Turbine Generator Installation Supervision Chen Xianjun Chadfa Bo Baifeng Congjiang Water Resources Commission Jiangyan Engineering Construction Supervision Station, Hunan Cili 4272214. No rework is the best pace of safety, in the actual installation process. Due to full preparation. Achieved the desired goal. The preparatory work that should be done before the installation of the hydrogen generator leaven was introduced, and the installation supervision process of its main departmental division was described. And the existing questions and methods of handling. 1 Introduction Three Francis turbine generating units with a capacity of 100 units at Jiangya Hydropower Station were led by Dongfang Electromechanical Co., Ltd. The supply contract was signed on June 6, 1996. The contract amount was 14.45 million U.S. dollars. Turbine model runners are provided by Canada Ice Corporation. The governor electrical cabinet and the excitation device are manufactured by the Swiss 88. The fluorine plastic thrust shroud is produced in Russia. On April 20, 1997, the first batch of hydro-generator units reached the construction site and was delivered at the end of 1998. The hydro-generator unit is the main equipment of the Jiangya hydropower station and the key process of electro-mechanical installation engineering. The installation project involves a large amount of work and the process is complicated. There are many control links such as the design of civil engineering construction equipment and supply engineering. It is a key project for supervision engineers to carry out quality and schedule control. In order to do a good job in the installation of water turbine generators. Jiang, the project supervision terminal station has two full-time on-site supervision engineers for follow-up supervision. Ensure that key processes are completed as scheduled. It laid the foundation for achieving the overall goal of power generation for the units of Jiangya Hydropower Station. The Jiangyin hydropower station turbine generating unit smoothly connected to the grid on May 16, 1999. The crew started the test run successfully. Various operating indicators are excellent. To achieve the objectives expected by the owner, 2 preparatory work for the installation of the hydro-generator set to do all the preparatory work, is to ensure that the next step of the installation work is a prerequisite for the smooth progress. Under the supervision and coordination of the supervision engineer, relevant units have earnestly implemented the following preparations for installation. 1 Organization equipment unpacking acceptance. According to the installation progress of the hydro-generating unit. The supervision engineer organizes the supplier of the owner and the installation unit to carry out the unpacking acceptance and inventory of the equipment that needs to be installed. The arrival equipment meets the contract requirements and is delivered to the installer. Unpacking acceptance is performed 1525.1 before equipment installation. If it is found that the device has quality questions or missing pieces, the supplier sends the person to the site for processing or reissue the goods. The progress of unit installation. 2 Implement the installation measures. Prior to the installation of the hydro-generator unit, the installation unit reported to the supervising engineer the installation organization measures of the hydro-generating unit, and important components such as the generator stator rotor. Also submitted a single construction organization measures. The supervising engineer organized the relevant units to review the above-mentioned construction organization measures and ensure that the measures were in place. At the same time, the supplier was required to send corresponding technical personnel to the site to guide the installation according to the different stages of the installation of the hydro-generating unit. 3 Provide a qualified installation station. The components of the hydro-generator unit are large in size. And the installation of some components requires high environmental requirements. therefore. Providing qualified installation work stations is an important part of ensuring the installation quality of hydraulic turbine generator sets. After the construction work surface has submitted the certificate, the unit equipment can enter the site. Jiangji Hydropower Station is a underground factory with a small installation site. During the construction period, the seepage of the cavern wall in the powerhouse is serious. Air humidity, dust and more. Poor environmental conditions, generator stator. Rotor transformers and other electrical equipment before installation. It is necessary to take certain measures. Ensure that the installation environment meets the regulatory requirements. 4 Carefully check the equipment. Before the installation of the hydro-generating unit, all components shall be thoroughly cleaned and inspected, with the major dimensions of the important components. The tolerance ovality should be retested and recorded. Some parts also need to be disassembled. Or perform relevant tests and meet the qualification requirements. Can be installed. 3 Hydro Turbine Installation Supervision 3.1 Embedded Component Installation Supervision The hydraulic turbine embedding components mainly include the tail water pipe seat ring metal volute liner and the servo lining. There is also a corresponding oil and gas buried pipe. Cable buried pipe and so on. The general requirement for the installation of hydraulic turbine embedded components is to correctly determine the height coordinate level. The connection joints of the over-flow surfaces are sealed after the adjustment passes. The welds require a smooth and smooth transition. Reinforced support embedded in the component. Do not dismantle until the concrete maintenance period has passed. The spiral pressure steel pipe should avoid cross-welding. And all welds shall be subject to 100 ultrasonic inspections and 1020 ray inspections, and unqualified welds shall be re-welded by the use of carbon arc bubbles. Re-inspection, surface distribution of buried turbine components buried in the process. Received date 20000216. Author brief introduction Chen Xianjun 艮 Changjiang Water Publications Committee Jiang Ya Deputy Director of Engineering Construction Supervision Station Every engineer. 3.1.1 Pen Water Pipe Installation Supervision 7 The Underwater Turbine liner and volute of the under-engine turbine are provided by the manufacturer. The installation unit is assembled into a unit section at a steel pipe plant and then transported to the site for installation. When lining tiles in the draft tube are assembled. The supervising engineer asked the installer to carefully check the dimensions of the tile and the dimensions of the lining of the draft tube. It was found that the individual tile size was about 10 more than the design size. The supervising engineer organized the factory personnel to verify this and asked for the excess to be disposed of. While checking the volute tile. A cross-welded joint was found. The specification required to be avoided as far as possible. The supervising engineer asked the manufacturer to provide a report on the quality analysis of the volute cross weld, confirming that there was no welding quality. In addition. It has been found that volute casing tiles have porosity at the weld groove, and that the quality of the surfacing welding is too high for the quality of the manufacturer. Prior to welding, the supervising engineer requested the installation unit to handle it. To ensure the quality of the welded tiles, before installing the draft tube in the liner, the installation unit proposes not to retain the concrete in accordance with the design requirements. Reinforce the construction plan for concrete placement. The supervision engineer approved this construction plan. And it is required to add reinforced reinforcements after lining the draft tube in the draft tube. Prevent the concrete pouring from deforming the liner of the draft tube. When lining installation in draft tube. Benefits 1 Cheng 1 found a fight on the outer wall of a liner, then the supplier provided and shipped, but the installation unit neglected the anchor installation. At the supervision engineer's request. According to the design requirements of the factory every 25301 repair welding anchor bar. Supervision Engineer's installation of the lining of the draft tube. The center ellipticity and level are controlled. Full compliance with the requirements, 3.1.2 seat ring and volute installation monitoring seat ring split body shipped to the installation site, in place on the steel pier for assembly, but found that the seat ring attachment bolts are not shipped. The engineer in charge of supervision contacted the manufacturer in a timely manner. The non-destructive inspection of the spiral casing weld of the 10,1 bolts to the construction site must be carried out by an inspector with a Class 1 inspection certificate issued by the National Institute of Non-Destructive Testing. In order to do a good job in the inspection of the volute weld. To ensure the welding quality, the supervision engineer recommended that the owner commissioned the Yangtze River Scientific Research Institute to carry out a random inspection of the volute welds. Responsible for the control of welding quality. Non-destructive inspection results of volute weld seam qualification rate 1 Prior to the installation of the seat ring and volute, the installation unit proposed a plan for the use of the concrete ring volute without concrete support piers. The supervision engineer organized the relevant units to discuss and agreed to change the seat ring pier to a steel pier. The volute still uses concrete piers. The supervising engineer adjusted the shell. When the volute was installed, he found that the welding space of the butterfly-shaped joint at the seat joint was too small. Welding is extremely difficult, and the supervision engineer has repeatedly called the factory resident and the installer to coordinate. And put forward a reasonable solution. The volute casing was found to be installed to detect the deviation of the perimeter of some adjacent sections up to 3,4,1. The supervision engineer of the guaranty asked the installer to fill the gap with the same material. Or surfacing to fill the way to solve. After the installation of the volute, the supervision engineer retests the level of the seat ring. The result is excellent. The level of the seat ring has a great influence on the installation quality of the hydro-generator unit. The supervising engineer regards the level of the seat ring as the focus of installation quality control. For this reason, on the basis of the design, the supervising engineer requires the installation unit to increase the number of the seat ring and the volute. Reinforced steel, and when the concrete is backfilled, the seat ring is equipped with 8 thousand points. Monitor the deformation of the seat ring. After the volute concrete was backfilled, the supervising engineer retested the level of the seat ring again, with little change. The seat ring is of good quality. 3.1.3 The lining of the pit and the lining of the servomotor shall be buried. The lining of the pit of the supervising machine shall be installed after the concrete of the volute is poured over the waistline. The machine pit is lined with four blocks in the installation field and adjusts the ovality. Correspondence. The 7-axis crane is lifted into the machine pit and the seat ring. Install the buried pipe around the pit lining. Harmful 1 Outlet relay lining and entrance door 10 When installing relay lining, pre-embedded mark position on the volute. The supervisory surveyor retested the installation quality of the lining of the pit and the burying of the relay pit and signed the certificate. In order to carry out civil engineering reinforcements. Cast concrete 2 Turbine body installation supervision The turbine body consists of a water guide and a rotating part. The pre-assembly work should be carried out before the water guide mechanism is officially installed. The purpose is to accurately adjust the center of the bottom ring and the top cover. Working seal and service seal Center The center of the water guide housing is centered to allow drilling of the hinged top and seat rings. Bottom ring and seat ring work Seal base and top cover Service seal base and top cover Locating pin holes for housing and top cover. Position them. Check the guide vane and top cover. The concentricity of the guide vane hole in the ring between the bottom rings. The water guide mechanism pre-assembles the base ring, the amount of glycosides is +, and the head adjustment margin is only to ensure the concentricity of the moving guide vanes. And the concentricity between the top cover and the bottom ring center, coordinated by the supervision engineer. Failure to install according to the manufacturer's prescribed installation procedure presupposes the installation of a movable guide vane. Lift the top cover and casing to adjust the concentricity between the center of the bottom ring and the movable vane with the center of the top cover stop ring. After the water guide mechanism is pre-installed. It was found that the size of some guide vane end gaps was too small. The supervising engineer organized the manufacturer's agent and the installer to negotiate and decided to take the guide leaf to preload the average face gap value. With the car pressure pad, at the same time in the plane on the seat ring plus 3,1 copper pad, so that the vane face gap close to the design value. The top cover sleeve rubber seal was cut during installation. The supervision engineer organized the manufacturer's generation and installation personnel to perform multiple analyses and took a variety of measures to test the installation. Finally, it was decided to increase the chamfering of the bottom hole of the sleeve position to make the seal. Smooth installation is performed on the servo before the installation of pressure test. One oil spill was found. According to the analysis of the supervising engineer's manufacturers and installers, the cylindrical pin end cover is long and the sleeve clearance is too small, causing oil leakage exceeding the standard, after three times of disassembly and assembly. Test qualified. During the installation of the servomotor tubing, it was found that the clearance height of the servo lining between the servomotor and the servomotor was not enough, and the inlet and outlet tubing collided with the pit lining. The supervision engineer negotiated with the manufacturer's agent and the installer to decide to switch the servomotor supplied by the manufacturer into the oil drain pipe and use it to directly lead out with the elbow. Move to the outside of the pit lining. This reduces the height of the tubing and avoids colliding with the pit lining. When the unit starts trial operation. It was found that the top cover leaked too much. Only gravity drainage can not meet the roof drainage requirements. The top cover spare self-priming pump always starts, and the reliability of the self-priming pump is poor. After the research and decision, it was decided to change the water supply of the main shaft seal from one-way water supply to two-way water supply, and another set of decompression water supply device; the self-priming pump was replaced by a submersible pump, and the modified top cover drainage scheme could completely implement gravity drainage. The operation is in good condition, and the 4 generator installation supervision hydro-generator installation workload includes stator assembly. Rotor assembly. The lower frame and the flexible tank are installed with the upper frame and the inner pipe of the machine pier. The following describes the installation supervision process of the main components of the generator. 4.1 The stator assembly assembly shall be installed before the stator stator assembly circle is installed. The measuring round is a measuring tool for the installation of the stator core. The measurement accuracy is very high. When the installer checked the verticality of the cylinder with a frame-type spirit level, the supervising engineer raised objections. It is required to measure with a hanging piano cord with headphones and an internal micrometer to ensure accuracy. After installing the unit to correct the measurement method. Calibrate the vertical alignment of the center bolt measured with a frame level gauge. The results are quite different. The supervising engineer attaches great importance to the installation of the positioning ribs. The quality of the installation quality of the positioning ribs directly affects the quality of the stator core installation and the stator offline, and thus affects the installation quality of the entire stator. Positioning ribs must be straightened before installation. In the straightening, it was found that the ribs were heavily rusted and deformed. According to the analysis, the manufacturer's packaging non-standard engineer repeatedly asked the installer to ask for a micrometer calibration. But did not pay attention. When 8 equal cents are preloaded. The difference of 5 cannot be closed. The analysis indicates that the micrometer error is too large, because the accuracy of the micrometer cannot meet the requirements. The gap between the block and the ring plate is too large. It was necessary to add copper pads to readjust the pre-installed positioning ribs. When positioning rib lap welding. Found cracks, supervision engineers asked the installer to deal with, and the welds were subjected to magnetic particle inspection to meet the requirements. The stator core laminations were inspected by the supervising engineer to meet the design requirements. Stator core loss test parameters are better than the standard, due to the excellent quality of the stator core laminations. Stator hangs off the line to work more smoothly. However, some equipment defects have also been discovered. The supervision engineer and the manufacturer's installation staff have coordinated. And deal with it in a timely manner. For example, the upper and lower coils connected to each other may not be placed between the coil heads, affecting the welding quality. The supervision engineer negotiates with the manufacturer. It was decided to plan the parallel heads to 3, and let go of the head block. Ensure 7 welding quality. The semiconductor glue sent to the construction site could not be prepared on the construction site. The supervision engineer informed the manufacturer in time to prepare it at the factory and send it to the construction site. The lead wire collided with the connection line between the boards and was taken up by the method of raising the connection wire. Stator pressure plate and pressure arc can not be on, can not install the screw, the supervision engineer and the factory on behalf of the agreed. Grind the plate into an arc and install it. When the stator bar was used as a single pressure test, 61 bar end burns. The supervising engineer promptly informed the manufacturer to deal with the site. After the stator goes offline, it is welded together. The supervision engineer carried out a careful inspection of the welding quality. Part of the solder joint crack was found and rework was required. Until satisfied. The stator stator is subjected to DC leakage and AC withstand voltage tests. The test results are good. 4.2 Rotor Assembly Supervision The rotor of the generator is supported by the upper and lower pressure plates of the center body arm. Magnet. Wind shutter. Magnetic pole and other components. When installing the rotor yoke pull rods, individual pull rods were found to be shorter. The screw is flush with the nut. The supervision engineer negotiated with the manufacturer and agreed to weld the short screw and nut to ensure the strength of the pull rod and the magnetic pole of the rotor before mounting. A single magnetic pole is required to withstand voltage test. After the magnetic pole is opened out, when the single magnetic pole is used for the 4900 withstand voltage test, there are 9 magnetic pole discharges and the withstand voltage test is unqualified. After cleaning the magnetic pole. Drying, of which four pressure qualified. There are also five magnetic pole test voltages that rise below the specified value. The supervision engineer and the manufacturer's agent and installer repeatedly analyze the reasons. Find it multiple times. The plate pin hole was found. Thoroughly processed, the magnetic pole 4900 pressure test passed. After the magnetic pole is hung on the yoke, a single pole is used for the 4400 withstand voltage test. Also found that four magnetic poles failed, and there is the same quality, the supervision engineer asked the factory personnel to deal with. The overall resistance test of the rotor passed smoothly. When the large shaft of the generator was lifted into the pit, the elevation of the thrust pad was found to be low and collided with the thrust bracket. The supervision engineer and the manufacturer's installation personnel held a meeting at the site. The research decided to reduce the thickness of the tray without affecting the strength of the thrust tray. This ensures that the thrust bracket and the bracket have more than 3 clearances and meet the requirements for safe operation of the unit. After the generator rotor is lifted into the pit. Measured and analyzed. It is found that the rotor center elevation is lower than the center of the stator 8. The specification exceeds the specification requirement of no more than 6. The supervision engineer's manufacturer and the installer's decision were made. Decrease the stator height to meet the broad specification requirements. When the first hydro-generator set was over-speed tested, due to collision between the spindle fill valve and the shroud rotation gap being too small, the inner circle of the valve cover was expanded by 3, in addition. It was found that the magnetic pole joint was all everted and the rooted magnetic pole lead was straightened. The magnetic poles of the varus were ligated, the straightened magnetic pole lead was rearranged, and the clips were added. The first-mentioned treatment plan was proposed by Dongfang Motor Factory and approved by the supervision engineers. The overspeed test was successfully passed. 5 Conclusion The total installation period of single-machine installation of Jiangyin hydropower station is 14 months, and the installation duration of the main body is 5 months. Both the main single test and the start-up test run were successful. The installation period was short and the construction quality was excellent. They were well received by the unit startup acceptance experts. Supervision engineer. The installers and the Dongfang Motor Factory have a consensus on the site. That is, there is no question of reinstallation of the installation quality of the hydro-generator unit, which is the best construction progress. During the installation of the hydro-generator unit. It did achieve the intended purpose. The supervision and management of hydro-generator units will be regarded as a key supervision project. At the same time, the quality and progress are coordinated and controlled. It is the successful experience editor of Jiangbei Hydropower Station's mechanical and electrical construction supervision. Chang Hansheng received the 8th page. After flowing through the workspace. It is discharged by an exhaust fan that is temporarily installed at the outlet of the vent pipe of the penstock. A fan is installed on the side wall of the installation yard during the overhaul of the unit. Specially used to exclude exhaust gas generated by welding. 5.4 Noise in Noise Reduction Design Plant noise mainly comes from the operation of the turbine generator unit and auxiliary machinery, especially the fan. To reduce the noise of the plant. In addition to the factory decoration. In addition to building soundproofing measures, the following measures have been taken in the ventilation and air conditioning system. The fan room is located away from the central control room and the main plant 2 with a larger capacity of the fan. The damper is installed on the foundation, and a muffler is installed at the suction outlet; the main building is 2 The capacity of the blower is relatively large, and the soft start method is adopted. Avoid the sharp turning on the air pipe arrangement as much as possible. The selection of the wind speed in the fixed pipe shall not be too high. 5.5 The moisture-proof dehumidification is for the underground powerhouse. It's more humid. In particular, the turbine is more serious. to this end. In addition to the building structure added moisture-proof partition wall. In addition to the ground drains, three dehumidifiers with a dehumidification capacity of 61 were installed on the turbine floor. 6 Conclusion At present, the Jiangyan project has not been completed. The ventilating and air-conditioning systems in the main plant and the main transformer room have not yet been put into operation, but they have been viewed from the air-conditioning and ventilation systems in the computer room of the central control room that has been put into operation. The effect is better. Dehumidifiers that have been put into operation have a very significant moisture-proof and dehumidifying effect on the turbine layer. Liu Yi edited water and soil basin to benefit future generations
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