RAINPOWER AS

PROCEDURE FOR
INSTALLATION OF THE GOVERNOR
SN POWER
CHEVES HEPP
PELTON TURBINE
Unit 1 and 2

Document No.: RP-H-N-I-P-001 ARA000273-O1N

0
Rev

2013-03-15
Date

Issued first time

Description

E. Larsen
Written by

Dept

J. Jensen
Appr

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installation.doc

Document

PROCEDURE
Document no.: ARA000273-O1N
SN POWER
KH doc. no.:

Cheves HEPP - Pelton turbine unit 1 and 2

Revision No.:
Page

0
2 of 11

Subject:

Installation procedure for governor

First issued date:

2013-03-15

This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.

Order no.

Index

221304

R010

Activity

Code

Customer

Project Doc. No.

SN Power
Site

File Name

Cheves HEPP Pelton Turbine

CONTENT
1

PURPOSE ........................................................................................................ 3

DEFINITIONS ................................................................................................. 3

RESPONSIBILITY AND ROLES ................................................................. 4

DESCRIPTION ............................................................................................... 5

4.1

Instruction manual ............................................................................................. 5

4.2

EHS (Environmental Health and Security) ....................................................... 6

REFERENCES ................................................................................................ 6

5.1

Drawings............................................................................................................ 7

5.2

Site Installation Control Forms ......................................................................... 7

DEVIATIONS .................................................................................................. 7

ENCLOSURES ................................................................................................ 7

INSTRUCTION MANUAL ............................................................................ 8

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installation.doc

Document

PROCEDURE
Document no.: ARA000273-O1N
SN POWER
KH doc. no.:

Cheves HEPP - Pelton turbine unit 1 and 2

Revision No.:
Page

0
3 of 11

Subject:

Installation procedure for governor

First issued date:

2013-03-15

This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.

PURPOSE
The procedure describes the installation steps for the Pelton turbine governors
supplied by Rainpower AS, hereafter named RP, for SN Power - Cheves HEPP
turbine 1 and 2, hereafter named SNP.
The procedure is designed to ensure that the installation will be performed in
accordance with Contractual requirements and to a high standard of
workmanship. Sketches and diagrams are included to support the installation
sequences described herein.
The procedure is made for the 1st unit, and may be revised for the next unit if
changes are regarded as favourable for the progress of work.

DEFINITIONS
Site Installation Control Form (SICF) forms to verify and record
performance of the installation steps. Tolerances, as built dimensions from
drawings and measured dimensions at site are included in the forms as
appropriate. The sheets are designated as Form 1, Form 2, etc.
Control comparison with specified requirements to verify compliance.
Technical information documents that specify detailed requirements.
This may be the Contract, drawings and other relevant information in order to
secure the performance of the installation work.
Inspection Plan (TP) document describing the various inspections to be
performed during site installation with reference to the Installation Procedure
and applicable SICF.

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installation.doc

Document

PROCEDURE
Document no.: ARA000273-O1N
SN POWER
KH doc. no.:

Cheves HEPP - Pelton turbine unit 1 and 2

Revision No.:
Page

0
4 of 11

Subject:

Installation procedure for governor

First issued date:

2013-03-15

This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.

RESPONSIBILITY AND ROLES

RP is responsible to provide its subsuppliers and SNP with appropriate
information to perform the installation work
RP acts as supervisor for the installation company, hereafter named IC who
is performing the installation work
The RP supervisor is located at site as long as deemed necessary to
terminate the installation work and in accordance with contractual
obligations
RP is responsible to see that all SICF are filled in and approved by IC after
accomplishment of each step whenever recording is required
RP shall witness and approve the SICF
RP may hand the SICF to SNP for review and approval
If some changes in installation sequences are requested by RP, the changes
shall be submitted to SNP for his approval during site meetings whenever
meetings are carried out on regularly basis. A design amendment may be
issued and signed by the two (2) parties
RP is responsible for issuing this procedure, and for preparation of revisions
to the document as necessary to capture any changes or corrections to the
procedure

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installation.doc

Document

PROCEDURE
Document no.: ARA000273-O1N
SN POWER
KH doc. no.:

Cheves HEPP - Pelton turbine unit 1 and 2

Revision No.:
Page

0
5 of 11

Subject:

Installation procedure for governor

First issued date:

2013-03-15

This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.

DESCRIPTION

4.1

Instruction manual
The sequences of the installation work are given in the Instruction Manual that
is included in the procedure refer section 8.
The Instruction Manual expresses the specific steps of work for installation of
the equipment, and provides reference to relevant documents and SICF as
appropriate.
The Instruction Manual includes columns for:
The actual item and activity number
The specific activity to be carried out with number
The company responsible for the activity
Detailed description of the activity
Sketches and references to relevant drawings, documents and SICF
To avoid confusion or conflicts, no design values or tolerances that are
stated on the drawings are repeated in the manual, however nominal
values and tolerances may be included in the SICF

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installation.doc

Document

PROCEDURE
Document no.: ARA000273-O1N
SN POWER
KH doc. no.:

Cheves HEPP - Pelton turbine unit 1 and 2

Revision No.:
Page

0
6 of 11

Subject:

Installation procedure for governor

First issued date:

2013-03-15

This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.

4.2

EHS (Environmental Health and Security)

The section is addressing only particular risks (if applicable) related to the
tests and work explained in this procedure.
For details how to mitigate risks, refer to applicable procedures and site safety
plan issued by RP. Safety plan issued by SNP overrules the RP plan whenever
interpretations about the understanding are raised.
Note that pre-work hazard assessments should be performed prior to any task
to determine any and all safety issues and their elimination, control or
mitigation with special care to:

Rotating equipment/machinery
Electrical hazards
Flood/drowning hazards
Pressurized substances (oil, nitrogen, air, water)
Fire (cable/electrical fire, oil fire)
Noise
Overhead/lifting hazards

For safety purposes SNP should check, test or certify, as appropriate, all
handling and lifting equipment to be used during the installation work.
This equipment is supposed to be permanent equipment installed at site.
IC shall present valid certificates for handling of lifting tools for SNP and RP.

REFERENCES
Contract between SN Power and the Consortium Rainpower AS, Jeumont and
ABB.
General requirements for welded constructions, RP doc. No. 30103.
Procedure for flushing of oil pipes to governor and main inlet valve MIV
RP doc. 24993

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installation.doc

Document

PROCEDURE
Document no.: ARA000273-O1N
SN POWER
KH doc. no.:

Cheves HEPP - Pelton turbine unit 1 and 2

Revision No.:
Page

0
7 of 11

Subject:

Installation procedure for governor

First issued date:

2013-03-15

This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.

5.1

Drawings
INDEX
R670
R510
R010

5.2

TITLE
Mech./Hydraulic Over Speed Device
Piping Arrangement
Hydraulic diagram

Site Installation Control Forms

Title

DRAWING NUMBER
RP-D-N-I-P-014
RP-D-N-I-P-001
RP-D-N-I-P-013

Form No

Verification of cleanliness and shooting plastic bullets

Pressure Oil Pipes - Test Result

Cable check

DEVIATIONS
None.

ENCLOSURES
None.

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installation.doc

Cheves HEPP Instruction for installation of the governor

No.
No. ITEM
ACTIVITY
of
step

8
1

Resp

JOB STEPS

INSTRUCTION MANUAL
INSTALLATION OF THE
GOVERNOR

OIL PRESSURE
UNIT (OPS)
WITH
ACCUMULA_
TOR

1-1

Preconditions

SNP/
CW

The erection area shall be cleaned and drained for water.

All civil works shall be finished, and if required floors, walls
roofs etc. shall be painted prior to start installation of the
governor system.

SNP/
CW

The erection area shall be lighted, electric power supply and

compressed air shall be available.

RP/
SNP

Components will be received and stored in/out-door according

to instruction/agreement between RP and SNP.
The components will be moved to the erection areas according
to Contractual schedule and installation sequences.

1-2

General

IC/RP

All bolt threads will be lubricated prior to inserting bolts/nuts.

All bolt connections will be tightened according to torque
values indicated on applicable drawings.

2-1

Preparations

RP/IC/
CW

The OPS shall be moved to the machinery hall floor in order to

be reached by the machinery hall over-head crane.
The floor where the OPS shall be installed shall be inspected
and prepared to installation of the OPS.
Prepare as necessary caterpillars to move the OPS on the floor.

2-2

Installation

The OPS shall be lowered by means of the machinery hall

over-head crane through the hoisting hatch to final level
Prior to off loading the OPS, the caterpillars, if needed,
shall be placed underneath the OPS. The OPS will be
moved to the correct position on the floor
The OPS will be fastened to the floor using concrete
anchor bolts drilled in the floor.
All outlets are plugged and they shall remain plugged until
the installation of the piping is completed

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REFERENCE

Cheves HEPP Instruction for installation of the governor

No.
No. ITEM
ACTIVITY
of
step

Resp

OVERSPEED
DEVICE

PIPING

JOB STEPS

3-1

Preparations

RP/IC

The combined shaft system is aligned.

3-2

Installation

IC/RP

The over speed device assembly shall be installed according to

drawing.

4-1

Preparations

RP/IC

The necessary amount of pipes and couplings shall be present

prior to installation.
The same applies to special tools for couplings according to the
Walform system.

4-2

Installation

RP/IC

The necessary amount of pipes and couplings shall be present

prior to installation, drawing RP-D-N-I-P-001.
The couplings shall be of the Walform type and assembled in
accordance with the Walform Tube Fittings procedure
Special tools for couplings connections according to
instructions from the Walform system shall be present.
Every single coupling shall be check for proper assembly prior
to pressurizing the pipe lines. The check shall be verified with
mark-up each coupling.

4-3

Cleaning

RP/IC

The cleaning will be carried out in two (2) steps:

1 Bullet cleaning
2 Flushing

4-4

Bullet cleaning

RP/IC

A high pressure Plastic gun shoots plastic bullets through

the different parts of the piping
Cleaning shall be verified in SICF, Form 1

4-5

Flushing

RP/IC

The second step cleaning shall be carried out by the hydraulic

flushing method. The flushing shall be carried out in
accordance with written procedure. The cleanliness values shall
be recorded in SICF, Form 1.

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REFERENCE

Installation Procedure for Walform Tube Fittings.

Drawing No. RP-D-N-I-P-001 Piping Arrangement.

Procedure for flushing and pressure test of the oil piping

system - RP 24993
SICF, Form 1 Verification of cleaning.

Cheves HEPP Instruction for installation of the governor

No.
No. ITEM
ACTIVITY
of
step
4-6

OIL TANK

Pressure testing

Resp

RP/IC

JOB STEPS

The pressure testing shall be performed with the same loop

arrangement as for the flushing.
The pressure test shall be carried out in accordance with written
procedure.
The result of the pressure test shall be recorded on SICF,
Form 2

5-1

Cleaning

RP/IC

The cleanliness of the oil sump tank is verified during FAT in

workshop.
However the tank may be inspected at site by removing the
inspection hatch and visually check inside prior to oil filling.

5-2

Oil type

RP/IC

Recommended oil for operation of the OPS and flushing shall

be hydraulic oil according to ISO-VG 46.

5-3

Oil filling

RP/IC

Filling the oil tank shall be done in accordance with the

governor O&M manual.
New oil will be filled through a filtration unit. It is assumed that
no samples for cleanliness documentation should be regarded as
necessary.
The mobile filtration unit shall be used when filling all units.

ELECTRONIC
6-1
AND CONTROL
CUBICLES

Installation

RP/IC

The governor electronic cubicle is located together with the

panels for unit local control and shall be installed according to
drawing.
The control cubicle is installed according to drawing.

CABLING

Installation and
test

RP/IC

Cabling and labels shall in principle be installed according the

relevant wiring diagrams.
Ensure that all connections are properly connected to the
terminals in the cabinets.
Crimping sleeves shall be adapted to all cables.
Cable check shall be done by hook-up in the wiring/cable
diagrams and verified in SICF, Form 3.

7-1

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REFERENCE

SICF, Form 2 Pressure Test Result.

SICF, Form 3 Verification of cabling

QUALITY INSPECTION PLAN

GOVERNOR

Dok. nr. / Doc. No.

Rev.

ARA000273PRI

Side / Page

av / of

Sign. dato / Date

Retten til utnyttelse av denne beskrivelse tilhrer Rainpower ASA og m ikke kopieres, utleveres eller forelegges uvedkommende uten tillatelse fra Rainpower.
This document and the design is the property of Rainpower ASA and must not be used nor disclosed to any part without Rainpowers permission.

Ordre nr. / Order No.

Kunde / Customer

Prosj. dok. nr. / Proj. Doc. No.

400409

SN Power

RP-Q-N-I-P-001

Indeks / Index

Anlegg / Site

Filnavn / File Name

R010

Cheves

ARA000273-PRI

Rainpower and Rainpowers customer shall be able to inspect all stages in the process at
supplier and sub-suppliers. These inspections might happen any time at any location.
All NDT shall be reported, also indications that has been repaired.

05.01.12

First Issue

TFa

Rev.

Dato / Date

Beskrivelse / Description

Sign.

Avd. / Dept.

Godkj. / Appr.

QUALITY INSPECTION PLAN

1

10

Index

Name, drwg. No.

& item No.

Production
stage

Inspection

Procedure

Location

Responsible

Witness

Report
form

RC Remarks

R010

Governor

Assembled

FINAL

Commissioning
procedure

SITE

RP

CLIENT

PROT

Drytest on
site.

R490

GOPS 600
Hydraulic
controls

Assembled

VI
FUNCT
FAT Report
PRESSURE

SUPL

RP

CLIENT

PROT

Assembled
test.
FAT

R450

Accumulators

Assembled

VI
FUNCT
FAT Report
PRESSURE

SUPL

RP

CLIENT

PROT

Assembled
test.
FAT

R620

Electronic
governor HY14P

Assembled

VI
FUNCT

Assembled
test
FAT

R670

Overspeed trip
device

Assembled

VI
FUNCT

Calibrated
before test at
site.

FAT Report

FAT Report

SUPL

SUPL

RP

RP

CLIENT

CLIENT

PROT

PROT

11

Enclosure to document no. ARA000273-PRI

The enclosure gives guidelines for filling in as well as explanations for use of the inspection plan.
The paragraph numbers refer to column number.
1

INDEX

Numbering of inspection activity and/or item designation according to Rainpower project index list.
2

NAME, DRAWING AND ITEM NO.

The name of the part or the parts. Drawing and item number has to be specified when it is suitable to
identify the part or parts
3

PRODUCTION STAGE

E.g., designed, welded, machined.

4

INSPECTION

Inspection or testing to be performed. The following abbreviations are used:

CA

Chemical analysis

MAT

Material test

TT

Tensile testing

CIT

Charpy impact test

HT

Heat treatment

BT

Bend test

CR

Contract review

PQR

Welding procedures qualification

WPS

Welding procedure

WELDER

Qualification of welders

NDT-OP

Qualification of NDT inspectors

CALC

Checking and approval of calculations

RESSTR

Residual stress analysis

DRAW

Checking and approval of drawings and specifications

PURCH

Review of purchase orders

RECEIPT

Receiving inspection

CERT

Certificate check

VI

Visual inspection

NDT

Extent of non-destructive testing

ACCEPT

Acceptance criteria

UT

Ultrasonic testing

3 of 5

RT

Radiographic testing

MT

Magnetic particle testing

PT

Penetrant testing

HB

Hardness test

DT

Dimension and form control

BAL

Balancing

PRESSURE

Pressure testing

LEAKAGE

Tightness inspection

FUNCT

Function testing

FINAL

Final testing

PROCEDURE

Reference to the document which describes the inspection or testing procedure.

6

LOCATION

Location for the inspection or test.

MS

Machine shop

SFS

Steel fabrication shop

SUPPL

Supplier's workshop

SITE

Erection site

STOCK

Warehouse department

RESPONSIBILITY

The letter designation, possible group number for the organization unit, who is responsible for the
inspection or test performance.
SUPPL

Suppliers workshop

RP

Rainpower

BUYER

The customer

WITNESSING

Representation, if any, by a party other than he who performs the inspection test.
Internal party is given by the letter designation, external as follows:
RP

Rainpower

CONS

Consultant or classification society

CLIENT

The customers representative

_____

Hold point, i.e. the process must not proceed until passed by the witness

as indicated by underlining.
9

REPORT FORM

Reference to form numbers.

PROCESS

Signature in Process Description

PROT

Inspection record

10

REPORT TO BUYER

Cross for reports to be forwarded to the buyer.

Site Installation Control Form

Ordre Nr. /Order No

Indeks/Index

Kunde/Customer

Rapport nr./report no.

R010/K010

SN Power

Form 1

Byggested/Fab. site

Sak/subject

Side /Page

Tegn. nr. /Drwg. No.

Cheves HEPP
Uni 1 and 2

Pos. nr /Part No

Del / Part

MIV and Governor during

installation

Survey of pipe cleaning with plastic bullets and

oil

221304

1
Dato / Date

Unit No.

Cleaning with plastic bullets

PIPE LINE

CLEANING
RESULT

Other pipe lines No. 1 (to be determined at site)

Other pipe lines No. 2 (to be determined at site)

Other pipe lines No. 3 (to be determined at site)

Other pipe lines No. 4 (to be determined at site)

Flushing with oil

LOOP SERVOMOTORS

RESULT
CLEANLINESS TEMPERATURE
LEVEL

Servo 1
Servo 2
Other pipe lines (to be determined at site)
Other pipe lines (to be determined at site)

Acceptance criteria:
Cleanliness level

NAS 1638 class 7

60 65

Temperature for VG 64 oil

Velocity

6 m/s

Pump capacity (6 m/s and

internal pipe dia. 8mm)

Performed
01_Form 1 _ Cleaning pipes

300 l/min

Witnessed

Approved

Approved

av / of

1
Sign

Site Installation Control Form

Ordre Nr. /Order No

Indeks/Index

Kunde/Customer

Rapport nr./report no.

R010/K010

SN Power

Form 2

Byggested/Fab. site

Sak/subject

Side /Page

Tegn. nr. /Drwg. No.

Cheves HEPP
Unit 1 and 2

Pos. nr /Part No

Del / Part

MIV and Governor during

installation

Pressure tests of misc. pipe lines

221304

1
Dato / Date

Unit No.

Pressure tests of miscellaneous pipe lines

PIPE LINE

PRESSURE (bar)

Other pipe lines No. 1 (to be determined at site)

Other pipe lines No. 2 (to be determined at site)

Other pipe lines No. 3 (to be determined at site)

Other pipe lines No. 4 (to be determined at site)

Acceptance criteria:

Test pressure

bar

Holding time

min

Medium

Performed
02_Form 2 _ Pressure test pipes

Water

Witnessed

Approved

Approved

av / of

1
Sign

Site Installation Control Form

Ordre Nr. /Order No

Indeks/Index

Kunde/Customer

Rapport nr./report no.

SN Power

Form 3

Byggested/Fab. site

Sak/subject

Side /Page

Tegn. nr. /Drwg. No.

Cheves HEPP
Unit 1 and 2

Pos. nr /Part No

Del / Part

MIV and Governor during

installation

Survey of cabling

221304

K500

1
Dato / Date

Unit No.

Survey of cabling

WIRING DIAGRAM

RESULT

Wiring Diagram SSG

Wiring Diagram Turbine and MIV Equipment
Wiring Diagram OPS
Wiring Diagram Governor

Performed
03_Form 3 _ Survey of cabling

Witnessed

Approved

Approved

av / of

1
Sign