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4.5.5 Hydraulic Testing of Runner (Kaplan) in Service BayFig 4: Testing of Runner [Goncharov]The correct assembly of the blade-actuating mechanism and the tightness of theflanged joints of the runner and of its blade seals are checked after assembly. The tightness ofthe runner is checked by hydraulic tests, while the correct assembly of the blade-actuatingmechanism is verified by rotating the blades.The runner is hydraulically tested before the hub extension is fitted. This makes itpossible to check the tightness of the joint between hub body and hub bottom. Servomotorcylinder cover (2) is placed on hub (1) before the test. A temporary cover is used if thepermanent cylinder cover is integral with the shaft flange. The openings in the cylinder overfor the connection with the shaft are blanked off with plugs (3). The gap between piston rodand cylinder cover is closed with seal (4). Temporary connecting piece (5) with two unions isplaced on the piston rod. One union is connected to the opening in the rod and oil is deliveredthrough this opening into the servomotor cylinder beneath the piston. The second union isconnected to the opening in the rod, delivering oil into the cylinder above the piston. Theother ends of these unions are connected to pump (7) via hoses (6) (Fig. 4).The hub is filled with oil through a plug in the bottom and pipe (8). The air escapesthrough valves fitted on top and bottom of the servomotor cylinder. Oil delivery to the hub isstopped when oil flows from these valves. Oil is then delivered through pipe (9) by pump(10). The oil pressure is thus raised to a level which usually corresponds to three times theheight of the oil column from the runner hub to the oil supply head.The runner must remain under the test pressure for 24 hours at a runner and oiltemperature of not less than 10 o C. During testing, the blades are successively set to their noload,half-load, and full-load positions, and held in each position for 8 hours. No oil shouldleak through the fixed joints of the runner. The maximum permissible oil leakage per daythrough the seal of each blade is as follows:Runner diameter, m ………………. 3.0 5.0 7.2 9.3Oil leakage per day, 1…………….. 0.10 0.15 0.18 0.20AHEC/MNRE/SHP Standards/ E&M Works – Guidelines for Operation and Maintenance of Small Hydropower Station 59
The blades are set to the no-load position by the oil pressure acting on the bottom ofthe servomotor piston. Pressure on the top of this piston causes the blades to move into thefull-load position. This pressure is created by a pump. The smoothness of blade actuation istested at the same time, as are the blade travel and setting angle.4.5.6 Centering and Alignment of Vertical Hydro Generator• Alignment of rotor during installation is ensuring rubbing surface of thrustbearings and the shaft mirror disc face are perpendicular to rotor centre.• The procedure for rotor centering is as follows.- First centering of turbine shaft is checked since its flange andcentre line from reference bases centering of the generator rotor- The generator is then provisionally centered relative to turbineshaft.- Then perpendicularity of rubbing surfaces of thrust bearing andshaft flange face to the generator shaft centre line is checked.- Then final alignment generator and turbine is done.I. Procedure for alignment of unit- Set elevation of thrust bearing- Carry out rotational check of gen. shaft- Calculate maximum throw and direction- Minimize throw by scrapping insulated surface of mirror disc.- Couple generator shaft with turbine shaft- Again check elevation & level of thrust bearing- Carry out rotational checks- Find out run out at LGB & coupling flange- If throw is still more again carry out scrapping of insulated surface of mirrordiscs. Again check by rotation method and repeat till throw is with in limit- Check throw and its direction at TGB- Minimize throw by providing shim between coupling flange- Check throw at LGB, coupling flange and TGB, ensure these are with in limit.This is necessary to establish unit axis.- Check verticality of shaft with respect to duly leveled thrust bearing at correctelevation.II.Coupling of ShaftsA. Before coupling of generator shaft and turbine it is to be checked that followingrequirements are met:Sl. Type of DeviationNo.1. Shift of Gen. shaft axis with turbineshaft axis2. Non parallelity of mating surfaces ofboth flanges at shaft dia.Upto 600 mmUpto 1000 mmUpto 1500 mmAllowable Deviationin mm0.01 mm0.0200.0250.030AHEC/MNRE/SHP Standards/ E&M Works – Guidelines for Operation and Maintenance of Small Hydropower Station 60
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STANDARDS / MANUALS / GUIDELINES FO
Page 3 and 4:
ITEMSPAGE NO4.2 Preventive Maintena
Page 5 and 6:
SECTION - IGUIDELINES FOR OPERATION
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2.1.2 Lake/Storage/PondThe operatio
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2.2.3 Electrical• Air seal valve
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• Start command initiated(iv)Sync
Page 13 and 14: ‣ Check whether supply to various
Page 15 and 16: - Intake gates, bye pass gates, D.T
Page 17 and 18: • To arrange for evacuation of ma
Page 19 and 20: SECTION - IIGUIDELINES FOR MAINTENA
Page 21 and 22: 2.3 PREDICTIVE MAINTENANCEThis sort
Page 23 and 24: 6. Oil Leakage Unit:i) Check any le
Page 25 and 26: 5. Shaft Gland Seal and Air Seal:i)
Page 27 and 28: v) In case the runner is found to b
Page 29 and 30: iii) Preheating of the blade to abo
Page 31 and 32: E. GovernorDifferent types of gover
Page 33 and 34: Sl. No. Description Periodicity Rem
Page 41 and 42: 4.2.1 Daily ChecksSl.No.Assembly It
Page 43 and 44: 4.2.3 Annual Inspection & Maintenan
Page 45 and 46: Sl.No.Assembly Item Check Point Met
Page 47 and 48: • Check all joints, tightness of
Page 49 and 50: S.No.Item to beinspectedInspection
Page 57 and 58: 4.4 PREVANTIVE MAINTENANCE OF HYDRO
Page 59 and 60: Spherical valves (for heads more th
Page 61 and 62: • Check rotor level, verticality
Page 63: • Any possible inbalance of runne
Page 67 and 68: IV.Rotational Checks‣ Arrangement
Page 69 and 70: Fig 6: Resultant Method of Throw Ca
Page 71 and 72: Fig 9: checking Verticality of Gene
Page 73 and 74: oFig 11: Checking Balancing of Gene
Page 75 and 76: Procedure for preliminary alignment
Page 77 and 78: Fig 14: Determining Displacements o
Page 79 and 80: SECTION-IIIGENERAL GUIDE LINES1.0 G
Page 81 and 82: • On placing them on operation du
Page 83 and 84: Safety Precautions and Practices in
Page 85 and 86: Results of test and measurements ca
Page 87 and 88: (NAME OF POWER STATION)DAILY GENERA
Page 89 and 90: (NAME OF POWER STATION)DAILY TRIPPI
Page 91 and 92: UnitGENERATION(MU)TOTALTIME(Hrs:Min
Page 93 and 94: MONTHLY TRIPPING REPORTFOR THE MONT
Page 95 and 96: AHEC/MNRE/SHP Standards/ E&M Works
Page 97 and 98: (POWER STATION)ANNUAL MAINTENANCE S
Page 99 and 100: UNIT/ EQUIPMENT/ FEEDER BAY/:DATE &
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