GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No.

- GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

2TFV00-0000-00718586 Revision -

Technical Description Francis Turbine

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

2TFV00-0000-00718586 Revision -

TABLE OF CONTENTS
1 Scope of Supply...................................................................................................................................... 4 1.1 Supply limits with civil work.................................................................................................................... 4 2 General Information............................................................................................................................... 5 2.1 Design Parameters................................................................................................................................ 5 2.1.1 Main Data........................................................................................................................................... 5 2.1.2 Operating Conditions.......................................................................................................................... 5 2.1.3 Output and Efficiency.......................................................................................................................... 5 2.1.4 Hydraulic Engineering Codes:............................................................................................................ 5 2.2 Design and Construction Requirements................................................................................................ 5 2.2.1 General............................................................................................................................................... 5 2.2.2 Applicable Standards and Codes........................................................................................................ 6 2.2.3 Allowable Stresses and Load Cases................................................................................................... 7 2.2.4 Surface Finish..................................................................................................................................... 7 2.2.5 Painting and Surface Treatment......................................................................................................... 8 3 Equipment Description........................................................................................................................... 8 3.1 Runner................................................................................................................................................... 8 3.2 Shafts.................................................................................................................................................... 9 3.2.1 Turbine Shaft...................................................................................................................................... 9 3.2.2 Couplings............................................................................................................................................ 9 3.3 Inlet Parts............................................................................................................................................... 9 3.3.1 Spiral Case with inlet pipe................................................................................................................. 10 3.3.2 Stay Ring and Support Ring.............................................................................................................. 11 3.3.3 Pit Liner............................................................................................................................................. 11 3.4 Distributor............................................................................................................................................. 11 3.4.1 Wicket Gate with Bearing.................................................................................................................. 12 3.4.2 Wicket Gate Mechanism with Operating Ring...................................................................................12 3.4.3 Servomotor....................................................................................................................................... 14 3.4.4 Head Cover....................................................................................................................................... 14 3.5 Bottom Ring ........................................................................................................................................ 15 3.6 Shaft Seal............................................................................................................................................ 16 3.6.1 Operating Seal (hydrostatic)............................................................................................................. 17 3.6.2 Standstill Seal................................................................................................................................... 18 3.7 Draft Tube............................................................................................................................................ 18 3.8 Bearing................................................................................................................................................ 19 3.8.1 Guide bearing................................................................................................................................... 19 3.9 Accessories.......................................................................................................................................... 20 3.10 Installation Device.............................................................................................................................. 20 4 Materials................................................................................................................................................ 20 5 Spare Parts............................................................................................................................................ 21

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

2TFV00-0000-00718586 Revision -

6 Instruments and Control Equipment................................................................................................... 21 7 Transportation, Erection and Commissioning...................................................................................21 8 Tests....................................................................................................................................................... 22 8.1 Shop Assembly and Tests.................................................................................................................... 22 8.2 Field Tests............................................................................................................................................ 22 8.3 Field Efficiency Tests........................................................................................................................... 23 9 Training.................................................................................................................................................. 23 10 Operation and Maintenance............................................................................................................... 23

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

2TFV00-0000-00718586 Revision -

1 Scope of Supply
This proposal document provides an overview to the works and services performed by Voith Hydro. Particular emphasis is given to those aspects of the product scope which demonstrate the superiority of many of the special features incorporated into todays design. The turbines will be complete with spiral case, stay ring, pit liner, head cover, Guide Vanes with operating mechanism, bottom ring, draft tube, runner, shaft, shaft seal, guide bearing, and accessories. Supports, stiffeners and other packing material necessary for transportation and erection are included. Special tools and devices required for installation, disassembly and maintenance of the equipment will be supplied as well as piping, instrumentation, cabling and wiring. The scope comprises design, manufacture, shop testing, transportation, erection at site, site testing, commissioning and reliability run of the unit. The documentation of supplied equipment contains assembly drawings, calculations, as-built drawings and operation & maintenance manuals.

1.1 Supply limits with civil work

Aligning, fixing and bracing of turbine structures and parts which will be embedded and/or grouted in the secondary, and the following concrete stages, is included in the turbine scope of supply. Concrete and grouting material for embedment of all components, i.e. supply, placement, monitoring and verification of the concreting process is responsibility of the civil works contractor. Piping to be embedded in the concrete for pressure measurement and Winter-Kennedyconnections are included. Intake and draft tube embedded drainage pipes and all associated valves, the installation and pressure testing before embedment, are included. Gratings to cover floor trenches will be provided and installed by the civil works contractor. The supports for the piping to be laid in the trenches are included.

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

2TFV00-0000-00718586 Revision -

General Information

2.1 Design Parameters

2.1.1 Main Data

For main data see Guaranteed Technical Particulars.

2.1.2

Operating Conditions

For operating conditions data see Guaranteed Technical Particulars.

2.1.3

Output and Efficiency

For turbine output and efficiency data see Guaranteed Technical Particulars.

2.1.4

Hydraulic Engineering Codes:

International Code for Hydraulic Turbines, Storage Pumps and Pump-Turbines - Model Acceptance Test, IEC Publication 60193 (1999) Field acceptance tests to determine the hydraulic performance of hydraulic turbines, storage pumps and pump-turbines; IEC Publication 60041 (1991) Cavitation Pitting Evaluation in Hydraulic Turbines, Storage Pumps and Pump-Turbines; IEC Publication 609 (1977)

2.2 Design and Construction Requirements

2.2.1 General

The turbines will be of the Francis type with vertical shaft arrangement. The turbine is designed to run safe and stable considering multiple daily start-stop-cycles. The turbines are rotating counter clockwise when seeing from above. The turbine shaft is directly coupled to the generator shaft. The power unit will be equipped with three guide bearings, one close to the runner on the head cover, other below the generator and third on top of the generator. The thrust bearing, for carrying the weight of the rotating parts of the turbine and the generator as well as the hydraulic thrust, will be furnished as part of the generator.

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

2TFV00-0000-00718586 Revision -

The uniform water inlet to guide apparatus is performed by a full spiral case with stay ring and stay vanes. The water discharge from runner to tail race is done by an elbow-type draft tube with steel lining up to the length of 5 m from runner center line. Thereafter, its shape will be formed in the concrete as per the suppliers drawing. The flow is regulated by Guide Vanes operated by two servomotors supported on the civil structure of the turbine pit. Reliable operation including Safe closing of the Guide Vanes shall be achieved by a nitrogen/oil pressure accumulator. The turbine will be designed and constructed to provide clearances for axial movement of its rotating parts as required by the generator design for inspection, adjustment and dismantling of the thrust bearing. The maximum turbine internal pressure resulting from pressure surge and water hammer for emergency closing of the units against the maximum flow at maximum head water level will be calculated. The design pressure for spiral case, stay ring, head cover, distributor and other pressure parts will be equal to the calculated maximum internal pressure. For the arrangement of the turbine please refer to the power house layout drawings For further technical data refer to Guaranteed Technical Particulars. Design modifications(if any) and improvements/optimization wherever required shall be discussed and carried out during detail engineering of machines by Voith after necessary approval from customer.

2.2.2

Applicable Standards and Codes

The standards, codes and manuals cited throughout this technical description are used to establish the level of safety, precision, quality, class of materials, acceptability, tolerances etc., to which the work is to be performed. Where these are cited, the latest revision or edition will prevail. Other standards, codes and manuals that will provide an equivalent level of safety, precision, quality, class of materials, acceptability, tolerances, etc. may be substituted. Specific standards, codes and manuals are referred in the appropriate parts of this specification documents. Following is a list of references to sources for some general codes and manuals cited in the specification documents. IEC and ISO are the leading Standards. ANSI - American National Standard Institute

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine
ASTM ASME AWS AISC ISA VDE DIN IS ISO IEC NEMA IEEE American Society for Testing and Materials American Society of Mechanical Engineers American Welding Society American Institute of Steel Construction Instrument Society of America Verband Deutscher Elektrotechniker Deutsche Institut fr Normung Indian Standards International Standardization Organization International Electro-technical Comission National Electrical Manufacturers Association The Institute of Electrical and Electronic Engineers, Inc.

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In addition to the application of many international accepted standards Voith turbines are subject to several internal standards, which are more detailed and more specific for hydraulic machines than contemptible general standards.

2.2.3

Allowable Stresses and Load Cases

The turbines will be able to withstand all stresses arising in continuous operation or occurring occasionally without being endangered or damaged. The turbine components will be sized in accordance with the proven internal Turbine Design Guidelines, on which our component design and dimensioning is based. This internal standard defines precisely the allowable stresses for different load cases and takes into consideration the availability of finite element calculations. The Voith Hydro standard for allowable stresses and the definition of the loading cases are summarized in document Turbine Design Guidelines / Allowable Stress Levels.

2.2.4

Surface Finish

All surfaces of the turbine water passage area will provide a smooth-contoured hydraulic surface. The surface finish roughness will be indicated on the component drawings and Voith standards will be at least in accordance with ISO 4287, Roughness comparison specimens.

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine 2.2.5 Painting and Surface Treatment

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All equipment furnished and installed will be completely painted for final use, with the exception of those parts or surfaces that are specifically designated as unpainted. Surfaces to be painted will receive the preparatory treatment and coating according to Voith Hydro Technical Group - GA General Application for Paints, Coatings and related materials in Hydro Power Plants. (Attached along with offer) All paint materials, supplies and articles furnished will be standard products of recognized reputed manufacturers. The paint used for touch-up in the field will be of the same quality and colour as used in shop painting. The touch-up painting will be done with material corresponding to each coat shown in the painting schedule.

3 Equipment Description
3.1 Runner
The runner will be a weld fabrication of high strength stainless steel composed of 13% chromium and 4% nickel and will consist of the crown, the blades, the band, the runner cone and the labyrinth rings. The runner cone will be an integral part with the runner crown. The rotating labyrinth rings will be integral parts of the runner when supplied. Numerically controlled machining of runner entrance and discharge creates perfect hydraulic passage. Runner inspection and quality control regarding hydraulic surface are according to IEC 60193. The surface finish of the hydraulic passages will be ground smooth to minimize the hydraulic friction losses. The runner will be designed to allow axial movement. The runner will have a bolted flange connection for attaching to the shaft.

The runner will be statically balanced according to ISO1940-1 class G6, 3. The finished runner is supplied in one piece from the manufacturing works.

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

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Fig.1- Typical 3D view of Runner

3.2 Shafts
3.2.1 Turbine Shaft

The shaft will be of forged steel and will be provided with flanges on both ends suitable for the attachment with the generator shaft at one end and turbine runner at the other end. The turbine shaft will be designed to operate safely without excessive vibration and at maximum torque without exceeding the allowable stresses.

3.2.2

Couplings

The coupling between runner, turbine shaft and generator will be preferably of friction type with pre-stressed bolts which is inline with specification requirement. However, based on detailed calculations of transmittable friction torque, final decision regarding type of coupling shall be discussed and agreed during detailed engineering. Based on final coupling type, shaft alignment shall be decided and also discussed during detailed engineering.

3.3 Inlet Parts

The complete spiral comprises the inlet pipe, the spiral case and the stay ring.

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

2TFV00-0000-00718586 Revision -

Although the spiral will be embedded in concrete, it will be designed to withstand, without any support from concrete, the internal design pressure, given by the water hammer calculation. The design stresses for this condition will not exceed the maximum allowable stresses. The spiral case together with the inlet pipe and the stay ring will be pressure tested at site prior to concrete embedment. Bulkhead for inlet pipe and stay ring will be supplied. Embedment will be done with partial internal pressure (approx. 50 % of Minimum static head). The spiral case will be dewatered by a piping system leading from the inlet pipe to the draft tube. The piping will be opened and closed by a manual operated valve.

3.3.1

Spiral Case with inlet pipe

The spiral case will be factory welded to the stay ring assembly as far as practicable and suitable for transportation. The spiral case will be made as a welded steel plate construction. The spiral case will be designed for fabrication in radial sections. Field joints will be kept to a necessary minimum in order to allow transportation of the maximum possible assembly. The use of longitudinal joints between spiral case plates will be avoided as far as practicable. Where longitudinal joints are necessary, their location will be carefully selected to facilitate welding and weld examination. The connection joint between the spiral case and the inlet pipe will be field welded. Sufficient adjustment allowance will be provided to align the segments before field welding. All necessary stiffener rings, pads or brackets and connections for the application of jacks and tie rods during field erection will be supplied. These appendices will be designed to support and position the spiral case during all conditions of installation and concreting. The spiral case will rest on solid foundation and bracing during embedment. One watertight man door will be located for convenient access to the interior of the spiral case. The inner surface of the man door will conform to the contour of the spiral case interior. Four pressure taps with pipe connection will be installed on the inlet section of the spiral case, suitably located and arranged for head measurements and for connection to the spiral case pressure gauge. The pressure taps with pipe connection will be installed at points where conditions are most favorable for measurement of flow. The type, number, construction and location are as to meet

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

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the requirements of the Winter-Kennedy method of determining discharge, for use in index tests. A spiral case drain connecting the lowest point of the spiral case extension with the draft tube will be provided. The piping will be flanged on-site to the prepared spiral case drainage connection.

3.3.2

Stay Ring and Support Ring

The stay ring will consist of the upper and the lower ring shaped deck, connected by the stay vanes forming a rigid tie across the throat of the spiral case. The streamlined stay vanes will be of suitable number. The stay vanes will be shaped and positioned to guide the water to the Guide Vanes. The stay ring will be made of steel; either integrally cast or fabricated of plate and/or cast components welded together. It will also withstand the tension due to the internal design pressure of the spiral case. At the bottom of the stay ring a support ring will be arranged in order to provide support during erection and to transmit the forces into the concrete structure.

3.3.3

Pit Liner

The pit liner will be made as a welded steel plate construction. Field joints where necessary, will be kept to a minimum in order to allow transportation within transport limits. The connection joint between the pit liner and the stay ring will be field welded. The pit liner serves as steel cladding of the turbine pit. It will have recesses for two servomotors for driving of wicket gate mechanism of the distributor.

3.4 Distributor
The distributor will consist of a suitable number of moveable Guide Vanes, each consisting of a streamlined body with stems supported through the bearings on to the head cover and the bottom ring. The Guide Vanes will control and guide the water to the runner. The gates will be linked via levers and links to the operating ring which will be operated by 2 oil-servomotors. The anchorage of the servomotors is supported in the turbine pit. A gate locking device provided in one position will ensure the position of the Guide Vanes for maintenance purposes .

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine 3.4.1 Wicket Gate with Bearing

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The Guide Vanes will be high strength chrome-nickel (13% chrome, 4% nickel) stainless steel castings with integral stems. Each gate is supported in 3 self-lubricating guide bearings, one located in the bottom ring in a removable cartridge and 2 in a removable cartridge block in the head cover together with the trunnion seals. The cartridges allow a fast disassembly during maintenance services.

3.4.2

Wicket Gate Mechanism with Operating Ring

The wicket gate mechanism will consist of the gate levers, gate links, operating ring and gate servomotors with anchorage. The gate lever will consist of the inner and the outer lever. The inner gate lever will be firmly attached and dowelled to the wicket gate stem. A shear pin between the outer and the inner lever will transfer the torque for all considered operation loads. The gate links will connect the outer gate levers with the operating ring. The operating ring is actuated by two servomotors and will distribute the forces and movements to all of the Guide Vanes simultaneously. In order to protect the linkage and the gates the shear pin will break in case of excessive forces due to foreign material jamming between the gates when closing the distributor. A friction brake will prevent the wicket gate from swinging freely when the shear pin is broken. The gate lever movement will be limited by means of gate stops to prevent contact between wicket gates and runner. All gate mechanism bearings will be self-lubricating bushings. The position of the operating ring will be monitored by limit switches. For visual check a position scale will be installed on the operation ring and the head cover. Each gate link is provided with one limit / proximity switch, to indicate occurrence of shear pin breakage.

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

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Fig. 2- Typical cross-sectional view of wicket gate mechanism

Fig. 3- 3D model of a typical gate lever

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

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Fig.4- Typical plan view of distributor

3.4.3

Servomotor

The servomotors will provide the necessary forces to maintain the distributor in different opening positions as required by the turbine regulating system during operation and to safely close the distributor under any operating condition of head and load. One number of linear transducer shall be mounted on one of the servomotor to get feedback of servomotor guide vane movement. Double-acting, oil-pressure operated hydraulic servomotors will be supplied, provided with connections for the oil piping. The servomotor support will be integrated with the pit liner. The reaction from the servomotor will be transmitted to the surrounding concrete.

3.4.4

Head Cover

The head covers will be fabricated from steel plates. It will be of rigid construction, substantially ribbed and designed to minimize deflections and vibration and to prevent distortion and interference with the Guide Vanes and the gate operating mechanism under the maximum water pressure and other forces acting including those from turbine guide bearing. The head cover will be bolted to the machined flange of the stay ring upper deck using a stationary seal which will seal against the stay ring upper deck. The head cover will support the turbine guide bearing and shaft seal.

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

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Provisions will be made for lifting the head cover in one piece from the turbine pit through the generator stator bore by the power house crane. Thrust relief pipes are attached to the head cover in order to minimize the hydraulic thrust on the runner. Sufficient clearance for moving the runner axially will be provided. The head cover will contain the removable cartridges for the bearings and seals of the upper wicket gate stems. Suitable drainage passages along the nose vane will be provided in the head cover to permit leakage water from the seals to the drainage system. Additionally, a headcover drainage pump with all accessories will be supplied to remove any water collecting in the lower part of the head cover. The head cover will also be equipped with a stationary wearing ring as a counter-part to the upper runner labyrinth seal.In the area adjacent to the wicket gate end surfaces, stainless steel facing plates will be provided on the head cover.

3.5 Bottom Ring

The bottom ring will be fabricated from steel plates The bottom ring will be flanged to the lower deck of the stay ring. The bottom ring will contain the cartridges for the bearing and seal of the lower wicket gate stems. The bottom ring will be of enough strength and stiffness, that the maximum deflection will not interfere with the Guide Vanes or reduce the gaps of bearings to inappropriate values. The bottom ring will also be equipped with a stationary wearing ring as a counter-part to the lower runner labyrinth seal. In the area adjacent to the wicket gate end surfaces, stainless steel facing plates will be provided on the bottom ring.

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

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3.6 Shaft Seal

The shaft sealing system will comprise the operating seal and the standstill seal, intended to prevent water from entering to the turbine pit, through the shaft / cover clearance.

4 5

Fig.5- Typical 3D-Modell of shaft seal

1 - Maintenance Seal 2 - Sliding Ring 3 - Seal Ring

4 - Water Collecting Ring 5 - Retaining Ring 6 - Splash Ring

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

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1 - Water collecting pan 2 - Support ring 3 - Holding/retaining ring 4 - Compression spring 5 - Indicating pin 6 - Seal ring 7 - Seal ring inserts (synth. material impregnated with molybdenum) 8 - Sliding ring 9 - Shaft 10 - Stand still seal

Fig.6-Typical schematic view of shaft seal

3.6.1

Operating Seal (hydrostatic)

A water sealing system of the self-compensated hydrostatic axial type will be designed around the shaft, positioned below the lower guide bearing, to limit the water leakage between the head cover and the shaft. The hydrostatic operating seal consist basically on a seal support ring, a static seal ring with a synthetic seal ring insert and a metallic sliding ring(fixed to the turbine shaft). The static seal insert will axially seal against the sliding ring. Filtered water will be fed into the seal ring insert chamber between the two seal surfaces and creates a water film which acts as a hydrostatic bearing separating the rotating sliding ring and the stationary seal ring. There is no physical contact between the two rings and therefore theoretically no wear. Flushing purified water will prevent any sand from entering the shaft seal surfaces, so that the wear rate for the seal ring is very low. The seal ring is pressed against the sliding ring by a number of stainless steel springs which also ensure the seal function if the unit is at standstill and the lubrication water supply is switched off. The seal is able to move axially it can easily follow any relative movement between

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3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

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the stationary and the rotating parts of the turbine. The diameter of the seal ring is designed to equalize forces from the water pressure acting on the seal ring, therefore the seal is not sensitive to changing water pressures. The seal support will be bolted to the head cover. The design will allow the inspection and replacement of the sealing components. A wear indication for the seal ring insert shall be provided to supervise the wear, without the disassembling of any part of the sealing housing.

3.6.2

Standstill Seal

The standstill seal will be installed between the water passage and the Operating seal. It is intended to protect the operating seal during extended periods of standstill. The standstill seal consists of an inflatable rubber profile which applies to the shaft when pressurized, thus sealing off the water passage. When being relieved, the water pressure of the water passage pushes back the sealing lips from the shaft. The seal must be applied only when the turbine is stopped. It is applied manually by operating the control valve. A limit switch on the operating valve prevents the turbine from being started, when the standstill seal is applied. The operating valve will be secured with a padlock. The air to inflate the standstill seal will be taken from the compressed air system. If necessary a pressure reducing valve will be provided to reduce the air pressure to a value applicable for the standstill seal.

3.7 Draft Tube

The draft tube will be of the elbow type. The draft tube will consist of the draft tube cone and the draft tube liner. The draft tube cone will be bolted to the bottom ring at upper side and to the draft tube liner at lower side. The draft tube lining will be a welded steel plate assembly. To facilitate transportation it may be sectionalized for field welding. Because of its rigid design with outside stiffening rings and ribs and concrete reinforcements the draft tube will withstand safely pressure variations and pulsations under all operation conditions. The draft tube liner will have a suitable number of pads and connections for the application of jacks or leveling screws and tie rods during field erection. The draft tube will have a steel lining

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3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

2TFV00-0000-00718586 Revision -

until 5 m distance from turbine center line. From there the draft tube will be shaped in concrete according to the requirements given by the hydraulic neat line. The draft tube will rest on solid foundation and bracing during embedment. Fixations will be designed to support and position the draft tube during all conditions of installation and concreting. The cone will be split in two parts with dismantling joint to facilitate runner removal from bottom. The draft tube cone will also provide access to the draft tube inside via a man-door to enable inspection and maintenance service. The inner surface of the man door cover will conform to the interior contour of the draft tube liner. A test cock will be provided below the sill of the door. The upper portion of the draft tube cone directly below the runner will be made from stainless steel with an extension of approx. 500 mm. A steel drain box will be provided in the liner at the lowest point of the draft tube, protected by a suitable and removable inlet grating. A connection for the spiral case drain pipe will be provided. A connection for the thrust relief pipe will be provided. One set of pressure taps with pipe connection will be installed.

3.8 Bearing
3.8.1 Guide bearing

The turbine guide bearing will support the turbine shaft and will be designed for radial forces originated from the turbine runner. The radial forces will be transferred via bearing housing, head cover and stay ring into the civil structure. The turbine guide bearing will be of the segmented, adjustable, multiple-shoe, self-lubricated type. The shaft is running on the bearing pads. The segments are machined in a way to self adjust to the optimum position with respect to load and circumferential speed. The bearing elements are lined with a high-grade anti-friction Babbitt metal securely anchored to the bearing backing. The guide bearing will be located above the shaft seal and will be as near as possible to the runner and will consist of a bearing support or housing and removable bearing elements. It will permit axial movement of the shaft.

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3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

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The oil circulation will be of the self-lubrication type by the action of the shaft rotation. An oil reservoir of sufficient capacity to contain all the oil required by the bearing lubrication system is provided around the bearing. The bearing reservoir is an integral part of the bearing housing. Cooling of bearing oil will be done by an internal coolers placed in oil reservoir

3.9 Accessories
Working, operating and inspection walkways and platforms complete with non-slip type floor plates, stairs, ladders and hand railings will be furnished where necessary or desirable in the turbine pit. All pit walkways, platforms, stairways and equipment will be easily removable. A circular crane will be supplied inside the turbine pit, for assembly and disassembly of turbine components. This crane will be located below the generator lower bracket and will be integrated by a manual chain hoist, a manual trolley and a steel structure that allows the movement of the hoist over the entire turbine pit area. A runner trolley will be supplied to facilitate runner removal from bottom side. An inspection platform will be furnished to facilitate inspection and maintenance of the runner. The platform will extend over the cross-sectional area of the draft tube where it is installed. It will be made of prefabricated, light weight components in suitable sections so as to be easily transported into the draft tube. Provisions will be provided on the draft tube cone for supporting the maintenance platform. Parts for pressure tests will be included in the scope of supply as far as required for field tests. Oil for first filling of the governor pressure oil systems and for the turbine bearings with 10% as extra will be supplied.

3.10 Installation Device

All special tools required for normal operation and maintenance will be supplied. It shall be as per tender specifications(PTS-Turbine and accessories). However, those which are common with other part specifications shall not be doubled.

4 Materials
For all major parts, material are listed in turbine datasheet submitted with bid. The materials might be subject to changes according to market availabilities. Equivalent materials may be used. All used materials will be of accepted national or international standards and of proven reliability for the intended purpose.

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

2TFV00-0000-00718586 Revision -

5 Spare Parts
All spare parts to be supplied will be identical to the ones originally installed, of the same material and manufacture process. All spare parts will be packed not to be damaged during storage. All boxes will be marked for identification. All applicable spare parts as listed under mandatory spare parts of tender document shall be included in scope.

6 Instruments and Control Equipment

The turbine will be provided with supervisory instrumentation and protective devices, as necessary for complete operation with a high degree of safety, reliability and continuity of service. All necessary electrical wiring and piping materials within the turbine and in the turbine gallery from the pick-up points to the instrumentation board or terminal blocks outside the turbine pit will be provided. Cabling will be neatly arranged and designed to allow the maintenance of the turbines without a major disconnecting work.

7 Transportation, Erection and Commissioning

The transportation of the turbine equipment is in the scope of the turbine supplier. The customer has to provide storage areas and erection bays with sufficient space as per requirements. Concrete support outlines for the draft tube liners, spiral case, pit liner and any other concrete supporting structures required will be communicated by the turbine supplier and provided by others in the first stage concrete to suit the turbine design. The turbine supplier will furnish and install all supporting columns, jacks, leveling screws, tie rods and turn-buckles. All parts will be firmly secured in position to ensure that no movement takes place during placing of concrete and grout. The speed of concreting will be max. 0.5 m/h of elevation unless otherwise specified on the respective equipment drawing. The depth of liquid state of concrete for calculation of buoyant forces depends on the curing time of the cement at the prevailing temperatures. The shipping sections of draft tube liners, spiral case and pit liner will be assembled as required/ applicable. All the necessary bracings and stiffeners inside the draft tube required to maintain the shape and locations of the parts during concreting and curing will be supplied and installed. After curing of the concrete all such provisions will be removed and disposed of. Before installing the removable part, all parts will be thoroughly cleaned of rust and protective coatings, and all burrs and nicks will be removed. Sub-assemblies will be carefully fitted together.

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

2TFV00-0000-00718586 Revision -

The turbine manufacturer will indicate the largest and heaviest turbine components to be shipped / handled at site. During erection of each turbine and all its auxiliaries, the turbine supplier will test the turbine, governor and accessories in accordance with the requirements of the IEC and other agreed standards. Prior to taking each unit into commercial operation, commissioning tests will be performed on each completed turbine unit. The tests will be coordinated with the tests of the governor, generator and other equipment. The wire testing and function testing of signals between the turbine equipment at one side and the control- and protection equipment at the other side will be directed by the responsible party for field testing and commissioning of the control systems. The party responsible for the field testing and commissioning of the turbine equipment will participate in these tests as necessary to thoroughly test the wiring and functions of all signals related to the turbine equipment. The turbine supplier will provide all necessary labor and instruments to perform the tests.

8 Tests
8.1 Shop Assembly and Tests
The turbines will be assembled in the shop to verify the design, construction, machining for proper alignment, fits and clearances to the extent practical. Parts will be properly matchmarked, identified and doweled to assure correct assembly and alignment in the field. Critical dimensions and small clearances of the assemblies will be measured and recorded on a shop inspection sheet.

8.2 Field Tests

The pre-commissioning tests will include, but not be limited to: Pressure tests on all pressure oil piping (in connection with the governor equipment) and all pressure piping systems will be hydrostatic tested at a pressure of 1.5 times higher than the maximum operating pressure after installation for a minimum of 1.5 hours ( if already not tested at works). Measurement of mechanical clearances, levels, strokes and other measurements Functional tests of all auxiliaries and protective devices Operation of governor hydraulic units. Functional operation of the gate operating mechanism in the dry condition Operational tests of turbine bearings Start - stop sequences test in the dry The commissioning tests will include, but not be limited to:

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GMR Bajoli Holi Hydro Electric Project (180 MW) Techno-Commercial Bid Document ICB No. - GBHHPL/ICB-002/LOT 3

3 x 60 MW BAJOLI HOLI HE Project

Technical Description
Francis Turbine

2TFV00-0000-00718586 Revision -

Alignment and rotation checks in the dry Mechanical run Governor operation Guide Vane function test Timing tests including measurement of guide vane openings Initial no-load wet run to ensure satisfactory operation of auxiliary equipment Bearings test run Checking of interlocks and indications Tripping tests for turbine Load rejection and load acceptance tests

8.3 Field Efficiency Tests

A thermodynamic test at one turbine will be carried out to conduct the efficiency and capacity of the turbine as per the IEC 60041. The power output and efficiency tests on the turbine will be made at net effective head as near as practicable to the rated head if actual conditions allow. The turbine capacity will be determined from electrical measurements of generator output corrected for generator losses. The generator losses will be determined from generator efficiency curves and verified by measurement of air cooler and bearing heat loads.

9 Training
The operators personnel will receive instruction in operating the equipment while the commissioning of the first unit is performed ( as per contract documents).

10 Operation and Maintenance

Operation manuals and maintenance manuals will be provided before commissioning phase.

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