
pump control
12 Guide bearing oil level Level indicator Turbine pit 1
13 Turbine shaft seal housing Resistance Turbine pit 2
temperature
detector
14 Guide bearing oil cooler water Flow indicating Turbine pit 1
flow transmitter
15 Turbine shaft seal water Pressure switch Turbine pit 1
supply
16 Head cover water level Level switch Turbine pit 1
17 Vibration detector Vibration detector Head cover 1
with transducer
18 Vibration detectors (shaft Proximity probes Turbine guide 2
runout) bearing
housing
19 Water leakage to guide Water-in-oil Turbine pit 1
bearing oil detector
20 Turbine pressure head Pressure transducer Outside 2
turbine pit

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No. Nameplate Designation Instrument Location Quantity

21 Turbine discharge Ultrasonic Control room 1
flowmeter
22 Flow and efficiency Flow and efficiency Instrument 1
instrument cubicle
23 Unit output Active power Instrument 1
transducer cubicle
24 Shear pin failure signal Annunciator for Instrument 1
each shear pin cubicle
failure and auxiliary
relay with minimum
2 normally open
contacts

Instrument and Control Equipment Details:

General.

Instruments and controls shall be located so that they are easily accessible and their
dials, indicators, and nameplates are clearly readable. The proper scale ranges for
instruments, if not specified, shall be determined to suit the operating conditions. Data
for all instruments to be provided with the turbine, including type, size, scale range,
electrical ratings, and the name of the manufacturer, shall be furnished. Nameplates for
the instruments shall be furnished in English. A steel panel or panels shall be provided
for group-mounting the instruments and control equipment located in the turbine pit.
All instruments mounted on the instrument cubicle shall be of an approved type and
shall match, insofar as practicable, the other instruments with which they are

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associated. The dial type, scale markings, and type of connection and mounting shall be
coordinated with the governor cubicle. All piping and tubing, closure and air bleed
valves, and all connections required for the calibration and replacement of the
instruments shall be furnished.

Pressure Gauges:

Pressure gauges shall be of the bronze Bourdon tube, adjustable-movement type with
approximately 150-mm diameter white dials, with black scale markings and pointers.
Gauges shall conform to the ANSI B40.1, "Indicating Pressure and Vacuum Gages," or
equivalent standard and shall be of Grade A accuracy, or better. Water pressure gauges
shall be provided with non-plugging type pulsation dampers. Water and oil pressures to
be transmitted to gauges mounted in cubicles, such as the governor cubicle, shall be
transmitted with the use of suitable transducers installed at the source.

Thermometers:

The remote bulb thermometers with built-in thermal relay functions, shall be of the
vapor-pressure type. The thermometers shall be provided with a leakage alarm contact
circuit and adjustable, electrically independent, alarm and tripping contact circuits. The
thermometer dial shall be approximately 144 x 144 mm, suitable for flush mounting.
The dials shall be white, with black scale markings and units, and black pointers. The
dials shall also be provided with a color band alongside the gauge and of durable
materials arranged in accordance with the following color code:

a. Green range for normal operation.

b. Orange range for operation requiring caution or attention, but not of highest
emergency.
c. Red range for abnormal operation requiring immediate corrective action.

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Capillary tubing with insulated plastic sheath and all required insulating sleeves and
bushing shall be provided. The bulbs shall be located near points of expected maximum
temperature. Each thermometer shall be provided with two adjustable, electrically
independent, ungrounded, circuit-closing alarm contact circuits. Each relay shall close its
contacts to cause shutdown of the unit when the bearing temperature reaches
approximately 80°C. The relays shall be mounted in the governor cubicle, with leads
brought to the terminal blocks.

Resistance Temperature Detectors:

The resistance temperature detectors shall be dual platinum, 100 Ω at 0 °C, attached to
the guide bearing metal, the guide bearing oil reservoir interior, and the turbine seal
housing interior near the point of expected maximum temperature. Each guide bearing
shall have 2 resistance temperature detectors located in the metal segments, and two in
the oil reservoir, located diametrically opposite. Each detector shall be connected by 3
leads to the turbine terminal box. One wire from each detector shall be connected to a
common point or bar on the terminal blocks. The common point or bar shall be
insulated from ground, but provisions shall be made for a grounding connection on or
near each terminal block. All wiring and conduit between the detectors and the terminal
box shall be provided.

Oil Level Indicator:

The level indicator shall be provided with a scale of sufficient length to indicate oil level
in the guide bearing reservoir when the unit is at rest and also in operation. The
indicator shall be located near the reservoir, in an accessible location where it can be
easily read from the turbine pit walkway. The oil level indicator shall have electrically-
independent, ungrounded, circuit-closing alarm contact circuits. Two circuits shall be

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provided for high oil levels and 2 circuits for low levels. The leads shall be wired to the
turbine terminal box.

Cooling Water Flow Indicating Transmitters:

Flow indicating transmitters shall indicate the flow between the maximum and 10% of
the maximum flow. They shall be provided with 2 adjustable, ungrounded, circuit-
closing, electrically-independent low flow alarm contact circuits, complete with valve,
stainless steel orifice plate, and orifice flanges (or other suitable flow measuring device),
located in the discharge line for measuring the bearing cooling water flow and in the
supply lines for the turbine shaft seal and for runner wearing rings. Signal leads, 4-20 mA
dc, shall be wired to the turbine terminal box.

Pressure Switch:

The pressure switch shall be provided with 2 independent, adjustable, ungrounded

alarm contact circuits. The contacts shall be arranged to close in the event that the
pressure in the shaft seal water supply falls below the minimum pressure required, as
established in the design of the turbine. The switch shall be provided with a calibrated
dial and external adjustments for setting the operating pressure. The leads shall be
wired to the turbine terminal box.

High-Water Level Switch:

A high-water level switch with 2 independent contact circuits shall be provided in the
head cover to provide indication and alarm on rising water level in the head cover. The
switch shall be complete with aluminum enclosure NEMA Type 4. The leads shall be
wired to the turbine terminal box.

Vibration Detector:

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Three vibration detectors shall be furnished with the turbine, one mounted on the head
cover for vertical vibration at a location selected in cooperation with the Purchaser and
two mounted on the turbine guide bearing housing for X and Y direction vibrations (run-
out) of the turbine shaft. The vibration detectors shall be suitable for connection to the
Purchaser’s remotely mounted vibration monitor. The Turbine Manufacturer shall
coordinate with the Generator Manufacturer to ensure that the detectors and monitor
are compatible. The leads shall be wired to the turbine terminal box.

Water-in-Oil Detectors:

A detector which detects the water leakage in the bearing shall be located in the guide
bearing (oil) reservoir. The detector shall be provided with 2 sets of electrically-
independent contacts. The leads shall be wired to the turbine terminal box.

Details of Turbine Instrument Cubicle:

General.

Unit protection and operation monitoring instruments as listed in the following

paragraphs shall be mounted on the turbine instrument cubicle. The instrument cubicle
shall be located next to the governor mechanical cubicle in the turbine floor. The finish
color shall be coordinated to match the other cubicles. A door on the back side of the
cubicle for adjustment and maintenance and openings for cable entrance from the top
and bottom shall be provided. Thermostatically controlled space heaters and cubicle
light and switch shall be furnished with the cubicle. Power supply at 230 V, ac, 50 Hz or
110 V dc required for monitoring instruments, transducers, heaters, etc. shall be
provided by The Supplier under Section 6.

Differential Pressure Transducers:

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The differential pressure transducers shall sense the differential pressure and generate a
linear output proportional to the differential pressure. It shall be 2-wire type and shall
have facilities for span and zero adjustments. Pressure cavities, flanges, drains, vents,
and isolation diaphragms shall be type 316 stainless steel. Pipe fittings shall be standard
1/2-in. NPT. Hardware for mounting the pipe and transducers shall be furnished. The
differential pressure transducer shall have the following characteristics:

 Excitation voltage 110 V dc, 230 or 400 V ac

nominal
 Regulation 0.4% over voltage range
 Load impedance 1800 Ω
 Accuracy 0.25%
 Long term stability 0.25%
 Power supply voltage 110 V dc, 230 V ac nominal

Pressure Head Transducers:

The pressure head of the turbine shall be measured by the pressure transducers
connected to the spiral case inlet and draft tube outlet. The characteristics of the
pressure transducers shall conform to the above differential pressure transducer
description, with working pressure no less than the maximum internal water pressure
head specified in 3-12 Spiral Case. The output of the transducer shall be input to the
flow and efficiency measuring instrument and to the governor electrical cubicle.

Active Power Transducer:

The active power electrical transducer shall be mounted in the instrument cubicle.
Current inputs shall be arranged for connection to current transformers in the generator

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neutral. Voltage inputs shall be arranged for connection to potential transformers

(voltage ratio: 11,000 - 110 V). The transducer shall transform the active power
measured to a 4-20 mA dc output signal indicating the generator active power. The dc
signal shall be input to the flow and efficiency measuring instrument and to the
governor electrical cubicle. The load resistance of the transducer shall be 0 - 750 Ω with
a rated frequency of 50 Hz and accuracy of 0.25%.

Discharge Flowmeter:

Turbine discharge shall be measured by the ultrasonic flowmeter. The transducer

output representing discharge shall be input to the flow and efficiency measuring
instrument and to the governor electrical cubicle.

Flow and Efficiency Instrument:

The flow and efficiency instrument shall be able to receive, separately, input signals of
pressure head, unit active power, and turbine discharge and shall have calculation
functions. The turbine discharge input signals shall be obtained from the ultrasonic
flowmeter. It shall be equipped with necessary pushbuttons and digital display of net
head (m), discharge (m3/s), active power (kW), water consumption rate (m3/s per kW),
and unit efficiency (%) and shall display the corresponding readings of instantaneous
parameter values. The display shall contain a maximum of 6 digits with Purchaser units.
The net head measurement display shall range from minimum to maximum net head
(displayed in meters), while the discharge measurement display shall range from 25% to
110% of the maximum discharge. The flow and efficiency instrument shall have
separate output signals of net head, discharge, water consumption rate and unit
efficiency by means of dc 4-20 mA signals to the computer control system. Alternatively,

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these functions can be incorporated into the microprocessor of the digital governor
specified in Part-02 Section 5-07 Digital Microprocessor.

Shear Pin Failure Signal:

A light box with the number of windows corresponding to the number of shear pins shall
be furnished and installed in the instrument cubicle. Each window shall be activated
with the respective shear pin failure contact. Four normally open common contacts
shall be provided. A lamp test push button shall be provided with the light box.

Turbine Terminal Box:

All wiring within the turbine pit shall be routed to the greatest extent possible in
rigid, hot-dip galvanized, metal conduit. The conduit layout shall be arranged to prevent
interference with the dismantling of the turbine. The metal conduit shall be routed to
an accessible turbine terminal box outside of the pit through the pit concrete. All signal
wiring shall be brought to the terminal box through the metal conduit.

The terminal box shall be installed on the wall outside of the turbine pit. Barriers
shall be provided inside the terminal box to separate instrumentation, control, and
power terminations.

The signal wiring of instrumentation outside the turbine pit shall be brought to
the terminal box through cable rack or metal conduit.

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3-24 SPARE PARTS

All spare parts shall be interchangeable with and be of the same materials and
workmanship as the corresponding parts of the original equipment furnished.

Specified spare parts (also referred to as Mandatory Spare Parts) listed in Annexure-3B

A set shall be defined as the complete requirements for one turbine.

In addition to the above spare parts, the Supplier shall list and price, for optional
purchase at the discretion of the Purchaser,

Each of the spare parts shall be fully identified by part number and drawing number,
shall be separately priced, and shall be delivered by the Supplier to the Site with the
original equipment for the first unit.

The spare parts shall be provided to the Purchaser. The Employer and the Purchaser
shall sign and verify that all spare parts are received and are in good working condition.
The spare parts shall be inventoried and stored in an area acceptable to the Supplier
and Purchaser. Any spare parts replacing other defective parts utilized during the
construction of the plant shall be replaced by the Supplier at its cost.

3-25 SPECIAL TOOLS AND MAINTENANCE EQUIPMENT

Tools and equipment required for the installation and maintenance of the turbine, as
listed in annexure-3B.

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3-26 SHOP ASSEMBLY AND TESTS

Shop Assembly:

The turbine shall be assembled or sub assembled in the shop to verify the design,
construction, and machining for proper alignment, fits, and clearances. Parts shall be
match-marked, identified, and doweled to insure correct assembly and alignment in the
field. When necessary, dowels shall be furnished for insertion after field assembly and
drilling. The shop assembly shall include the pit liner with walkways, platforms,
stairways, and hand rails, etc., assembled to the extent practicable. The draft tube liner
shall be assembled and match-marked by means of points established with accuracy to
ensure its easy and accurate reassembly in the field. The spiral case with stay ring
sections shall be assembled together. The shop assembly of the stay ring and spiral case
and of the draft tube shall be done for each turbine. The homology check of the runner
water passages shall be conducted in accordance with 3-6, Runner, after the finished
runner sections have been assembled in the shop. The water passage homology checks
of other parts including the spiral case, stay vanes, wicket gates, bottom ring, discharge
ring, and draft tube shall also be performed. The wheel case including wicket gates,
gate operating mechanism, head covers, bottom ring, shaft, and runner shall be
completely assembled. The gate servomotors may be assembled and tested separately.
Where it is not possible to include components of one assembly, those shall be
assembled separately, subject to Purchaser’s approval, in which case suitable provisions
shall be made to simulate the missing parts of the assembly to assure that all parts will
fit properly when the turbine is assembled in the field.

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Gate Operation:

The assembled wicket gates shall be operated through their full movement at a rate of
movement of not more than 120 s for a full movement, to demonstrate that the gates
and gate operating mechanism function correctly without interference.

Shop Measurements:

Critical dimensions and small clearances of the assemblies shall be measured and
recorded on shop inspection forms prepared by the manufacturer, showing both the
design and the actual measured dimensions. Copies of shop inspection forms shall be
submitted to the Purchaser prior to the first shop assembly inspection. Wicket gate
clearances between top of gates and head cover, between bottom of gates and bottom
ring, and along the line of contact of closed gates (without squeeze on the gates) shall
be measured and recorded. Wicket gate opening shall be measured at the top, bottom,
and at mid-height and shall be recorded at the 50% and 100% gate opening. Assemblies
shall be plumb and level, and the bottom ring and head cover, including the mating
surfaces for the guide bearing and shaft seal, shall be checked for concentricity.

Pressure Tests:

All components and devices subject to governor oil pressure, lubricating oil pressure,
compressed air pressure, and/or cooling water pressure shall be shop tested at a
pressure 50% greater than the maximum design pressure for a period of one hour. A
combined list of such pressure tests shall be prepared and shall include the design
pressure, test pressures, and test dates, and when completed, it will serve as an
inspection record.

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Shear Pin Break Tests:

To demonstrate that the wicket gate shear pins will give a smooth break and not deform
at the design breaking load, a shop test shall be performed using equipment to simulate
the actual operating conditions. Two shear pins shall be tested per unit. The details of
the test procedure and the test results together with the sheared pins shall be
submitted to the Purchaser for examination and acceptance.

Guide Bearing:

The guide bearing shall be trial fitted with the shaft journal and adjusted for proper fit at
site.

Witnessing of Shop Assembly and Tests:

The shop assembly and tests will be witnessed by the Purchaser as specified in 1-10.4,
Shop Assembly, Measurements, and Functional Tests.

3-27 MODEL TESTS.

Scope

The bidding process has provided for the Supplier to make a recommendation
concerning the need or benefit of a hydraulic model test to be performed by the
Supplier, following the award of the contract. The Purchaser would then have the right
to accept the Supplier’s proposal for the Supplier’s performance of this model test. This
model test would be intended to refine the turbine design.

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New model tests are not otherwise required as part of the Work under this contract. If,
however, model tests are recommended by the successful Supplier and the
recommendation is accepted by the Purchaser, then the model tests shall be performed
as specified by the requirements herein. These requirements include the Supplier’s
performance of Computational Fluid Dynamics (CFD) flow analyses, optimization of the
design, fabrication of the model components, performance of developmental model
tests and acceptance model tests, provision of all model test reports and data and
provision of the Supplier’s technical assistance to the Purchaser and the Employer,
during the turbine model tests. The developmental testing and the witnessed model
acceptance testing shall be conducted at the Supplier’s hydraulic laboratory or in a
laboratory that is under subcontract to the Supplier.

Related Sections

The Work specified in this section shall be coordinated with and performed in
accordance with the standards, codes and requirements specified in Part-02 Sections 1,
3, 5, 6, and Volume 8.

General

The Supplier shall perform computational fluid dynamics (CFD) analyses and other
investigations of the flow in the turbine water passages that are necessary to refine the
proposed model test program. The results of these studies shall be presented in the
recommendation to perform model testing as a basis for the Supplier’s proposed
improved turbine characteristics. The objective of the model testing shall be to improve
the hydraulic design of the proposed turbine by maximizing and optimizing its operating
range, by optimizing the location and minimizing the severity of the part gate rough
operating zone, by maximizing the capacities, by maximizing the efficiencies, by

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eliminating or minimizing the severity of cavitation and by minimizing the vibration

levels.

The Supplier shall submit a report describing that model for Rufiji Hydropower project is
semi-homologous to Similar Project. The Supplier shall prepare and submit a CFD report
to show the effects of modifications made to the RHPP. The Supplier shall prepare a
transposed model test report that includes the expected performance, cavitation,
stability, torques, runaway speed, axial thrust and other specified data for RHPP
prototype turbine along with the model tested data from Similar project. The CFD
analyses and flow studies shall include the spiral case, the stay ring, the head cover, the
wicket gates, the runner, the bottom/discharge ring and the draft tube. The results of
the CFD analyses shall be submitted to the Purchaser and shall include information
about the methods utilized, the successive refinements to the design and the
recommendations for the proposed hydraulic design. The results shall include the three-
dimensional diagrams of the computation grid, the pressure distribution, the vectors
and velocity angles, the determination of losses and any additional diagrams required
for a complete visualization of the flow conditions in the proposed design. This
documentation shall also include detailed descriptions of the CFD computer program,
the assumed boundary conditions, the suggested adjustments to the physical model and
the conclusions.

After receiving approval from the Purchaser to proceed with the model tests, the
Supplier shall finalize the CFD analysis and flow study and shall submit a draft of the
completed CFD analysis for the Purchaser review. After the Purchaser has accepted the
results from these mathematical analyses, the Supplier shall provide a homologous
scale model in accordance with Section , Turbine Model, and shall carry out
developmental model tests of the turbine to optimize the design and to define the

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expected prototype performance. Except as otherwise specifically agreed upon by the

Supplier and the Purchaser, the developmental model tests and the acceptance model
tests shall be carried out in accordance with the latest editions of the following standard
and code:

IEC 60193-1999 - International Standard for Hydraulic Turbines, Storage Pumps and
Pump-Turbines -Model Acceptance Tests.

The model test results shall be presented in U. S. Customary units or S.I units except that
the turbine output shall be presented in kW and shall be adjusted to a common
Reynolds Number, to be established in discussions with the Employer and Purchaser.

The Supplier shall investigate the repeatability of the model data for each gate opening
and net head, including the speed-no-load conditions. The Supplier shall investigate,
document and explain any apparent anomalies in the model test data.

The model tests shall be supplemented by the prototype turbine tests specified under
Part 14, Services at Site, to verify that the guaranteed turbine efficiencies, turbine power
output capacity, and the unit stability characteristics (pressure fluctuations/pulsations)
all meet the new guaranteed characteristics. These prototype tests will be performed
on one turbine (selected by Purchaser) after that turbine has been installed and placed
in satisfactory operation.

Model Test Schedule

The anticipated model test schedule shall have been submitted with the Supplier’s
recommendation for model testing. The Supplier shall confirm or adjust that schedule,
based upon pre-award discussions and as discussed in Item B below. The model-test

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schedule shall cover all work from the time when the Purchaser agrees to proceed with
the model tests through the time of submittal of final model test reports, including time
for periods of Employer and Purchaser review of the interim reports and final reports
and recommendations. The duration for the model test has been estimated to be 9
months to a year or as otherwise stated in the Supplier’s proposal. This model testing
shall be conducted while the Supplier is performing the design and procuring materials
for the prototype turbine. The Supplier shall develop the model-test schedule so as to
produce minimal impact on the overall project schedule.

Promptly upon receiving the Notice to Proceed for the model testing, the Supplier shall
proceed with the developmental model test work. The Supplier shall submit the
detailed model test program to the Employer and Purchaser within ten (10) days of the
Notice to Proceed. The contents of the test program shall include the test stand
parameters, general description of the turbine model, test items, measuring methods,
arrangement of measuring points, instrument calibration methods, estimated number
of operation points to be measured, calculation methods and contents of test reports to
be submitted. Upon reaching mutual agreement with the Employer and Purchaser as to
the test program, the Supplier shall proceed with developmental model tests. It is
expected that the developmental tests will include some initial internal tests that would
allow the Supplier to refine its program for the testing of various alternatives. The
Supplier shall provide the Employer and Purchaser with monthly updates concerning
the progress of the developmental testing. These updates shall include Excel files with
the data that define the performance of each tested alternative.

The Supplier shall complete the developmental model tests within the established
schedule and, after having achieved acceptable performance results, shall submit a
summary of the development test results and a draft of the final CFD analysis report.

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Three (3) printed copies and three (3) electronic copies (pdf format)) of the summary of
the development test results and the draft final CFD analysis report shall be submitted
for review, including all the results of the optimization of the hydraulic design of the
turbine. The draft final CFD analysis shall be submitted for review only if additional CFD
analyses were performed during the model developmental tests. After receiving and
incorporating the Employer and Purchaser’s comments, the Supplier shall submit to the
Employer and Purchaser six (6) printed copies and six (6) electronic (pdf copies of the
final CFD analysis report. If no additional CFD analysis is performed during the model
developmental tests, then the previously accepted CFD analysis may be submitted as
the final CFD analysis.

The Supplier shall perform – and the Purchaser and the Employer shall have the right to
witness – the model acceptance tests, including model construction and calibration of
the instrumentation. The Supplier shall prepare the test report describing the model
test results, stepped up to the prototype conditions. These results shall then, upon
acceptance by the Purchaser, become the new turbine performance guarantee values.
The model acceptance tests and the submittal of the final model acceptance test report
shall be completed in accordance with the schedule agreed upon by the Purchaser.

Turbine Model

The model shall be completely homologous to the prototype design in its hydraulically
effective parts, including the spiral case, the stay ring, the head cover, the wicket gates,
the runner, the bottom/discharge ring and the draft tube. The model shall also include
the runner seals (wearing rings). The Supplier shall identify, for approval by the
Employer, any items that are not completely homologous. The model shall include a
sufficient length of water passage beyond the end of the draft tube to assure that the
flow distribution is similar to that of the prototype. Any modifications that are required

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by the results of the final hydraulic optimization shall be made to the water passages of
the model prior to the completion of the final model tests. The high-pressure (intake)
net head measuring section and the low pressure (draft tube exit) net head measuring
section shall be geometrically similar to those of the prototype turbine. The areas of
these model sections shall be used in the calculation of velocity head, for the
determination of model turbine net head. The Employer and Purchaser may witness
any of the dimensional checks. The Supplier shall provide the Employer and Purchaser
with copies of the results from all dimensional checks.

The total uncertainty of the model test stand shall not be more than ±0.1%.

The diameter of the model runner shall be as per IEC, unless the Employer has accepted
the use of the Supplier’s existing model, which would be modified for use on this
project.

The dimensional deviations of the model turbine to the prototype shall be not more
than the smaller values of the allowable tolerances in the applicable IEC Codes.

Cavitation observation devices (including fiber optic equipment or borescopes, and a

transparent draft tube cone) shall be arranged at suitable locations of the model turbine
and the following phenomena shall be observed, photographed, videotaped and
recorded by the Supplier: (1) flow instabilities and vortices in the draft tube and (2)
cavitation phenomena on the runner blades (inlet and outlet), the runner crown and
band, discharge ring, wicket gates and the stay vanes.

Pressure pulsation transducers shall be arranged in the water passage, between the
runner and the wicket-gates, in the spiral case, in the draft tube cone, and in the draft

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tube elbow. The Supplier shall determine the number and location of transducers in
accordance with the applicable IEC Codes and the requirements given herein. The
Supplier shall include transducers at locations, which the Supplier shall select, such that
the transducers will measure the maximum magnitudes of the pressure pulsations. The
Supplier shall provide a drawing showing the location of the measuring points, for
approval by the Employer and Purchaser.

Model Tests

The Supplier’s performance of the model tests shall include the following special
requirements:

General: The model acceptance tests shall establish the turbine hydraulic
characteristics, including the model measurements and the stepped-up prototype
characteristics for the following items: the turbine efficiency and output characteristics,
the cavitation limits, the hydraulic thrust (steady state and calculated transient
characteristics), runaway speed and accompanying discharge, and the wicket gate
torque characteristics. Additional details are given below, concerning these testing
requirements.

Efficiency: The turbine efficiency tests shall be carried out under (1) the conditions of
zero cavitation (high Thoma number) and (2) at plant Thoma number. The guaranteed
efficiencies shall be based on the plant Thoma numbers that are associated with the net
heads and with the lowest given tailwater levels for the given guarantee points. The
efficiency tests shall be performed covering the whole operational range of the turbine
as specified in Section 7-03 Operating Conditions and at different wicket-gate openings
of the model from 0% to 110% wicket gate, at intervals of no more than 10% of the
maximum model wicket-gate opening. The actual wicket gate openings shall be

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reported as the angular rotation (degrees) from the fully closed position. The Supplier
shall provide a table that relates these wicket gate angles to the cylindrical openings
between adjacent wicket gates. The Supplier shall also provide, prior to Commissioning,
a table that relates the servomotor stroke (mm of travel) to the wicket gate angles and
the openings between gates, using the same zero reference that was used in the model
test.

Power Output: The maximum and minimum power output capability tests shall be
performed at each guaranteed net head. The calculation results shall include, separately
for each type of test, the possible deviations between the prototype and the model,
including the expected majoration of performance due to scale effects.

Cavitation Limits:

The cavitation limits for operation shall be determined by model tests under
corresponding conditions of wicket gate angle, net head and tailwater level sufficient to
cover the entire operating range to be expected in service, including the specific
conditions for which guarantees are given. To determine the cavitation limits for any
given turbine power output and net head, the model shall be operated under
homologous conditions, at the constant speed corresponding to the designated net
head and at the fixed wicket gate angles suitable to produce the turbine power output
corresponding to the desired value on the prototype. The test shall be conducted under
a constant net head but with varying tailwater or varying absolute pressure in a closed
system, so as to vary the Thoma cavitation coefficient “sigma”. These tests shall be
performed for each guarantee point and for representative points at the limits of the
achievable operating range, including operating points beyond the power saturation
limits, below the minimum power output and beyond the maximum and minimum
values of net head.

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The incipient cavitation Thoma number (i) and the Thoma number one (1) for each
different condition shall be determined by the model tests. The plant Thoma number
(pl) shall also be stated for each operating condition. The Supplier’s design shall be
such that the incipient cavitation Thoma number (i) is below the plant Thoma number
(pl) for the operating conditions at each guarantee point. All values of Thoma number
shall be referenced to the centerline of the distributor.

The incipient cavitation Thoma number is defined as the corresponding cavitation factor
at which the visible bubbles begin to form repeatedly on the surfaces of three runner
blades, as the suction head diminishes. Random bubbles are not considered as incipient
cavitation. The Thoma number one is defined as the corresponding cavitation factor at
which the efficiency is 1% less than the efficiency at Thoma number zero (0). The
Thoma number zero (0), as defined in IEC 60193, subclause 1.3.3.6.8, shall be
identified on each sigma break curve along with the incipient cavitation Thoma number
(i), the plant Thoma number (pl), and the Thoma number one (1).

All cavitation phenomena such as bubbles and vortexes shall be measured,

photographed, videotaped and sketched.

Pressure Fluctuations: Pressure fluctuations related to flow instabilities or vortices in the

model shall be measured by the use of pressure taps or transducers located in the
model water passages, including the draft tube, at points most likely to detect pressure
fluctuations. The measurements of pressure fluctuations shall be carried out over the
full operation range, under the conditions with the plant Thoma number. The pressure
fluctuations shall be recorded and analyzed and the results shall be presented in graphic
charts. The fluctuations shall be recorded in such manner that their amplitude and
frequency are defined throughout the entire operating range, including the overload
range. The peak-to-peak equivalent amplitude curve of pressure pulsations with mixing

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frequencies shall be clearly marked on the performance curve of the model turbine. The
data shall be collected for frequency analysis, to determine the main frequency and
amplitude of vibration. The Supplier shall provide an interpretation of these data to
indicate the expected prototype conditions.

Runaway Speed: The runaway speed characteristics, associated discharge and

associated hydraulic axial thrust shall be determined on the model, to verify the
expectation of compliance with the maximum runaway speed guarantee of the
prototype.

Wicket-Gate Hydraulic Torque: The wicket-gate hydraulic torque shall be measured on

the model, over the range of 0 to 110% gate opening for at least 4 different wicket gate
locations representative of different quadrants of the water passage. The condition
with one gate out of synchronism with the others shall also be measured.

Hydraulic Thrust: The hydraulic thrust characteristics shall be determined for the model
turbine operation, to permit accurate prediction of prototype thrust loads over the full
range of operation, including normal and transient conditions, and to verify compliance
with the maximum thrust guarantee.

Aeration Tests: Provision shall be included in the model for determining the effects of
compressed air aeration and/or other means of suppressing draft tube pressure
pulsations or of smoothing the turbine operation, by allowing the introduction of air
into the laboratory hydraulic circuit during performance tests. The quantity of air, the
resulting change in the amplitude of pulsations and the effect on performance shall be
measured and recorded. These tests may be performed separately, by request of the
Purchaser, to support decisions on whether aeration is necessary for the turbine design.

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Flow-Index Pressure Differentials: The pressure differentials shall be measured on the

model between pressure taps at flow measuring sections in the intake during turbine
operation, to obtain data for guidance in the evaluation of the relative discharge
formula for use in field index tests.

Supplemental Model Tests: Supplemental model tests shall be performed as may be

required to investigate special problems that may come to the attention of the Supplier
or the Employer and Purchaser or to determine other characteristics of particular
interest.

Scale-up of Characteristic Parameters

The Supplier shall perform the scaling-up of model turbine characteristics to those of
the prototype turbine in accordance with IEC 60193-1999, with the direct calculation
from model measured data. The Supplier shall also calculate the turbine majoration
adjustments.

Model Acceptance Tests

The Supplier shall provide a hydraulic test Employer to direct the model acceptance
tests in the hydraulic laboratory shall perform the necessary calculations and shall
provide all of the reports that are described herein.

In addition to the scope specified in Sections and , the model acceptance tests shall
include model dimensional checks and model test stand calibrations. The model
acceptance test procedure shall be prepared by the Supplier and will be subject to
review and approval by the Employer and the Purchaser.

Prediction of the expected prototype performance and the determination of the new
guaranteed stepped-up prototype efficiencies, flows and power outputs shall be based

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on the model acceptance test data with zero tolerance for uncertainties of
measurement.

If the prototype performance, converted from the model characteristics, does not meet
the original guaranteed values or if the model acceptance test results should indicate
any unfavorable conditions that would prevent satisfactory operation, the Supplier shall
modify the model and shall conduct the model acceptance test once again. All expenses
caused by the additional design, Engineering, model modification and retest shall be
borne by the Supplier. In no case shall the Supplier postpone the equipment delivery
date or increase the cost because of the retest.

Model Acceptance Test Report

The Supplier shall provide a model acceptance test report that shall be prepared in
accordance with IEC 60193-1999 and with the requirements that are stated herein. The
report shall, as a minimum, include the following contents:

Applicable specifications of the model test equipment and instruments.

Drawings of model hydraulic passages and flow-passing components, complete with

dimensions.

General Hill Chart of model data

The model General Hill Chart shall show Unit Discharge vs. Unit Speed or
Peripheral Speed Coefficient, overlaid with contours of Model Turbine Efficiency
and lines of Wicket Gate Angles. This chart shall cover and extend beyond the
entire range of turbine operation and shall show the individual Guarantee Points.

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The model turbine efficiency-hill diagram shall include contours of pressure

pulsation amplitude. The pressure pulsation curves shall be expressed in relative
values as H/H, where H is the peak-to-peak pulsation at ninety-five percent
(95%) confidence level in mixing frequency mode. The actual operating zone of
the turbine shall be marked. The data in the hill chart shall have a sufficient
number of points to allow straight-line interpolation among all parameters.

Curves of expected performance of the full-scale turbine, as derived from the model test
data, for the operating conditions specified in Section 3-04, Capacity and Efficiency.

Prototype turbine efficiency hill diagram showing discharge versus net head overlaid
with contours of turbine efficiency and lines of wicket gate angles, along with cavitation
limits for the range of tailwater elevations expected during normal operation.

This chart shall cover and extend beyond the entire range of turbine operation
and shall show the individual Guarantee Points.

Model cavitation test curves showing relationship of efficiency, power and discharge to
net head and Thoma number, for various representative wicket gate angles and net
heads.

These curves shall clearly define the Thoma zero number values, the incipient
Thoma number values and the Thoma number one values. A diagram shall also
be included showing these Thoma number values and the plant Thoma number
values for prototype turbine operation at various representative net heads,
plotted against discharge.

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Curves showing the relationship of runaway speed, runaway discharge and hydraulic
axial thrust to wicket gate angle and net head.

The Supplier shall also provide tables and graphs to indicate the calculated
values of maximum transient speed, maximum transient intake pressure,
minimum transient draft tube pressure, maximum transient thrust and
maximum transient counterthrust of the prototype turbine.

Descriptions of the pressure pulsations that were measured at different locations and
different net heads and outputs during model tests.

Portions of the recorded measurements of particular interest shall be included in

the model test report, with a discussion of expectations of corresponding
pressure fluctuations on the prototype. If the draft tube pressure fluctuations
appear to be excessive, the Supplier shall provide acceptable corrective
measures in the turbine design.

This section shall include the test results and the frequency analysis. The
pressure pulsation results shall be shown in terms of peak-to-peak pressure
pulsations at a ninety-five percent (95%) confidence level. The conversion of the
pressure pulsations of the prototype turbine shall also be included. The
pulsation amplitudes and frequencies shall be presented on waterfall diagrams.

Steady state hydraulic thrust characteristics indicating expected maximum thrust at

nominal design value.

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Wicket gate torque characteristics showing the torque on a gate in relation to gate
opening, for four different wicket gate locations representative of different quadrants of
the inlet area.

The condition with one gate out of synchronism with the others shall also be
shown.

Photographs and sketches showing the cavitation phenomena and the vortex core
formation in the draft tube

Calculations and descriptions of the guaranteed values of the prototype turbine.

A discussion of the vibration characteristics and expected operating conditions under

which rough running of the turbine may occur.

A compilation of all of the above data in Excel format shall be provided to the Employer
and the Purchaser.

Hydraulic Transient Calculations

The Supplier shall perform transient analyses based on the tested model characteristics,
combined with the given plant characteristics, and shall confirm that the specified
maximum rotational speed and specified maximum/minimum pressures will be
respected.
The Supplier shall, after the initial commissioning tests on the first unit, perform
transient calculations to represent the tested conditions. If there is a significant
discrepancy between the calculations and the test results, the Supplier shall adjust its
calculation model to match the test results and shall then provide revised hydraulic
transient calculations for the entire operating range.

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References

IEC 60193, “Hydraulic turbines, storage pumps and pump-turbines – Model acceptance
tests”

IEC 60609, “Hydraulic turbines, storage pumps and pump-turbines – Cavitation pitting
evaluation”

3-28 HANDLING OF COMPONENTS

Structural components shall be provided with reinforcement braces and spiders where
applicable to prevent deformation and strain during transportation and for handling
during assembly/erection.

The sections, segments and components shall be provided with eye-bolts and lifting lugs
of suitable size for handling.

The turbines shall be designed and constructed such that main parts viz. Runner, Shaft,
Top Cover, and Wicket-gates operating ring can be removed through stator bore
conveniently as a routine provision with minimal amount of dismantling and disturbance
to other parts of turbine or generator.

It shall be further ensured that the removal of runner shall not require the guide vanes
to be dismantled or displaced. Runner removal from bottom is required and
arrangement shall be designed accordingly. Removal of guide vanes shall also be
possible downward or partially upwards at the turbine pit level itself without need for
dismantling the generator components.

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In addition to the removal of turbine components through stator bore as mentioned

above, turbine construction shall provide for removal of the following components from
bottom without dismantling generator:

Runner,

Bottom ring/pivot ring,

Discharge Ring,

Wicket gates,

Draft Tube Cone,

The facing plates,

Wearing rings,

Any other part subject to wear due to silt.

The items at ii), iii), v) and vi) shall be removable either in a single piece or
in sections as feasible. The supplier shall, however, ensure that with this
provision the size of gallery for removal of runner does not exceed from the
provisions of layout drawings.

For quick removal and installation of runner and turbine components the following
handling equipment shall be included in the offer:

A special trolley running on wheels, and provided with movable servomotor

operating platform and devices, for the removal of the runner and
any other heavy parts from below which can be handled by electric
winch.

Electric winch for moving the special trolley carrying runner, draft tube
cone etc. in the reach of PH crane & back.

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Monorail and electric hoist on the turbine pit described under Turbine Pit
Liner.

Rails, hooks, etc. required for dismantling and erection shall be supplied.

Any additional device for the quick removal and installation, from below,
including devices for quick removal of bolts and screws.

Further the removal and replacement of worn out labyrinth wearing rings, cheek plates,
shaft gland, guide bearing and such other components shall be fast and easy. Where
possible the design shall provide for the removal and replacement of these components
particularly the labyrinth wearing rings, cheek plates, shaft gland etc. from below.

The supplier shall furnish all pertinent details/drawings explaining the procedure for
dismantling/handling the said components in the manner explained (upwards removal
through stator bore, bottom removal and in situ replacement), during offer.

The supplier shall indicate during the design stage the expected times, in hours,
required for replacement of the eroded turbine components on the following basis:

Total time (in days considering three working shifts) including dewatering and filling
operations needed to replace with spares, i.e. turbine runner, the guide vanes, the
facing plates and wearing rings and any other movable parts subject to wear due to silt
erosion or abrasion.

It is also intended to make use of the EOT crane for handling the runner and other
components for dismantling from below. This will require the rope to be lowered
through the bore of the generator shaft and the turbine shaft. The supplier shall make
provisions for enabling use of EOT crane for the said purpose.

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The design of the turbine shall permit an upwards vertical movement of the turbine
rotating parts viz. runner and shaft by an amount sufficient for access for adjustment of
the generator thrust bearing and for clearing the joint at the coupling of the turbine and
generator shaft. Similarly, downwards vertical movement of the turbine rotating parts
shall also be provided for resting on the ledge on discharge ring when detached from
generator shaft.

3-29 LIQUIDATED DAMAGES FOR SHORTFALL OF OUTPUT AND EFFICIENCY

For any shortfall in the tested values of rated output and the weighted average
efficiency of each turbine vis-à-vis the corresponding guaranteed values respectively,
shall be computed as follows:

Output
For MW shortfall in tested value of rated output of As per Contract
not less than 238.6 MW when operating at the best
efficiency point under the rated net head of 111.0 m
corresponding guaranteed value
Efficiency
For each one tenth of one percent (0.1%) shortfall in As per Contract
tested value of weighted average efficiency
corresponding guaranteed value

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For fractional values of shortfalls in percentage, the liquidated damages amount will be
computed on pro-rata basis.
The liquidated damages on account of shortfall of output and weighted average
efficiency shall be computed separately. The total amount of liquidated damages shall
be the sum of these two multiplied by number of turbines.
No tolerance limits shall be permissible over the calculated value of rated output.
However, tolerance in computation in efficiency shall be in accordance with the IEC
60041-1991 for field acceptance tests for hydraulic turbines.

Rejection limit
The Purchaser reserves the right to reject the turbine if the tested values of either the
weighted average efficiency or the rated output (not less than 238.6 MW) when
operating at the best efficiency point under the rated net head of 111.0 m falls short by
one (1) percent or more of the corresponding guaranteed values during field acceptance
tests.

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3-30 Spare Parts – Annexure-3B

A- Tools for Erection and Installation

These tools shall be brought to the site by the Supplier in order to erect and install the
complete turbine equipment. These tools remain the property of the Supplier and will be
therefore re-exported after completion of installation and commissioning. Alternatively, if
not listed below, they could remain partly or completely on site against payment of an
amount mutually agreed upon at a later date between Employer and Supplier.

B- Special Tools for Maintenance

Special tools for maintenance being part of scope of work include:

Hydraulic pumping unit including pressure line for pre-stressing of coupling bolts;

Coupling bolt pre-stressing equipment for the connection between shaft and runner and
between shaft and generator shaft or generator rotor;

Shaft lifting device including portable stands to support the turbine shaft;

Runner lifting device;

One set of lifting eye bolts, jack screws, shackles, slings and other devices required to
facilitate lifting major turbine parts by the crane and servicing the turbine;

One set of lifting device for connecting major components and assemblies to crane hooks,
including all lifting beams, pins, shackles and other devices required to connect the crane
hook or hooks to any turbine assembly;

One complete set of templates and other control devices for guidance in restoring runner
blades and runner band and crown to original shapes after welding repair of cavitated area;
Tools or instruments required for the maintenance and trouble-shooting of the electronic
governor.

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C- Spare Parts and Stores/Shelves/Cabinets

The Supplier shall supply as a minimum the spare parts listed below (specified spare parts)
and stores/shelves/cabinets for permanent storage. For the stock control of the spare
parts, an approved customized professional program shall be supplied by the Supplier
together with the software documentation. The Supplier shall provide also the 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.

Turbine:

One (1) Set of turbine Runner

Two (2) sets of wicket gates including bearings;

Two (2) sets of links, levers etc. including bolts and bushings;

Four (4) sets of protective devices (shear pins or similar) for guide vanes;

Two (2) complete sets of turbine bearing pads;

Two (2) sets of turbine bearing cooling coils or coolers;

Nine (9) sets of shaft seal wearing elements (including shaft protection sleeve);

Four (2) sets of stationary and rotating labyrinth rings for the runner;

Four (4) set of renewable stainless steel facing plates for head cover and bottom ring;

Nine (9) sets of all seals and gaskets;

Four (4) sets of all measuring and indicating instruments, limit switches, pressure and
position transducers etc.

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3-31 Turbine Data Sheet

1.1 Performance, Efficiencies and Weighted Efficiency

1.1.1 Guaranteed Characteristics

Item Designation Unit Value as Per Bidder Data JV Remarks

Basic Design
Water Density (used for
998.2
calculation) kg/m3 ____________
Acceleration due to
Gravity (used for 9.78
m/s2 ____________
Calculation)
Rates Speed rpm 150
Sense of Rotation
Clockwise Clockwise
(viewed from top)
Efficiencies
Net Head 118 m -
Turbine output of At Max Head -96.02%
100% at rated net % 96.02
head
Turbine output of 90%
% ____________
at rated net head
Turbine output of 80%
% ____________
at rated net head
Turbine output of 70%
% ____________
at rated net head
Turbine output of 60%
% ____________
at rated net head
Net Head 115 m -
Turbine output of
100% at rated net % ____________
head
Turbine output of 90%
% ____________
at rated net head
Turbine output of 80%
% ____________
at rated net head
Turbine output of 70%
% ____________
at rated net head
Turbine output of 60%
% ____________
at rated net head
Net Head 111 m -
Turbine output of % 96.0

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Item Designation Unit Value as Per Bidder Data JV Remarks

Basic Design
100% at rated net
head
Turbine output of 90%
% ____________
at rated net head
Turbine output of 80%
% ____________
at rated net head
Turbine output of 70%
% ____________
at rated net head
Turbine output of 60%
% ____________
at rated net head
Net Head 100 m -
Turbine output of
100% at rated net % ____________
head
Turbine output of 90%
% ____________
at rated net head
Turbine output of 80%
% ____________
at rated net head
Turbine output of 70%
% ____________
at rated net head
Turbine output of 60%
% ____________
at rated net head
-
Net Head 90 m % ____________
Turbine output of
100% at rated net % ____________
head
Turbine output of 90%
% ____________
at rated net head
Turbine output of 80%
% ____________
at rated net head
Turbine output of 70%
% ____________
at rated net head
Turbine output of 60%
-
at rated net head

Net Head 82 m % ____________

Turbine output of
100% at rated net % ____________
head
Turbine output of 90%
% ____________
at rated net head

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Item Designation Unit Value as Per Bidder Data JV Remarks

Basic Design
Turbine output of 80%
% ____________
at rated net head
Turbine output of 70%
% ____________
at rated net head
Turbine output of 60%
- ____________
at rated net head

Weighted Efficiency
Turbine Weighted
% 96.0
Efficiency

Maximum continuous
power output
at H net = 118.0m MW 255.28
at H net = 115.0m MW ____________
at H net = 111.0m MW 238.58
at H net = 146.5m MW ____________
at H net = 100.0m MW ____________
at H net = 90.0m MW ____________
at H net = 90.0m MW 149.82

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1.2 Turbine - Runaway, Axial Thrust, Fly Wheel Effect, Sound Pressure Level

1.2.1 Guaranteed Characteristics

Item Designation Unit Required Bidder Value JV Remarks/Queries

Value
Maximum runaway
speed at net head
118.0m (generator rpm 275
unloaded)
Maximum leakage
through wicket gate at
maximum static head of
l/s ____________
118.0m
Maximum hydraulic axial
kN ____________
thrust
Axial thrust at 110 %
rated load rejection kN ____________
Fly wheel effect of
turbine rotating parts tons
____________
(GD2) m²
Quantity of cooling
water required
Turbine guide bearing l/s
____________
oil-cooler
Maximum sound
pressure level at a
distance of 1 m at rated
operation
 at turbine pit dB(A) ____________

 at draft tube
dB(A) ____________
manhole

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1.3 Turbine – Flow Rate, Dimension and Weight

1.3.1 Guaranteed Characteristics

Item Designation Unit Value Bidder Value Remarks

Weight of finished-
machined runner
kg ____________
complete
Heaviest turbine part to
be handled by
powerhouse crane
kg ____________
during installation
Weight of shaft kg ____________
Turbine shaft diameter mm ____________
Required transport
opening for largest
turbine part
Width mm ____________
Height mm ____________
Maximum Diameter and
designation of turbine
part to be removed
through generator mm ____________
stator bore

1.3.2 Informative Data

Ite Designation Unit Value Bidder Value Remarks

m
Number of Runner ___________
pcs
Blade _
Runner discharge ___________
m
diameter _
___________
Draft tube outlet area m2
_
Turbine water ___________
discharge quantities _
 under maximum
m³/s ___________
overload operation

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Ite Designation Unit Value Bidder Value Remarks

m
Number of Runner ___________
pcs
Blade _
Runner discharge ___________
m
diameter _
___________
Draft tube outlet area m2
_
_
at maximum net
head
m³/s ___________
 at maximum
_
runaway condition
m³/s ___________
 at no-load at rated
_
net head

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