Lắp đặt turbine GUGLER
Safety during installation and commissioning
Never work at any equipment while the turbine is running
There are sudden but however slow movements of machine components, such as falling weights or the distributor mechanism
Disconnect the machine from mains before opening the machine and start of any work inside the machine.
Installation and connecting of the machine must be carried out by qualified personnel
Only qualified specialists with experience in forced oil connections should perform any work on these systems, ensuring that all tasks are carried out under proper supervision and in strict adherence to the provided instructions.
Hazard of high-pressure, pressure peak due to shut-off procedure
Closing times to be adapted by GUGLER representatives only
No manipulation on hydraulic system by unauthorized persons allowed
The change of safety-relevant settings (e.g the closing times) is strictly prohibited!
Avoid stumbling across cables, pipes or hoses
Take care for the general order and cleanness on site to reduce the risk of stumbling
It is essential to adhere to all safety data sheets, particularly those related to turbine substances, which can be found in the external chapter titled "DATA SHEETS." Additionally, it is important to consult the safety data sheets for sub-supplies, such as generators, to ensure comprehensive safety compliance.
Due to their weight or shape, machinery or components may be difficult to lift Transport and manipulation only with suitable transport equipment and lifting equipment! (e.g special devices)
When working with an oil forced connection the hazard zone must be marked with barrier tape
Keep oil binding media available!
Electrical equipment maintenance should only be performed by qualified electricians or trained individuals under the supervision of a qualified electrician It is essential to adhere to electrical safety regulations, ensuring that the machinery is turned off and secured against accidental re-starting during the work.
Avoid contact with hot machine parts and take special care when performing hot works Respect the legal requirements
Danger of slipping on spilled oil
In case of defilement clean site immediately
Keep oil-binding media available
Hazard of pointed or sharp edges during installation or service Although edges of assembled parts are deburred, use of appropriate personal protective equipment such as safety gloves
Note that contaminated surfaces may be hot, and the reference to the hot surfaces is not visible due to this contamination
Always use protective gloves when cleaning the machine, to prevent skin contact with contaminants and hot surfaces
Hazard of rough or slippery surfaces Use of appropriate personal protective equipment such as safety footwear with non-slip sole
Any works on energized parts or moving parts are strictly prohibited!
Ignoring the installation and commissioning manual can result in malfunctions and risks for health and safety, equipment life expectancy and performance!
The operating company must ensure adequate lighting on site, which corresponds to the national regulations
The foundation forces are indicated in the installation plan
On site the suitability of the foundation must be checked for plausibility
Points on which the components may be set up are indicated at the relevant drawings in order to avoid tipping or similar hazards
When overloaded electrical equipment can cause fire!
Fire hazard due to hot works!
Use the necessary protection according to legal requirements and protections (e.g railings, or fences) for hazardous locations (e.g tripping hazards, pits, shafts…) on the site
Erect a scaffold to perform installation, revision, repair or maintenance activities in areas with poor accessibility!
Apply warning label “P007” according to “EN ISO 7010” on the access door
“No access for persons with implanted cardiac pacemakers or heard defibrillators”
Gear oil and lubricants pose significant risks to water sources and should always be stored in approved containers It is crucial to avoid spills, and any spilled lubricant must be promptly cleaned up using appropriate binders and disposed of according to regulations Additionally, used or old lubricants must be disposed of in compliance with legal guidelines to ensure environmental safety.
The operating company or its general contractor is responsible for calculating the baseplate and ensuring the safe design of all surrounding components, including buildings, pressure pipes, steel structures for hydraulic engineering, and stop logs.
The structural separation of high voltage equipment, as well as all matters of explosion protection, are within the responsibility of the general contractor
The evaluation of fire hazards and the installation of fire extinguishers is within the responsibility of the general contractor
The operating company must establish regulations for all individuals who may interact with the machine, including external visitors on guided tours, trainees, and nearby workers.
The operating company is obliged to prevent access by the public, for example by the installation of the machine in buildings
The entrance doors shall be marked with the sign "No access for unauthorized persons" and " No access for persons with implanted cardiac pacemakers or heard defibrillators”
All machine components must be grounded!
Never tighten the connections above the allowed torque limit!
Bending of pipes has to be the preferred solution for assembly!
The national employee protection regulations are to be observed!
Without the approval of the manufacturer of the machine no alteration of the machine is allowed
Observe the relevant legal requirements for equipment as lifting equipment, scaffolding
Check list for readiness of power house
Before any installation work can start, the following arrangements must be made:
□ All windows and doors installed in powerhouse
□ First concrete and all recesses (cut-outs) according to installation plan
□ Stairs and handrails between different floors finished (Especially down to turbine level)
□ Heating available in cold season (below 10°C)
□ Sanitary facilities available (toilet, bathroom etc.)
□ Overhead crane with necessary equipment installed
□ Overhead crane tested and approved and ready for operation
□ Safety arrangements ready and complete
□ Fire extinguisher and emergency medical pack available
□ All GUGLER equipment available on site
□ Free access into powerhouse available
□ Cleaning of the entire powerhouse “well swept“
□ Lockable location for storage of expensive parts available
□ All-risk insurance policy sent to GUGLER
Installation
Draft tube
To ensure stability, accurately determine the positions for the standing feet of the draft tube cone and drill holes for securing the bottom plates to the ground It is essential to level the plates precisely for optimal performance.
□ Lift the draft tube cone (Client’s scope) into position in accordance with the general arrangement drawing
To ensure proper installation of the draft tube elbow, first identify the optimal positions for the standing feet Next, drill holes to secure the bottom plates of the standing feet to the ground, ensuring that the plates are leveled accurately for stability and functionality.
□ Lift the draft tube elbow (Gugler’s scope) into position in accordance with the general arrangement drawing
□ Adjust both parts to each other until that a smooth transition of the inside contour is reached
□ Weld the draft tube cone to the draft tube elbow (to be performed by a 3 rd party!)
□ Connect the pressure measurement pipes from draft tube elbow to the end of the draft tube cone (to be performed by a 3 rd party!)
Adjust the upper flange using the adjustment screws to achieve the specified height as per the drawing, ensuring it is perfectly leveled both in the flow direction and perpendicular to it.
□ Secure draft tube against any movement during concreting
□ Install/weld the dewatering pipe to the draft tube cone (to be performed by a 3 rd party!)
6.3.2.1 Protocol 1 – Draft Tube Alignment BEFORE concreting
□ Make sketches and fill Protocol 1 before concreting in accordance to general arrangement drawing
A(Alignment of axis of draft tube) =
B(Height of draft tube flange) =
C(Level of draft tube flange) =
D(Orientation of draft tube flange and bolt holes) =
Release for 2 nd Concreting (draft tube)
The previous installation steps were accomplished successfully, and the turbine is adjusted according to our drawings and secured against potentially moving during the concreting!
6.3.3.1 Protocol 2 – Draft Tube Alignment AFTER concreting
□ Make sketches and fill Protocol 1 before concreting in accordance to general arrangement drawing
A(Alignment of axis of draft tube) =
B(Height of draft tube flange) =
C(Level of draft tube flange) =
D(Orientation of draft tube flange and bolt holes) =
Preassembled Main Turbine Components
□ Now the preassembled turbine components (spiral casing, distributor, runner, turbine shaft) will be installed to the draft tube, for to be casted into the concrete later
Respect the general arrangement drawing and turbine main drawing
□ Remove the lower transportation security flange from below the connection flange – the upper security holds the turbine shaft in its position
□ Lift the preassembled components into position and make sure the orientation is exactly as advised on the drawing (orientation, centre axis, level)
□ Make sure that the spiral casing and all other components are perfectly levelled and orientated
□ Then apply a reduced number of bolts to the connection flange and the draft tube and make sure again if all components are orientated and levelled perfectly
□ As soon as everything is perfect, apply the remaining bolt connections
□ Install the turbine coupling according to drive train drawing Attention! High tightening torques need to be applied on the coupling screws
□ Check the guide vane opening according to the guide vane apparatus drawing – opening and closing of distributor can be done by chain hoist
Install the fully extracted hydraulic cylinder and secure the cylinder console in its designated position Ensure that the cylinder cannot be overextended to prevent the guide vanes from contacting the runner, and confirm that the guide vanes are completely closed when the cylinder is fully retracted.
□ The cylinder console anchoring can be concreted now (grouting) and after curing the foreseen tightening torque must be applied to the anchoring bolts
□ Be sure that everything is well aligned and then weld the cylinder console parts to fix everything
□ Check if all necessary parts of pressure relief pipe are installed since some are placed inside of
□ Install the Main Inlet Valve with help of the MIV frame
6.3.5.1 Protocol 2 – Turbine Alignment BEFORE concreting
□ Make sketches and fill Protocol 2 before concreting in accordance with general arrangement drawing
A(Alignment of axis of turbine shaft) =
D(Orientation of Main inlet valve and bolt holes) =
Release for 3 rd Concreting (turbine)
The previous installation steps were accomplished successfully, and the turbine is adjusted according to our drawings and secured against potentially moving during the concreting!
6.3.6.1 Protocol 2 – Turbine Alignment AFTER concreting
□ Make sketches and fill Protocol 2 before concreting in accordance with general arrangement drawing
A(Alignment of axis of turbine shaft) =
D(Orientation of spiral casing and bolt holes) =
Generator
□ In this chapter the generator is being coupled to the turbine
□ Before lifting of generator make sure that the coupling is installed on the turbine shaft (No use of EOT crane possible after generator is placed)
To modify the tilting frame, first, remove the welding between the base plates and the frame Next, securely attach the base plates of the tilting frame to the generator using M42 hexagon bolts Finally, re-weld the base plates to the tilting frame, ensuring that the terminal boxes are properly positioned to avoid any issues during the generator's tilting operation.
To safely position the generator from horizontal to vertical, use a tilting frame, ensuring that the frame is secured with logs to maintain tension on the EOT crane slings throughout the process.
□ Also check the generator documentation for instructions
□ Disassemble the tilting frame from the generator
□ Lift the generator and put it into position
□ Mount the generator shaft to the coupling
□ Move the draft tube cone below the runner so that the runner gaps are accessible
To initiate the hydrostatic unit on the generator, follow the installation process to elevate the drive train, enabling the shaft to rotate For comprehensive instructions, please consult the generator documentation.
To properly install the generator, place shim plates underneath and align the pins as specified in the generator foundation drawing It's crucial not to secure the pins until the entire drive train has been adjusted in accordance with the runner gaps, following the guidelines provided in the generator supplier's foundation drawing.
□ Adjust the runner gaps by moving the generator in position
□ Check runner gaps on draft tube side as well as on generator side and note down the values
□ The gaps should be equal around the runner
□ Adjust the Turbine guide bearing pads according to suppliers’ instructions
□ After adjustment, grouting of the generator base plates can be done Check generator documentation for more details!
Gap at draft tube side: Gap at generator side:
Shim plates on generator base feet:
Pipes
□ Apply the remaining pressure relief pipes
Installation of the hydraulic power unit
□ Put the hydraulic power unit into position, in accordance with the general arrangement drawing
□ Make sure all assembly works are carried out according to the instructions of the manufacturer, attached to these instructions in external chapter “HYDRAULIC POWER UNIT”
□ Connect the hydraulic pipes according to the hydraulic schema
□ Fill in the specified oil
□ Verify that the nitrogen filling of pressure accumulators is within the acceptable limits
□ Lock or seal the flow valves after adjustment to make sure the closing times cannot be changed
Never tighten the connections above the allowed torque limit!
Bending of pipes has to be the preferred solution for assembly!
All pipes must be protected against rust (e.g zinc-coated)
All pipes must be trimmed and cleaned after cutting to avoid contamination of the system
Fittings may only be used if bending is not possible
Hoses are only permitted on moving parts and where explicitly allowed by GUGLER
Installation of the generator cooling circuit
□ Install the cooling circuit according to the general arrangement drawing and cooling schematic
□ Fill in the specified liquids
Never tighten the connections above the allowed torque limit!
All pipes must be protected against rust (e.g zinc-coated)
All pipes must be trimmed and cleaned after cutting to avoid contamination of the system