tiêu chuẩn lắp đăt GB8564-2003 Specification for installation of hydraulic turbine and generator units

ICS 27.140
F 22

NATIONAL STANDARD OF
THE PEOPLE’S REPUBLIC OF CHINA
中华人民共和国国家标准
GB/T 8564-2003
Replace GB/T 8564-1988

Specification for Installation of
Hydraulic Turbine Generator Units

水轮发电机组安装技术规范

Issued on September 15, 2003

Implemented on March 1, 2004

Issued by General Administration of Quality Supervision, Inspection and
Quarantine of the People's Republic of China and Standardization
Administration of the People's Republic of China


NATIONAL STANDARD OF
THE PEOPLE’S REPUBLIC OF CHINA
中华人民共和国国家标准
Specification for Installation of
Hydraulic Turbine Generator Units

水轮发电机组安装技术规范
GB 8564-2003

Chief Development Department: China Gezhouba (Group) Corporation,
Sinohydro Corporation, China Three Gorges Project Corporation and Harbin
Electric Machinery Co., Ltd.
Implementation date: March 1, 2004

Standards Press of China
中国标准出版社
Beijing 2004


Contents
1 Scope............................................................................................................................................. 7
2 Normative standards................................................................................................................... 7
3 General principles....................................................................................................................... 8
4 General regulations..................................................................................................................... 9
5 Installation of vertical type reaction turbine .......................................................................... 12
5.1 Installation of built-in fitting......................................................................................... 12
5.2 Runner installation ........................................................................................................ 21
5.3 Preassembling of the guide apparatus.......................................................................... 24
5.4 Emplacement and installation of rotatable parts ........................................................ 26
5.5 Installation and adjustment of guide blade and/or servomotor................................. 27
5.6 Installation of water conduit and main shaft seal ....................................................... 29
5.7 Installation of fittings..................................................................................................... 30
6 Installation of tubular turbine ................................................................................................. 31
6.1 Installation of built-in fitting......................................................................................... 31
6.2 Installation of principal axes ......................................................................................... 34
6.3 Installation of guide apparatus ..................................................................................... 34
6.4 Installation of guide apparatus ..................................................................................... 34
6.5 Installation of the principal axes, runner and runner chamber ................................ 35

7 Installation of impulse turbine................................................................................................. 35
7.1 Installation of diversion conduit ................................................................................... 35
7.2 Installation of case.......................................................................................................... 36
7.3 Installation of the bearing of turbine shaft .................................................................. 36
7.4 Installation of turbine shaft........................................................................................... 36
7.5 Installation of sprayer and servomotor........................................................................ 37
7.6 Installation of runner..................................................................................................... 37
7.7 Installation and adjustment of control mechanism..................................................... 37
8 Installation and debugging of speed regulating system ......................................................... 37
8.1 Installation and debugging of oil pressure devices...................................................... 37
8.2 Installation of speed governor....................................................................................... 39
8.3 Oil filling adjustment test of speed regulating system ................................................ 41
8.4 Simulation test of speed regulating system .................................................................. 42
9 Installation of vertical type hydrogenerator........................................................................... 42
9.1 Combination of framework........................................................................................... 42
9.2 Grounding and scraping of bearing shell..................................................................... 43
9.3 Stator installation........................................................................................................... 44
9.4 Rotor installation............................................................................................................ 50
9.5 Overall installation......................................................................................................... 56
9.6 Installation of excitation system and devices ............................................................... 64
10 Installation of horizontal hydraulic generator ..................................................................... 65
10.1 Grounding and scraping of bearing bush .................................................................. 65
10.2 Installation of bearing pedestal................................................................................... 66
10.3 Installation of stator, rotor and/or fitment ................................................................ 66


10.4 Checking of each part of the bearing and clearance adjustment............................. 67
11 Installation of bulb-type hydraulic generator ...................................................................... 68
11.1 Installation of stator..................................................................................................... 68
11.2 Installation of rotor...................................................................................................... 68

11.3 Installation of principal axes and composition bearing ............................................ 68
11.4 Generator installation.................................................................................................. 69
12 Installation of pipelineand and fitments................................................................................ 70
12.1 Fabrication of pipe fittings and fitments of pipeline ................................................. 70
12.2 Pipeline welding............................................................................................................ 72
12.3 Installation of pipeline ................................................................................................. 73
12.4 Treatment of the inner wall of pipeline...................................................................... 75
12.5 Test of the conduit and pipe fittings ........................................................................... 75
13 Installation of butterfly valve and ball valve ........................................................................ 75
13.1 Installation of butterfly valve...................................................................................... 75
13.2 Installation of ball valve............................................................................................... 76
13.3 Installation of flexible connector................................................................................. 77
13.4 The installation of hydraulic control valve and air valve ......................................... 77
13.5 Installation of operating mechanism .......................................................................... 77
14 Electrical test of water-turbine generator set ....................................................................... 78
15 Trial run of water-turbine generator set............................................................................... 82
15.1 General specifications .................................................................................................. 82
15.2 Water filling test of assembling unit........................................................................... 83
15.3 Zero load trial run of unit ........................................................................................... 83
15.4 Test over paralleling in of unit and under load ......................................................... 86
Annex A......................................................................................................................................... 90
Annex B......................................................................................................................................... 94
Annex D......................................................................................................................................... 96
Annex E......................................................................................................................................... 98
Annex F ....................................................................................................................................... 101
Annex G ...................................................................................................................................... 104


Foreword
This standard provides basis for the installation, debugging and testing of

hydraulic turbine generator units and relevant auxiliary facilities and main content for
unit acceptance and examination. This standard is applicable to the installation of all
types of hydraulic turbine generator units and relevant auxiliary facilities.
This standard is the revision of GB 8564-1998 Specification for Installation of
Hydraulic Turbine Generator Units (hereinafter referred to as "the original standard").
The original standard summarizes technologies for installation of hydraulic turbine
generator units and relevant auxiliary facilities in and before 1988. On the basis of the
original standard, this standard contains supplements, deletions and amendments to
specifications for installation of large and medium hydraulic turbine generator units
and relevant auxiliary facilities including those imported since 1989, and makes
references of some relevant content in foreign standards.
Compared with GB 864-1988, the following changes are made herein:
-- The standard is clearly classified to be a piece of recommended standard;
-- Application scope of original standard is changed and "Scope" and
"Normative References" are stated separately herein;
-- The following contents are supplemented, such as installation of cylindrical
valve, aqueduct installation and bearing assembly of action turbine, assembly of
welded generator engine frame, assembly of generator stator base and iron core,
welding of disc-type rotor, installation of excitation system and commissioning of
reversible pump-storage unit.
-- Partial contents of installation of speed regulator, adjustment test of oil
charging for speed regulating system, technical requirements of pipeline welding and
quality inspection;
-- Installations of mechanical hydraulic speed regulator, initiator and
permanently-magnetic machine are deleted from the text of original standard, and
installation of mechanical hydraulic speed regulator and drying of stator winding are
stated in annex;
-- Indices and limit values of some articles are partially adjusted and increased.
Although stator windings of internal water cooling and evaporative cooling have
already been adopted in some units in China, experiences in design and construction

of these cooling types are immature and these cooling types may not be promoted in
the future. Therefore, these two cooling types are not covered herein.
This standard will replace GB 8564-1988 from the implementation date of this
standard.
Annexes B, C and G attached hereto are normative.
Annexes A, D, E and F attached hereto are informative.
This standard is proposed by and under the jurisdiction of China Electricity
Council Standardization Center.
Chief Development Department: China Gezhouba (Group) Corporation,
Sinohydro Corporation, China Gorges
Project Corporation and Harbin Electric


Machinery Co., Ltd.
Chief Drafting Staff: Fu Yuanchu, Zhang Hua, Wang Quanlong, Qin Xixiang,
Liu Yongdong, Zhao Shiru, Li Zheng'an, Zhang
Yaozhong, Du Qichen, Zhang Lianbin, Zhao Guishan,
Xu Guangtao, Gong Deping, Wang Tian, Yang Xiyin,
Huang Hongyong, Zhang Chengping, Liu Yanhua, Jiang
Xiaobing, Yin Longsheng, Liu Canxue and Tang
Wanbin.
China Electricity Council Standardization Center is responsible for interpretation
of this standard.


Specification for
Installation of Hydraulic Turbine Generator Units
1 Scope
This national standard regulates the installation, debugging of hydraulic turbine
generator units and the requirements of test. It is applicable to the installation and/or

acceptance of hydraulic turbine generator units in compliance with the following
conditions:
a) Unit capacity of 15MW and/or higher
b) Impulse hydraulic turbine with its nominal diameter of runner at 1.5m and/or
above
c) Radial-axial flow turbine with its nominal diameter of runner at 2.0 m and/or
above
d) Axial flow, mixed flow variable pitch turbine, and tubular turbine, with
nominal diameter of runner at 3.0m and/or above.
Hydraulic turbine generator units with unit capacity smaller than 15MW and units
with nominal diameter of turbine runner smaller than that specified in b), c), and d).
This national standard is applicable to the installation and/or acceptance of reversible
pump storage unit.

2 Normative standards
The following normative documents contain provisions, which, through reference
in this text, constitute provisions of this national standard. For dated reference,
subsequent amendments to, or revisions of, any of these publications do not apply.
However, it is recommended parties reaching agreement according to this national
standard carry out a study on if the most updated version of these documents may be
applied or not . For undated reference, the latest edition of the normative document
referred to applies.
GB3323 Methods for radiographic inspection and classification of radiographs for
fusion welded butt joints in steel
GB/T7409.3 Excitation system for synchronous electrical machines-Technical
requirements of excitation system for large and medium synchronousgenerators;
GB/T7894 Fundamental technical requirements for hydraulic turbine generators;
GB/T9652.1 Specifications of governors and Pressure oil supply units for
hydraulic turbines;
GB/T9652.2 Test acceptance codes of governors and pressure oil supply units for

hydro-turbines;
GB/T10969 Specifications for water passage components of hydraulic turbines;
GB/T11120L-TSA Turbine Oil;
GB11345 Method for manual ultrasonic testing and classification of testing results
for ferritic steel welds;


GB/T18482 Start - up test code for reversible pump - storage units;
GB50150 Emending explanation of Standard for hand-over test of electric
equipment electric equipment;
GB50168 Code for construction and acceptance of cable levels electric equipment
installation engineering;
GB50171 Acceptance of switchboard outfit complete cubicle and secondary
Circuit Electric Machine;
DL/T507 Start-up test code for hydraulic-turbine and generator units;
DL/T679 Code for welder technical qualification;
DL/T827 Start-up test code for bulb tubular hydraulic-turbine and generator units;
JB/T4709 Welding specification for steel pressure vessels;
JB/T6204 Specification for withstand voltage test on stator coil and winding
insulation of high voltage AC machines;
JB/T8439Technical requirements on suppress corona of high-tension machines
used in high altitude areas
JB/T8660 Standard for hydroelectric set packing, transportation and preservation

3 General principles
3.1 Installation of water-turbine generator set shall proceed according to this
national standard in compliance with the installation drawing approved by design
organization and manufacturer as well as related technical documents. Special
requirements raised by the manufacturer shall be satisfied according to related technical
documents. Supplementary provisions for requirements not listed in this standard and

technical documents of manufacturer shall be specified additionally. In case of a
conflict between the technical requirements from the manufacturer and this standard,
generally, the requirements of the manufacturer shall proceed. Otherwise, consult with
the manufacturer for a settlement.
3.2 Other than this national standard, installation of unit and its auxiliary facilities
shall also comply with current related specifications on safety, environmental
protection, fire control, and so on issued by the state or related authorities.
3.3 Equipment for water-turbine generator units shall be in accordance with the
regulations of current national standard and purchase contract. After the equipment
arrives at the acceptance spot, the installation party may participate in unpacking,
counting, checking the supply list and random packing list, and then operate according
to JB/T8660.
The following documents shall be taken as important evidence for acceptance of
both unit and it auxiliary equipment as well as quality acceptance.
a) Equipment installation, operation, instruction on operation and maintenance and
technical documentation;
b) All random drawing materials (including equipment installation drawing and
structure drawing of spare parts);
c) Certificate of analysis, inspection and test records;
d) Material quality and performance certificate of vital parts.


3.4 Before the installation, read design drawing, factory inspection record and
related technical documents carefully and be familiar with them, and then make out a
logical construction design in compliance with the actual conditions.
3.5 Before the installation, read related civil design drawing and participate in the
acceptance of the delivered civil construction parts. For places with flaws, the
installation must be carried out after treatment.
3.6 All materials used in the installation of water-turbine generator unit shall be in
accordance with design requirements. Primary materials must possess inspection

certificate and certificate of analysis.
3.7 Plan the installation field integrated. The following requirements shall be met:
a) Installation field shall be windproof, rainproof and dustproof. Unit installation
must proceed after the completion of the factory building roofs of this unit and adjacent
units are sealed.
b) Generally, the temperature shall not be lower than 5°C. Relative humidity of air
shall not be higher than 85%. For other equipments and parts that have requirements
over temperature, humidity and other special conditions, the installations shall be
implemented according to the design specifications.
c) Enough illumination shall be provided on the construction field;
d) Safety facilities for construction in compliance with requirements must be
equipped on site. Places to put flammable, high explosive items must have
corresponding safety provisions;
e) Civilize production. Installation equipment, construction tools and materials
shall be placed in order. The construction site shall keep clean. Passage remains to be
smooth. Clear the site on the completion of work.
3.8 After the completion of the installation of water-turbine generator set, proceed
the test run according to this national standard and DL/T507. Comprehensively check
the quality of design, fabrication and installation. After the test run is proved qualified,
proceed the acceptance of the unloading phase of this unit. Hand over related materials
according to the requirements of Annex A.

4 General regulations
4.1 Before installation, clear and inspect the equipment overall. Check the main
dimensions and/or tolerance of primary parts according to the drawing requirements as
well as ex-factory records.
Equipment inspection and flaw treatment shall have records and licenses.
Packed equipment under warranty may not have to be dis-integrated.
4.2 Generally, deviation of the elevation of entombment of equipment foundation
bedplate shall not exceed - 5mm ~ 0mm. Deviation of the center and azimuth

distribution shall not be greater than 10mm. Horizontal deviation is no greater than
1mm/m.
4.3 After fitting entombment part, reinforce it. Foundation bolt, lifting jack,
fastener, wedge, and floor plate shall all be spot-welded and fixed. The built-in fitting
and the concrete binding surface shall be free of oil sludge and serious rustiness.
4.4 Installation of the anchor bolt shall comply with the following requirements:


a) Check if the anchor bolt hole is in the right position. The inner wall of the hole
shall be roughened and cleaned. Deviation of the screw center line and base center line
shall not be greater than 10mm; the elevation and depth of the bolt shall be in
compliance with the design requirement; squareness deviation of bolt hole wall shall
not be greater than L/200 (L refers to the length of anchor bolt mm, the same for the
following context) and shall be smaller than 10mm.
b) Centre of second phase concrete direct burial and casing flush type anchor bolt
shall comply with design requirement. The deviation of center shall not be greater than
2mm. The discrepancy in elevation shall not be greater than 0mm ~ +3mm. Squareness
deviation shall be smaller than L/450.
c) Anchor bolt adopts embedded bar. Welding of screw on it shall conform to the
following requirement:
1) Material quality of embedded bar shall agree with the material quality of anchor
bolt basically;
2) Cross-sectional area of embedded bar shall be greater than that of bolt, and the
embedded bar shall be upright;
3) When the bolt and embedded bar adopts double side welding, the weld length
shall not be smaller than 5 times the diameter of the anchor bolt. When single side
welding is adopted, the weld length shall not be smaller than 10 times the diameter of
anchor bolt.
4.5 Use wedge plate pairs and the overlapping length shall be 2/3 upwards. For the
wedge plate that bears important parts, inspect the contact situation with 0.05mm feeler

gauge. The contact length of each side shall be greater than 70%.
4.6 Install the equipment after the substructure concrete intensity reaches 70% of
the design value. Second term concrete on the floor plate shall be poured and
compacted.
4.7 The coupling surfaces of equipment shall be smooth and burr free. For joint
close clearance, measure with 0.05mm feeler gauge and the gauge shall not pass
through. Partial clearance is allowed. Check with 0.10mm feeler gauge and the depth
shall not exceed 1/3 the width of plane of composition. The total length shall not
exceed 20% of the perimeter. No clearance shall exist around the assembling bolt and
pin bolt.
Generally, fitting surface at the combination slot staggering shall not exceed 0.10
mm.
4.8 Match marks shall be considered during component installation. When a lot of
machines are installed together, each machine shall be assembled with the part marked
with the same series design.
The serial numbering in the installation record of same kind of installation or
survey points for fixed parts shall begin from +Y and be numbered clockwise (begin
from generator end, same for the following context); for rotating installation, begin
from the position of No.1 polar of rotor. Except that the survey point on the jigger is
numbered counterclockwise, others are all numbered clockwise. Attention shall be paid
to the above numbering regulations of the manufacturer.


4.9 For connecting bolt with pre-tightening force requirement, the pre-tightening
force deviation shall not exceed the 10% of the set value. If not specified by the
manufacturer, preliminary tension shall not be smaller than twice the design work
stress and shall not exceed 3/4 of the yield strength of materials.
During the installation of closely-pitched connecting bolt, the screw thread shall
be applied with lubricant. Connecting bolt shall be fastened evenly by many times.
Adopt thermal state screwed bolt. After fastening, spot check the pretension of around

20% bolt.
After each part is installed, drill hinge pin tack hole and fit pin bolt according to
design requirement.
Lock and fasten the bolt, bolt cap, and pin bolt according to design requirements.
4.10 Universality measurement of the unit shall conform to the following
requirements:
a) Check and adjust all measuring tools in the qualified metrological examination
departments.
b) Deviation of X, Y datum line and height point used in the installation of unit
against the data mark of factory building shall not exceed±1mm.
c) Measuring error of the height deviation of each part shall not exceed±0.5mm.
d) Horizontal survey deviation shall not exceed 0.02mm/m.
e) Generally, diameter of the steel wire used by the center is 0.3mm ~ 0.4mm. Its
tension stress shall not be smaller than 1200MPa.
f) No matter which method to take in measuring the center or roundness of the
unit, the measuring error shall not be greater than 0.05mm;
g) Pay attention to the impact on the surveying accuracy by temperature
fluctuation. Amend the measured number according to the changes of temperature
during the measuring.
4.11 In the intensity waterproof test for field manufactured bearing equipment and
bridge pieces, the test pressure is 1.5 times the nominal operating pressure, but the
minimal pressure shall not be smaller than 0.4MPa. Sustain for 10 minutes, no leakage
or crackles, and so on.
During the tightness compression test of equipment and its bridge pieces, the test
pressure is 1.25 times the actual working pressure. Sustain for 30 minutes, no leakage
phenomena. During the leakage test, the test pressure is actual working pressure,
sustain for 8 hours, no leakage phenomena.
Carry out the waterproof test of single cooler according to design requirement. If
not regulated, the test pressure shall be twice the working pressure, but no lower than
0.4Mpa. Sustain for 30min, no leakage phenomena.

4.12 In the kerosene leakage test of vessel, sustain at least 4h. If no leakage
phenomena, do not dismantle the vessel after finishing the leakage test.
4.13 Single keystroke shall coordinate with keystroke for the examination. The
tolerance shall comply with design specification. Keystrokes in-pair shall be checked in
pair. The parallelism shall meet the design requirements.
4.14 Welding of assembling unit and its auxiliary facilities shall comply with the
following requirements:


a) Welders of assembling unit and its auxiliary facilities shall attend special item
training and examination regularly as required by the manufacturer. They must hold
certificate to take the position after they pass examinations and are licensed.
b) All the length and height of the welding seams shall meet the drawing
requirements. Welding quality shall be checked as required by the design drawing.
c) For important components, welding shall proceed according to the welding
process or welding procedure specification specified by the manufacturer after the
qualification of welding procedure.
4.15 Trademark of turbine lubricating used by assembling unit and
speed-regulating system shall comply with the design regulations. See Annex F.
4.16 All monitoring equipment and automation components of the assembling unit
shall be check and qualified according to the ex-factory specifications.
4.17 Assembling and general installation of the water-turbine generator as well as
installation shall all be kept clean. After the installation of assembling unit, clean and
check carefully both inside and outside the unit. No impurities or nastiness shall exist.
4.18 Antisepsis painting of each part of the water-turbine generator set shall
satisfy the following requirements:
a) Each part of the assembling unit shall be pre-treated and painted in the
manufacturing factory according to the design drawing.
b) Installation (including site-welding seams) needs to be painted with final
coating on site shall proceed according to the design requirements. If the color and

factory building ornament do not agree, except for the tube color, colors of other parts
are changeable.
c) During the installation process, if the finish coat is damaged partially, fix it
according to the requirements of original coating.
d) Coating of the site operation shall be homogeneous, bubble free, wrinkle free
and with the same color.
e) Installation that needs to be varnished on site according to contract or required
specially shall comply with regulations.

5 Installation of vertical type reaction turbine
5.1 Installation of built-in fitting
5.1.1 Installation of the steel liner on the nose of the splitter wall of draft pipe
shall comply with the following requirements:
a) Range deviation from the top of nose steel liner to the X-axis of assembling unit
±30mm;
b) Range deviation from the nose steel liner side to Y-axis of assembling
unit±15mm;
c) Discrepancy in elevation from the top of the nose steel liner (or bottom)
±10mm;
d) Squareness deviation of the nose steel liner 10mm.
5.1.2 Permissible deviation of installation of draft tube liner shall conform to the
requirements of Table 1.


Serial No.

1

2

3

4

5

Item
Dimension
of section
of elbow
tube
Lower tube
mouth of
elbow
Elbow pipe,
top tube
mouth of
conical
tube and/or
azimuth
Elevation
of the top
tube mouth
of shaft
tube and
conical
tube
Diameter of
the pipe
orifice of

conical

Table 1 Permissible deviation for Installation of Draft Tube Liner Unit: in millimeter
Runner diameter D
8000≤D<10,
D<3000
3000≤D<6000
6000≤D<8000
D≥10,000
000
±0.0015H (B, r)

Description
H – Section
height; B –section
length; r – arc
radius of section

±0.001H (B, r)

Smooth transition of the down tube mouth of elbow pipe and concrete pipe mouth

4

0~+8

6

0~+12

8

0~+15

±0.0015D

10

0~+18

12

Distance from X,
Y marks of the
measured tube
mouth to X, Y
reference line of
unit

0~+20

Evenly divided
into 8~24 points
for the
measurement
D – Design value
of tube diameter;
equally divided
into 8~24 points

6

7

tube
Perimeter
difference
of the
neighboring
pipe orifice
inwalls of
conical
tube
Center of
the down
tube mouth
of conical
tube
without
elbow pipe
liner

0.0015 L

10

15

20

0.001 L

Perimeter of pipe
orifice

25

Measurement or
examination with
plumbing bobs;
smooth transition
with the concrete
pipe mouth

30


5.1.3 Permissible variation of the installation of throating ring, foundation ring, and stand
ring shall comply with the requirements of Table 2. Special requirement of design shall be met.
Table 2 Permissible deviation for Runner chamber, foundation ring, and the stand ring
installation
Unit: in millimeter.
Runner diameter D
No
.

300
0
≤D

<
600
0

Item
D < 3000

1

Center and azimuth

2

Elevation

3

4

Flatne
ss of
flange
face to
install
coping
and
base
ring

Radial survey

2

3

Notes
600
0≤D
<
800
0

4

8000≤
D<
10000

5

D≥10
000

6

Measure
the
distance
between
X and Y

marks on
the
built-in
fitting
and X, Y
datum
line of
unit

±3
No
machinework
at the site

0.05 mm/m,
maximal no
greater than
0.60

Site
0.25
machinework
No
0.
0. 0.6
machinework 3
Circumferential
40
0
at the site

0
survey
Site
0.35
machinework
Difference between each radius
and the average radius shall not
Roundness of runner
exceed ±10% of the design
chamber
average clearance of the paddle
and runner chamber

Elevation difference of the
highest point and the lowest
point

Measure the three upper,
middle and lower sections
with axial flow; measure
upper spigot and lower
spigot with mixed flow


5

Foundation ring,
socket ring roundness
and/or its right
alignment with

runner chamber

1.0

1.5

2.0

2.5

3.0

variable pitch turbine;
evenly divide it into 8 ~ 64
measuring points
Evenly divides it into 8 ~ 32
measuring points. For mixed
flow unit, the lower fixed
sealing ring hub is taken as
the reference, and for axial
flow unit, runner chamber
hub is taken as the reference

5.1.4 Split runner chamber, foundation ring, socket ring plane of composition of screw-in
structure shall be applied with sealant, and the combination slot clearance shall be in
compliance with the requirements of Article 4.7. To prevent leakage, combination slot of
waterway surface may be sealed and welded. Weld surface shall be burnished and polished.
Combination if throating ring, foundation ring and socket ring of group weld shall meet the
design requirements.
5.1.5 During the installation of the upper ring of pillar socket ring and fixed guide vane,

direction of the azimuth deviation of socket ring and foundation ring shall be identical. To
guarantee end clearance of the guide blade is in accordance with the design requirements,
height from the foundation ring surface to the socket ring surface shall be controlled critically.
The distortion of socket ring caused by concrete pouring, deviation of measuring tool, as well
as the decreasing value of the end surface clearance caused by the tectorial distortion in service.
To reduce the distortion in the process of concreting, socket ring shall have reliable
reinforcement measures.
5.1.6 Permissible deviation for spiral casing erecting shall conform to the requirements of
Table 3.

1
2
3
4

5

Table 3 Permissible deviation of spiral casing erecting, unit as millimeter
Permissible
No.
Item
Notes
deviation
G
+2~+6
K1~ K2
± 10
e1 ~ e2
± 0.002 e
L

± 0.001 L, the
maximum value
is ±9
D

± 0.002 D


6

Pipe
flatness

orifice 3

Combination on the steel
platform or guy wire inspection
tube mouth shall be on the same
surface (belonging to the
inspection project).

5.1.7 Permissible deviation for spiral casing assemble shall conform to the requirements
of Table 4.

1

2
3

4

5
6

Table 4 Permissible deviation of spiral casing installation, unit as millimeter
Permissible
No.
Item
Notes
deviation
Center
Distance to 0.003 D
D - Inlet diameter of
of the Y axle of
spiral case. If the
straight the unit
steel pipe is well
pipe
assembled, then the
Elevation
±5
steel pipe is taken as
the reference and the
deviation shall not
be greater than 15%
of the spiral case
thickness
Elevation
of
the ±15

furthest point
Inclination of the 5
orientation pipe joint
mouth
Deviation
of ±5
orientation pipe joint
mouth and data line
Ultima thule radius
±0.004 R
R - Design value of
ultima thule radius
Pipe
orifice
knot ±0.002 H
H - Pipe orifice knot
height
high
(section
diameter),
(belonging
to
inspection project)

5.1.8 The following requirements shall be met for spiral casing weld:
a) Weld shall conform to the regulations of Article 4.14;
b) Generally, clearance between internodes, spiral cases and butt welds connected to the
socket ring is 2mm ~ 4mm. Unevenness of the waterway surface shall not be greater than 10%

of the slab thickness, but the maximal unevenness of longitudinal seam shall not be greater
than 2mm and the maximal unevenness of circumferential seam shall not be greater than 3mm;
c) If local clearance of groove is over 5mm, its length shall not exceed 10% of the weld
length. It is permitted to make overlay welding treatment at the groove.
5.1.9 Spiral case welding seam shall accept visual examination and non-destructive
examination. If not regulated by the manufacturer, the following requirements shall be met:
a) Weld appearance inspection shall conform to the regulations of Table 5;
Table 5 Appearance inspection unit of spiral welding seam
No.

Item

1
2
3

Crack
Surface slag
Undercut

4
5
6

Not fully welded
Surface porosity
Weld
Bead Manual welding
Remaining-height
∆h

Submerged arc welding
7

Width
of
the Manual welding
butt-joint welding
Submerged arc welding

8
9

Splash
Welding beading

Unit: in millimeter
Allowable defects
dimension
Not allowable
Not allowable
Depth not greater than 0.5;
continuous
length
not
greater
than
100;
accumulated total length of
the undercut on both sides

not greater than 10% of the
overall length of welding
seam

Not allowable
Not allowable
12<δ≤25; ∆h=0~2.5;
25<δ<80; ∆h=0~5;
δ-thickness of the steel plate

0~4
Cover 2~4 of the width of
the groove of each side and
the transition is smooth
Cover 2~7 of the width of
the groove of each side and
the transition is smooth
Clear up
Not allowable

b) Non-destructive test of welding seam
Non-destructive test of welding seam adopts radiographic inspection, the inspection
length is: For circumferential seam, it is 10%; for longitudinal seam and butt weld connecting


spiral case and socket ring, it is 20%; for the inspection of weld quality, according to the
GB3323 standard, circumferential seam shall reach Grade III, while the longitudinal seam and
butt weld connecting spiral case and socket ring shall reach the requirements of Grade II.
During non-destructive test, if supersonic flaw detecting is adopted, the inspection length
is: For circumferential seam, longitudinal seam and butt weld connecting spiral case and

socket ring, it is 100%; for the inspection of weld quality, according to the GB11345 standard,
circumferential seam shall reach Grade BII, while the longitudinal seam and butt weld
connecting spiral case and socket ring shall reach the requirements of Grade BI. For skeptical
parts, radiographic inspection shall be applied for double check.
c) Generally, steel liner of concrete spiral casing shall have kerosene permeability
examination and welding seam shall be free from penetrability defects.
5.1.10 Hydraulic site test of spiral case or pressure maintaining pouring spiral casing floor
concrete shall proceed according to the design requirement.
5.1.11 Before concrete pouring, clean the angle iron and pressure plate from spiral case
surface. Burr shall be planished. If the base material is injured, it shall be welded up and
planished, and magnetic particle inspection shall be taken.
5.1.12 Spiral case installation, welding and/or concrete pouring shall have measures to
prevent distortion of socket ring. Ascending velocity of concrete pouring shall not be greater
than 300mm/h. Generally, the height of each layer is 1m ~ 2m. The pouring shall be symmetric,
stratified and partitional. Generally, liquid concrete height is controlled at around 0.6m. During
the pouring course, the stay ring distortion shall be monitored. According to the actual
conditions, adjust the concrete pouring order according to the practical situation.
5.1.13 Roughness of waterway surface of built-in fitting shall comply with the regulations
of GB/T10969. Waterway surface welding seam of throat liner, runner chamber, and spiral
case (or spiral case underboarding) shall be planished. Waterway surface of built-in fitting and
concrete shall transite smoothly.
5.1.14 Permissible variation for the installation of pit liner shall comply with the
requirements of Table 6.
Table 6 Permissible variation of the installation of pit liner

Unit: in millimeter

Runner Diameter
No.

1

Item

Center

D
3000

5

< 3000 ≤D 6000
< 6 000
D
8000

10

15

≤ 8000≤D
< < 10 000

D
≥10,000

20

Notes

Measure
the
distance
between
undercoat
flange and
flange
bore
mouth at
the upper


part
of
holder;
evenly
divide it
into 8~16
points
2

3

4

Diameter
of upper
port
Elevation
of upper

port
Level
upper
port

±5

±8

±10

±12
Evenly
divide it
into 8~16
points
Evenly
divide it
into 8~16
points

±3

of
6

5.1.15 Permissible variation for the installation of servomotor foundation shall be in
accordance with the requirements of Table 7.
Table 7 Permissible variation for the installation of servomotor foundation
Runner Diameter (mm)

No.

1
2

3

Item

D<3000

Squareness
0.30
mm/m
Center
and ±1.0
elevation
(mm)

Degree
of 1.0
parallelization
to
the
co-ordinate
data line of
unit

3000≤D
<6000

6000≤
8000≤D D≥10,000
D
< <
10
8000
000
0.25

±1.5

±2.0

±2.5

±3.0

1.5

2.0

2.5

3.0

Notes

Measure
from the

flange
face of the
stay ring


4

Distance to the ±3.0
co-ordinate
data line of
unit (mm)

5.2 Runner installation
5.2.1Split runner of radial-axial flow turbine shall be assembled, welded and thermally
treated according to special group welding process and shall be in accordance with the
following requirements:
a) Welding seam of throating ring disallow undercut phenomena. Defect detecting test
shall proceed as required by the manufacturer and shall be in compliance with the following
requirements;
b) Runner crown combination slot clearance shall comply with requirements of Article of
4.7;
c) Runner crown flange inferior fovea value shall not be greater than 0.07mm/m. Epirelief
value shall not be greater than 0.03mm/m. The maximum shall not be greater than 0.06mm.
For principal axes, friction carry-over moment structure shall be adopted. Generally, no
convexity is allowed;
d) Undercut of welding seam at the lower ring shall not be greater than 0.5mm;
e) After the erection welding of differentiate paddle and/or paddle fillet, blade profile
shall be in compliance with the design requirements.
5.2.2 Before the site welding of seal ring, runner roundness at the part to install seal ring
shall be in compliance with requirements of 5.28. After the welding, seal ring shall be closely

jointed and the weld quality shall be in compliance with the design requirements. If hot jacket
is required for the seal ring, it shall be in compliance with the design requirements.
5.2.3 When the split runner seal ring is rounded, the measuring points shall be at 32 points
and the dimension shall be in compliance with the design requirements. The roundness shall
conform to the requirements of 5.2.8.
5.2.4 After the rounding, static balancing test shall be carried out on the split runner
according to requirements of Article 5.25. Diversion board shall be fitted during the test.
Clump weight shall be welded on the runner crown superface under the diversion board. The
welding shall be solid.
Roughness of waterway surface of built-in fitting shall comply with the regulations of
GB/T10969. Waterway surface welding seam of throat liner, runner chamber, and spiral case
(or spiral case underboarding) shall be planished. Waterway surface of built-in fitting and
concrete shall transite smoothly.
5.2.5 Runner static balancing test shall be in compliance with the following requirements:
a) Static balance instrument shall be concentric to runner. Deviation shall not be greater
than 0.07mm. Horizontal deviation of bearing base shall not be greater than 0.02mm/m;
b) When iron shot or rotating plate balanced method is adopted, sensitivity of static
balance instrument shall be in compliance with the requirements of Table 8.
Table 8 Distance from spherical surface center to the gravity center of runner


Quality of the runner - t
(Kg)
t<5000
5000≤t<10000
10000≤t<50000
50000≤t<100000
100000≤t<200000
t≥200000

Maximal distance (mm)

Minimal distance (mm)

40
50
60
80
100
120

20
30
40
50
70
90

c) .During the adoption of surveying rod strain method or static pressure ball-bearing
method, proceed according to the requirements and process as required by manufacturer.
d) Residual unbalanced moment shall be in compliance with the design requirements. If
no requirements are raised, requirements of Table 9 shall be met:
Table 9 Allowable imbalance value of the unit mass of runner eper
Maximal
running
rotation
speed
r/min
Allowable
imbalance

value of
the unit
mass of
runner eper
(g·mm/kg)

125

150

200

250

300

400

550

450

330

270

220

170

5.2.6 Operational test of runner blade of Kaplan turbine and tightness compression test
shall meet the following requirements:
a) Oiliness of test purpose oil shall be qualified and the oil temperature shall not be lower
than 5 °C;
b) Maintain 16h under the maximum test pressure;
c) During the test, during the test, switch on and off the paddle two or three times per
hour.
d) No leakage phenomena are allowed for each combination seam. oil leakage limit for
each single paddle package under or without test pressure shall not exceed the limit regulated
in Table 10, and be no greater than fuel oil leakage quantity during the ex-factory test;
Table 10 Oil leakage limit of each single paddle package per hour
Runner
diameter D
(mm)

D<3000

3000≤D<6000

6000≤D<8000

8000≤D<10000

D≥10000


Oil
leakage
limit of the
each single

paddle
package
per hour
mL/h

5

7

10

12

15

e) Runner servomotor shall move steadily. Generally, minimal oil pressure to turn on and
turn off shall not be greater than 15% of the nominal operating pressure;
f) Plot the relation curve of runner servomotor stroke and paddle rotor angle.
5.2.7 Joint of principal axes and runner shall be in compliance with the following
requirements:
a) Flange plane of composition shall be free of clearance. Check with 0.03mm clearance
gage and it shall not fill in;
b) Drop pit of screw bolt of flange shield shall be filled and leveled up.
c) Runner boss screw bolt shall be spot welded and fastened. Frame cover weld shall
adopt measures to prevent distortion. Welding seam shall be planished.
5.2.8 Right alignment and/or roundness of each part of the runner shall be examined with
principal axes as the center. The difference between each radius and average radius shall meet
the requirements of Table 11.
Table 11 Permissible variation of right alignment and/or roundness of each part of the
runner

Permissible
No.
Item
Notes
deviation
1) Seal ring
±10%
design Tip of blade is
2)
Fitting clearance
measured only
surface of seal
when
it
is
ring
necessary, and
3) Tip of blade
when
the
quantity flow is
0
Nominal head <
1
4) Wearing ring ±15%
design
200 m
of
diversion clearance
board

5)
Flange
protection cover
also serves as
sealing
cover
during overhaul
Nominal
1)
Exterior ±5%
design Corresponding
2
head≥200 m
margin of upper clearance
fixed parts are


canopy
2)
Exterior
margin of lower
ring
3) Seal ring of ±0.10 mm
upper claw tooth
4) Runner band
seal

coping
and/or
base ring

5.3 Preassembling of the guide apparatus
5.3.1 Before the preassembling of guide apparatus, measure the unit pit and determine the
roundness of bore opening at of socket ring to determine the unit center. Determine the surface
elevation and level of stay ring and foundation ring. Calculate height difference. Article 5.1.3
and the drawing requirements shall be met.
If the design includes water turbine with cylindrical valve, the cylindrical valve shall
attend the preassembling of guide apparatus.
5.3.2 Spread sealant on the plane of compositions of leaf type base ring, top cover, inner
top cover and so on and the clearance on the plane of composition shall be in compliance with
the requirements of Article 4.7. If shrinking or mechanism driving-in is needed for seal ring,
design requirements shall be met.
5.3.3 Preassembling of guide apparatus shall meet the following requirements:
a) Lower stay column seal ring shall be installed on the radial-axial flow turbine
according to the centering measuring point given after the determination of unit pit. The center
of lower stay column seal ring shall be taken as the fiducial center of the unit. Examine the
right alignment and roundness of each fixed sealing ring according to fiducial center of unit.
The difference between each radius and the average radius shall meet the requirements of
permissible variation of corresponding parts listed in Table 11. When the workface height of
seal ring exceeds 200mm, the upper and lower circles shall be checked.
b) Centre of axial wheel and runner chamber shall be taken as the unit fiducial center.
Check the right alignment of sealing socket and bearing block flange spigot according to the
unit fiducial center line. The permissible variation shall meet the requirements of Table 12.
Table 12 permissible variation for the right alignment of sealing socket and flange
spigot of bearing block Unit: in millimeter
Runner
D<300 3000≤D<600 6000≤D<800 8000≤D<1000 D
Notes
0
0

0
≥1000
diameter D 0
0
Permissibl 0.25
0.50
0.75
1.00
Evenly
e variation
distribut
e 8~24
points
c) Upper spigot centre of deriaz turbine and runner chamber shall be taken as the unit
fiducial center;


d) Preassembling quantity of guide blade shall not be less than 1/3 of total;
e) After the adjustment of base ring and top cover, the quantity of symmetric, screwed
fitting-up bolts shall not be less than 50% and shall meet the requirements of Table 13. Check
the clearance of guide blade sections. Clearance left on both sides of the header and end of
each guide blade shall identical. No regular inclinations are permitted. The maximal total
clearance shall not exceed the design clearance. Deformation value of the bearing rear head
cover shall be taken into account.
Table 13 Permissible variation of base ring and top cover Unit: in millimeter
Runner diameter D
Project

3000≤D 6000≤D 8000≤D
<6000

<8000
<10000
Roundness of 5% design clearance of runner sealing ring
the wearing
ring
Concentricity
of seal ring

D<3000

0.15

Check
the 0.35
surface level
of base ring

0.20

0.45

0.60

D
≥10000

Notes
Evenly
distribute 8~24
measuring

points
Evenly
distribute 8~24
measuring
points
The number of
circumferential
measuring
points shall not
be less than the
number
of
guide
vanes.
Adopt
the
difference
of
elevation
between
the
culmination and
nadir point

Right
In compliance with the design requirements
alignment of
wicket gate
housing
5.3.4 Guide apparatus without preassembling but directly installed formally shall also

meet related requirements of 5.3.1 ~ 5.3.3.
5.3.5 Installation of cylindrical valve shall meet the following requirements:
a) After the group welding of tunnel body, roundness of tunnel body under free condition
shall meet the design requirements;