CHAPTER-7

TURBINE AND GOVERNING SPECIFICATIONS

7.1 Sample Technical Specifications of Large Hydraulic Turbines and Governing Equipment for
Vertical Kaplan Turbines (suitable changes be made for other types)

Scope

Vertical shaft Kaplan type hydraulic turbines each with a capacity of ………. kW and each consisting of the
following main assemblies:
• One set of embedded parts consisting of draft-tube cone complete with man-hole, knee-lining, pier-
liner fabricated from structural steel in suitable number of parts keeping in view the transport
limitations and necessary brackets, lugs, anchors supporting Jacks and bolts.
• One set of Foundation parts consisting of spiral casing with stay-ring fabricated from steel plates with
upper and lower rings, cast steel stay-vanes, complete flange bolts and jacks etc., Pit liner of fabricated
steel and Runner Chamber of stainless steel.
• Set of Guide Apparatus and Servomotors consisting of turbine top cover, lower ring, regulating ring,
set of stainless steel guide vanes, bushes with housings, levers, links, connecting pins and two
servomotors with mechanical/hydraulic lock on one of the servomotors.
• Adjustable blade Kaplan Runner consisting of cast steel hub, set of stainless steel (13 Cr4Ni) blades,
runner blade turning mechanism, runner cone, runner servomotor located within runner hub.
• Forged carbon steel Turbine Shaft having integrally forged flanges at both ends and skirt for guide
bearing with coupling bolts and guard.
• Self-cooling turbine guide bearing of self oil-lubricated pad type, complete with necessary valves,
sight level indicators-cum-relay, temperature measurement and signaling device.
• Turbine Shaft Sealing of rubber lip type or any other design complete with connection for clean
cooling water supply and inflatable type repair seal for maintenance of main seal without dewatering
the turbine water path.
• Oil distributing header for supply and distribution of oil to runner servomotor with required oil
pipelines inside the turbine-generator shaft.
• Set of limit switches for indicating shear pin failure along with connected cable up to terminal block in
turbine pit and mounting arrangement.
• Vacuum breaking valves on turbine top cover
• Set of chequered plates for platform in turbine pit only
• Set of mono-rail and chain –pulley block for assembly and dismantling guide vanes/guide bearing.
• Set of chain pulley block and longitude mono-rails for handling drainage and dewatering pumps.
• Pump motor set and one ejector with suitable water level sensors for drainage of leakage water from
turbine top cover.
• Necessary cable junction boxes and cables from electrical items for termination at convenient points.
• Turbine Gauge Panel with necessary instruments and safety devices,

b) Governing Equipment consisting of digital Electro-hydraulic governor, speed signal generator, over
speed trip device, emergency shut down device, restoring mechanism, oil pressure unit oil leakage unit
and oil pipe lines,
c) Central Grease Lubrication System for Turbine if required,

175
 d) Governor oil, lubricating oil and grease for flushing and first filling of with 20% extra quantity, site
consumables like welding electrodes, paints and cleaning agents etc. in sufficient quantity,
e) Turbine Model Testing, if desired,
f) All special tools, tackles and handling devices required for assembly/dismantling of turbine and inlet
valve assemblies at site during erection and maintenance, templates for repair of turbine runner and
pumps and test plugs for hydraulic testing,
g) Set of Mandatory Spare Parts for five years trouble free operation as per schedule of spares,
h) Insurance, transportation, receipt and storage of goods at site,
i) Installation, testing, commissioning and acceptance testing of the turbines, inlet valves and associated
equipment,
j) Preparation and submission of Drawings of all equipment, Operation & Maintenance manual and
Erection & Commissioning Manual including those for bought out items.
7.2 Standards

Turbines shall meet provision made in the following standards (latest edition) unless otherwise mentioned.
(a) IEC 41: 1991, Field acceptance tests to determine the hydraulic performance of hydraulic turbines,
storage pumps and pump-turbines.
(b) IEC 193: 1965, International code for model acceptance tests of hydraulic turbines. Amendment
No. 1 (1997).
(c) IEC 193A: 1972, First supplement to IEC 193 (1965).
(d) IEC 308: 1970, International code for commissioning, operation and maintenance of hydraulic
turbines.
• IEC 609: 1978, Cavitation pitting evaluation in hydraulic turbines, storage pumps and pump-
turbines.
IEC 545: 1976, Guide for commissioning, operation and maintenance of hydraulic turbines.
(e) IEC 60994: 1991, Guide for field measurement of vibrations and pulsations in hydraulic
machines (turbines, storage pumps and pump turbines)
(f) IEC 61362:,- Guide to specification of hydro-turbine control systems.
(g) ISO 3740: 1980, Acoustics- Determination of sound power levels of noise sources- Guidelines for
the use of basic standards and for the preparation of noise test codes.
(h) IEC 61366 Hydraulic turbine of giving outputs higher than rated outputs to match 10% overload
capability of the generators.
(i) VDI 2056 and VDI 2059; Vibration level in rotating machines

7.3 Turbine Basic Data & General Information on Water Conductor System

Turbine Basic Data

(a) Maximum water level (U/S) ……….. m

(b) Maximum tailrace level ……….. m
(c) Minimum tailrace level ……….. m
(d) Maximum gross head (static) ……….. m
(e) Maximum net head ……….. m
(f) Minimum net head ……….. m
(g) Rated Design head (net Head) ……….. m

176
 (h) Rated Turbine Discharge ………. cumecs
(i) Operating Head Range (115% to 67%) ………..1 m
(j) Rated output at rated head and rated discharge ……… kW
(k) Preferred rated speed …………..
(l ) Permissible Speed rise ……….. %
(m) Permissible Pressure rise ……. % of rated head
(n) Turbine Efficiency at rated head & discharge ……….% ( Min.)
(o) Overload Capacity ( at max. head) 10 % continuous
(Note:- Specify as per field data and performance requirement)

7.4 General Information

The Vertical Shaft Kaplan turbine with adjustable blades and wicket gates shall be directly coupled to
synchronous generator of …… kW rating. The direction of rotation shall be clockwise when viewed from
drive end.

General arrangements of the Power House and turbines have been tentatively outlined in contract
drawings. There may be minor change in elevation of turbine Centre line based on the required minimum
suction height recommended by the successful bidder, however no significant increase in suction height
will be accepted.

Detailed information on water conductor system i.e. power channel, intake, penstocks, tail race structure
and other details of site are given in Salient Features of Project.

7.4.1 Basic Provisions

Each turbine shall be designed to give a rated output of …….. kW (corresponding to …….. kW at
generator terminals) at design head of ……… m with guide vane opening of not more than 95%. The
turbine shall have adequate capacity commensurate with the 10% continuous overload capacity of the
generators at maximum head.

The turbine should be capable of operating between 120% to 60% variation of rated head and 110% to
60% variation of rated discharge. The turbine shall comply in all respect of various standards with the
requirement of the latest issue of Indian Standard and IEC – 41.

The specific speed of the turbine shall be selected as per the best modern practice and the turbine shall be
of proven design. Similar machines designed on the basis of model offered against this tender should be
under satisfactory operation at least on two different projects for at least last three years.

The turbine shall be so constructed as to allow all the removable parts to be dismantled conveniently. The
design shall permit horizontal/vertical movement of runner shaft by an amount sufficient for adjustment of
bearings and for cleaning the joint at the coupling between the turbine and generator.

Turbine main inlet valves of butterfly type for shutting-off pressure water supply from the penstock to the
turbine distributor shall be provided, complete with necessary piping, control and gauge cabinet, up-stream
connecting and down-stream connecting pipes with companion flanges, dismantling joint, bypass, drain and
air bleeder valves, operating mechanism and necessary auxiliaries including gaskets, anchor bolts, sole
plates, and other items necessary for a complete installation. Depending upon operating requirements, the
valve shall be either fully open or fully closed and no partial opening of the valve is envisaged. In the
closed position the valve shall be leak tight.

All the equipment shall be neatly arranged and shall be easily accessible for operation and maintenance.
Necessary chequered plates for trenches and openings shall be supplied by the Contractor.

177
 Contractor shall ensure the co-ordination between turbine & generator manufacturers (if both are separate)
so that the generator to be coupled with the turbine is matched in respect of speed, runway speed, moment
of inertia, overload capacities, coupling other relevant requirements.

7.5 Performance Guarantees and Liquidated Damages

7.5.1 Output and Efficiency Guarantees

Maximum Output and efficiency of the turbine at design head shall be stated in Guaranteed Technical
Particulars of Turbine and will be guaranteed by Contractor. The turbine shall also be suitable for safe and
efficient performance at part loads lesser than 60 (sixty) percent of rated output with minimum head
conditions.

Field test (as per IEC-41-1991) shall form the final basis to establish fulfillment of guarantees of the
turbine and for purposes of liquidated damages and rejection of plant

7.5.2 Weighted Average Efficiency

The Bidder shall guarantee the weighted average efficiency of the turbine at rated net head using the
following formula for the purpose of bid evaluation, calculation of amount of penalty and rejection limits
of the equipment:

ηt (AV) = 0.40 η t (100) + 0.40 η t (80) + 0.20 η t (60) (based on flow duration)
where, ηt (AV) = Weighted average efficiency
η t (100) , = efficiency at 100% of rated output at the design head of … m.
η t (80) , = efficiency at 80% of rated output at the design head of …. m.
η t (60) = efficiency at 60% of rated output at the design head of ….. m.

(Note:- Specify as per flow duration curve for annual energy)

7.5.3 Bid Evaluation With Respect to Efficiency

In the evaluation of bids, equalization on account of differences in efficiencies of turbines of the various
Bids will be made at the rate of Rs. …….. (Rs. …..) per turbine for each one tenth of one percent (0.1%)
by which the rated average efficiency given in (or computed for) any offer is lower than the highest
weighted average efficiency among the various offers. For differences lower or higher than one tenth of
one percent (0.1%), the equalization will be computed on pro-rata basis.
(Note:- This will depend upon energy costs)

The basis for selection of the offers will be the overall economy to Owner considering power house civil
works, values of efficiencies, prices of matching generators and power house auxiliaries etc. The speed and
setting of the turbine and its design shall be such as to result in the most optimum generating unit at the
least cost.

7.5.4 Output and Efficiency Tests

Output and Efficiency test as per IEC-41 shall be conducted at different heads and guide vane openings to
determine guaranteed efficiency parameters. Any deviation from IEC-41 shall be clearly stated in the offer.
Bidder shall furnish details of test methods, agency which will conduct the test, provisions to be made for
field testing, calibration of instruments for purposes of test and all other relevant details in the offer.
Contractor shall be under obligation to accept these tests for purposes of liquidated damages. Purchaser
reserves the right to appoint the contractor or any independent agency or agency recommended by
contractor for conducting these tests.

178
7.5.5 Penalty for Shortfall In Weighted Average Efficiency and Output

For any shortfall in the tested values of rated output and weighted average efficiency (as determined on the
basis described in clause 7.5.1 & 7.5.2 from the guaranteed values, penalty shall be applied at the rate of
one half (1/2) percent of total unit price of turbine (including price of governing system) for each one tenth
of one percent by which test figure is less than the corresponding guaranteed figure. The penalties on
account of shortfall of output and efficiency shall be computed separately for each unit and the total
amount of penalty shall be the sum of these two. No tolerance shall be permissible over the test figures of
rated output. In case of efficiency, tolerance will be allowed as per appropriate IEC test code for model test
and/or field acceptance tests for hydraulic turbines. The ceiling on the total amount of penalty on account
of shortfall in the weighted average efficiency and the output will be 10% of total unit price of the turbine
including price of governing equipment.
(Note:- These figures of penalty depend upon purchasing authority)

7.5.6 Rejection Limit

The Purchaser has the right to reject the equipment if the test value of either weighted average efficiency or
the rated output is less than the corresponding guaranteed value by two (2) percent or more after allowing
tolerance in computation of efficiency.

7.5.7 Cavitation Guarantees (For Reaction Turbine runners)

The Supplier shall guarantee the runner against excessive pitting caused by cavitation for 18 months from
the date of commissioning or 8000 hours of operation, whichever is earlier as per clause 3.3.1 of IEC-
60609-2.

Excessive pitting shall be defined as the metal removed from runner by a weight of W=0.15 D2 per 1000
hours of operation, where, D = Discharge diameter of the runner and W = weight in kg. If the 18 months of
guarantee period expires before completion of 8000 hours of operation, the guarantee shall apply to the
actual hours of operation proportionately.

In case of cavitation pitting exceeding the guarantee, the Contractor shall, at his cost, take corrective
measures such as repair as per original design, repair as per modifications or replacement etc., and turbine
after modification etc., shall be subject to fresh cavitation guarantee as for the original equipment. In
determining whether or not excessive pitting has occurred, uniform metal removal by erosion, corrosion or
by the presence of injurious elements in water, etc., shall be excluded.

Setting of runner: Setting of the runner below minimum tailrace water level shall be started in the bid and
shall be taken into consideration for bid evaluation. All runners below minimum for tailrace water level will be
loaded at the rate of …. per mm of purpose of evaluation.

Critical and Plant Sigma: Values of critical sigma as determined from cavitation model tests as per IEC 193
A shall be given in the form of curves for different heads of operation. Plant sigma curves as recommended by
the manufacturer shall also be plotted on it clearly to show the safety margin available.

7.5.8 Vibrations and Noise Limit

Turbine design shall ensure smooth and quiet operation with low vibrations, pressure pulsation, power
fluctuations and noise. The vibration amplitude at the shaft shall not exceed the values specified in ISO-7919
(part-1) and ISO-3945 or VDI 2056 and VDI 2059 when measured with instruments with 1 Hz cut-off
frequency.

Maximum noise level resulting from any of the operating conditions shall not exceed 85 db (A) at any place
1.0 m away from any operating equipment in the machine hall.

179
7.5.9 Runaway Speed

The maximum runaway speed shall be stated and guaranteed by the supplier. All rotating parts and
bearings shall be capable of withstanding the forces and stresses occurring during runaway speed for at
least 30 minutes without any damage to any part. The guide bearing and guide cum thrust bearing shall be
capable to withstand runaway speed for 30 minutes without supply of cooling water and continuously with
cooling water without abnormal increase of vibrations and temperature.

7.5.10 Speed Rise, Pressure Rise and Inertia

The moment of inertia of the generating unit and closing time of wicket gate and runner blades shall be so
selected that the maximum momentary speed rise of unit shall not exceed 35% of normal speed and
pressure rise shall not exceed 20 % of maximum head. The turbine manufacturer shall coordinate with the
generator manufacturer for achieving the required flywheel effect.
(Note: Specify speed rise as per Chapter 4).

7.6 Model Test

The Bidders shall offer the turbine with already tested model and proven performance of prototype
machines atleast at one project site for a period not less than two years. The Bidder shall enclose copy of
the relevant model test report with operating points of the turbine offered marked on the hill chart of the
model to substantiate the output, efficiency and plant sigma figures offered and guaranteed by the Bidder.
Bidder shall arrange certificate of trouble free operation of the similar turbines from their owners and
enclose the same in the technical Bid. If felt necessary by the Purchaser, the Bidder shall arrange physical
inspection of the equipment at respective Power Houses before finalization of the order.

The Purchaser reserves the right to witness fresh model tests to ensure that the guaranteed parameters will
be met by the prototype. For this purpose, the Bidder shall quote charges for conducting the model test in
his laboratory and or in an independent approved laboratory in the presence of Purchaser’s Engineers and
their consultants.

o The tests shall be as per IEC test code publication No.193 and 193A. “International code for Model
Acceptance Test of Hydraulic Turbines”. Model test results shall be subject to the approval of the
Purchaser. The contractor shall commence manufacture of the prototype after approval for the model test
results. Prototype efficiencies shall be derived from model tests by the Moody’s step-up formula as
contained in IEC 193 for Francis turbines.

Tests to be conducted on Model

The final model test series shall include but not be limited to the following tests:
Performance (efficiency & output) test under various head conditions and corresponding to 100%, 80%
and 60% rated output.
Determination of peak efficiency at rated design head at rated speed.
Measurement of hydraulic thrust and runaway speed test at full guide vane opening at maximum net head.
Complete Hill chart
Cavitation at maximum, rated and minimum head at openings corresponding to guaranteed output.
Checking of Model dimensions as per IEC.

7.7 Rectification to Meet Guarantees

The Contractor shall be given three months or mutually agreed time to improve/modify the design of the
turbine or to carry out rectification etc., as may be required so that the guarantees are met in case the model
tests prove unsuccessful in meeting the guarantees. If the second attempt is also unsuccessful, penalty or
rejection of the equipment, as the case may be, shall be applied. However, no delay in the original delivery
schedule shall be allowed if the model test results do not meet the guarantees and rectifications are made
by the Contractor there after within a period of three months or mutually agreed period as stated above.

180
7.8 Stresses and Factor of Safety

All parts of turbine shall be designed and constructed to safely withstand the maximum stresses during the
normal running, runaway and short circuit conditions, out of phase synchronising and brake application.
The maximum unit stresses of the rotating parts shall not exceed two thirds of the yield point of the
material. For other parts, the factor of safety based on yield point shall not be less than three in normal
conditions. For over-load and short circuit conditions, a factor of safety of 1.5 ( one and a half ) on yield
point shall be permitted.

7.9 Deviations from Technical Specifications

All deviation from General Technical Specifications and Technical Specifications under this section should
be clearly brought out at one place in the 'List of Deviations' from Technical Specifications. Any deviation
not clearly mentioned in the List of Deviations, but described elsewhere in the equipment Description shall
not be acceptable. After award of contract, the contractor has to fulfill all the requirements of technical
specifications except the deviations clearly spelt out and accepted by Owner.

7.10 General Arrangement and Constructional Features of Turbine

General Arrangement and Constructional Features of the turbine and associated equipment shall meet the
requirements described below:

7.10.1 General: All equipment shall be arranged so as to be easily accessible for inspection and maintenance
without interfering the operation of other components.

7.10.2 Embedded Parts of Turbine

Draft Tube Knee Lining: Major portion of the draft tube knee, where velocity of water is comparatively
high, shall be provided with steel lining. The liner will be fabricated from steel plates and heavily ribbed on
its outer surface to give rigidity.

It shall be manufactured in number of parts to facilitate transportation and joined together by welding at
site. The liner would be rigidly held in concrete with the help of anchors and jacks. Leveling bolts will be
provided at the base of liner for leveling it during installation. Sufficient number of holes of suitable size
will be provided at the base of liner for concreting and grouting. Plate plugs will be provided for plugging
these holes after concreting.

Draft Tube Cone

The draft tube cone shall be fabricated from steel plates. Sufficient number of ribs will be provided on the
outer surface of cone for rigidity. A hatch will be provided in the cone for access to the draft tube for
inspection and minor repairs. The upper end of cone will be fixed to the runner chamber and the lower end
to the draft tube knee liner.

Pier Nose Liner

For the concrete central pier for the draft tube, a pier nose liner shall be provided. The pier nose liner shall
be fabricated from welded structural steel plates. The liner shall be adequately braced and provided with
base pads and leveling screws for adjustment during installation.

Foundations and Embedded Pipelines

The details of foundations and embedded pipelines at various levels for turbine, inlet valve, governing and
auxiliary equipment will be supplied as per the relevant drawings.

181
7.10.3 Foundation Parts of Turbine

Stayrings

Stayring will be designed to withstand the hydraulic forces and part of the thrust bearing loads, generator
stator and other dead loads above stayring, if required during design stage.

The stayring shall be a cast fabricated construction. It shall consists of upper and lower mild steel fabricated
rims connected together by streamlined cast steel stay-vanes. The profile of stay-vanes will be designed to
give the minimum hydraulic losses.

If required, stayring shall be manufactured in two parts and joined by bolts and nuts at site for the
convenience of handling and transportation. Suitable foundation bolts and wedges will be provided for
installation and fixing the stayring in position during erection.

Notes: Stayrings transmits hydraulic, equipment and concrete loads and supports most of the major turbine
components through welded joints. It spans the water passages and transients loads across the span to units
foundation in Francis and vertical axial flow type turbine.

Generally number of stay vanes is the same as the number of wicket gates varying from 16 to 24. However
under some conditions, such as low head units, only half as many stay/vanes as wicket gates may be used.

Runner Chamber

Runner chamber shall be fabricated from stainless steel plates with mild steel ribs. The chamber shall be
made in two parts with flanged joints, if necessary, to facilitate handling and transportation. The portion
above runner centerline shall be machined cylindrically to facilitate the lowering of the runner and that
below the runner center line as spherical to ensure minimum clearance to reduce leakage at all runner blade
openings.

The chamber shall be carefully shaped and heavily ribbed to maintain its circularity and to reduce
vibrations. Necessary anchor bolts, turn buckles etc. shall be provided to support and facilitate erection. The
chamber shall be machined at its upper end for bolted connections to stay ring/pivot ring and at its lower
end for welding to draft tube cone liner.

Turbine Pit Liner

The turbine shall be provided with a steel lining from stayring to the chequered plate coverings. The liner
will be provided with ribs on its outer surface and welded to the stayring at site. Turn-buckles and anchors
will be provided for installation and securing the liner in position.

7.10.4 Working Mechanism

Guide Apparatus

The guide apparatus regulates the flow of water through the turbine with the change in load and also serves
as closing device. It shall consist of guide vanes, turning mechanism of guide vanes, guide vane bearing
bodies containing the bearings for upper journals of guide vanes, turbine top cover, pivot ring with lower
bushes of guide vanes, regulating ring and guide vane servomotors.

The guide vanes shall be cast from stainless steel. Each of the guide vanes shall have three supports - one
for the lower journal and two for the upper journal.

The bushes for guide vanes support shall be made of bronze and grease lubricated. Feeding of grease to the
upper bushes shall be done through a hole drilled in the flange of the guide vane bearing body. Grease to
lower journal bearing shall be supplied by a separate pipe connected to the hole through the guide vane.

182
 The bushes of the upper journal of the guide vanes shall be replaceable individually by removing the guide
vane bearing body which is connected to the turbine cover with the help of studs. The lower and middle
bushes shall be provided with rubber cup sealing to prevent the leakage of water.

The turning mechanism of guide vanes shall be designed to ensure the simultaneous equal turning of guide
vanes during opening and closing of guide apparatus. It shall consist of regulating ring, link assemblies,
straps, levers and shear pins.

The regulating ring shall be made of welded construction from mild steel plates. It will rest on a base
rigidly fixed to the stayring. Self lubricated pads will be provided at the rubbing faces between regulating
ring and its support to minimise friction. It shall be rotated with the help of two servomotors installed
diametrically opposite in turbine pit.

The link assemblies shall be made in the form of turn-buckles which shall allow for adjustment in length
during assembly. The bearing bushes for these pins shall be made of self lubricated synthetic material. The
design of the wicket gates shall be such that, if any individual wicket gate becomes disconnected from the gate
operating ring, no part of the gate can come in contact with the turbine runner and the failure of one shear pin
shall not cause progressive wear of adjacent shear pins. The failure of shear pin / breaking link shall be
indicated on annunciation panel through limit switch.

In the design of guide vanes, provision shall be kept for adjusting the face clearance between guide vanes
and turbine top cover and between vanes and lower rings of guide apparatus. Also, guide vanes shall be
prevented from lift under water pressure.

The turbine cover shall be fabricated from mild steel plates and shall be rigidly connected to the upper belt
of stayring with the help of studs. One Pump Motor set and one ejector will be provided for the drainage of
top cover leakages. Windows shall be provided in its internal vertical cylinder to have access to turbine
sealing for repairs.

The lower ring of guide apparatus shall be fabricated from mild steel plates. The cups which house the
bushes are made from forging. The lower ring shall be suitably fastened with the runner chamber with the
help of bolts.

Suitable arrangement of breaking links or shear pins should be provided on all or alternate wicket gate to
facilitate full closure of rest of the wicket gates if some foreign object is struck between two wicket gates.
Electronic limit switches shall be provided to indicate the breaking/shearing of pin/link.

Note:- Some design incorporate individual servomotors for each wicket gate. However practice in India to
have conventional arrangement using a gate operating ring and two gate servomotors. Small units use only
one servomotor. In low specific speed machines, wicket gates are in close proximity to runner buckets or
vane it is advisable to calculate the natural frequency of the gate to ensure that frequency is for removed to
avoid resonance.

7.10.5 Servomotors of Guide Apparatus:

Two servomotors shall be provided for turning the regulating ring. One of the servomotors will be fitted
with a manually operated stopper for retaining the turbine in closed position without oil pressure in it for
long period. The stopper will be provided with contact switch to indicate its closed or open position on the
control panel. The stopper shall be designed for hydraulic load on guide vanes in fully closed position.
One scale shall be provided to indicate servomotor stroke.

The servomotor shall consist of a fabricated/cast cylinder, piston with cast iron rings, piston rod fastened
with piston through pin, end covers and oil supply flange connections. Piston rod will be surrounded by a
sleeve which will pass through one end cover. Stuffing box with gland sealing will be provided to arrest oil
leakage through sleeve. Suitable sensors will be installed on one of the servomotor for transmitting
servomotor position to governing system for regulation and indication.

183
7.10.6 Runner

Turbine runner shall be Kaplan type with adjustable blades and shall mainly consist of a hub, blades
(preferably four no.), blades hubs, blade turning levers and cross head, servomotor, blade seals and end cone.
Blades shall be operated automatically in conjunction with wicket gates by means of electro-hydraulic
governor. The blade position Vs wicket gate position relationship at all operating heads shall be controlled
electronically. Position feed back of runner blades shall be achieved through an electronic position sensor with
4 to 20 mA output analogue signal mounted on the oil distributing head. Pressure oil will be supplied to
opening or closing side of runner blade servomotor through concentric pipes running through generator rotor
and turbine shaft from distributing oil head located inside the bulb.

The control of runner blades shall be designed to give full opening command on loss of feedback signal or loss
of control oil pressure.

Blades

Runner blades shall be cast or forged in 13%Cr 4% Ni stainless steel. The runner blades will be polished and
ground smooth and will be free from roughness, blowholes, porosity, cracks and high spots etc. Blades shall be
assembled on hubs/journals with pre-stressed coupling bolts. The holes of coupling bolts on blade stub shall be
covered by welding stainless steel contoured cover plates. Clearance between blade inner edge profile and
runner hub shall be kept minimum at all position of blades. Clearance between blade tips and runner chamber
shall be minimum – not more than 3 mm and it shall be ensured that runner blades will not strike the chamber
even at run-away speed.

Runner Hub and Cone

The runner hub shall be cast in 1.5% Mn. steel casting and shall be accurately machined spherically in the area
of blade movement. It shall be free from any kind of casting defect like porosity, blow holes, hair line crack,
surface crack etc. the blade windows shall be fitted with bronze bushes capable of taking outward thrust of
blades. Runner cone of cast steel or fabricated from steel plates shall be coupled to downstream side of runner
hub and its contour will provide smooth water flow.

The hub and cone shall be filled by lubricating oil (same oil as used in pressure oil system) for lubrication of all
bearings/bushes and blade adjusting mechanism at a pressure of about 1.2 bar by means of an oil reservoir
located at some height inside the machine hall.

Blade Turning Mechanism

The runner servomotor and blade turning mechanism will be accommodated inside the runner hub. The
mechanism shall connect the blades with runner servomotor and shall ensure free movement and
equal/identical position of all blades corresponding to any position of servomotor piston. All elements of the
turning mechanism shall be designed to withstand maximum oil pressure in servomotor at all positions. The
servomotor piston will be made in cast iron/steel with atleast two piston rings in nodal cast iron to prevent
leakage of oil across the piston. The piston rod, levers and cross head/star shall be manufactured in forged steel
the piston and the cross head will be securely fastened to servomotor rod by forcing and jack nuts. All the
levers and axles will be securely fixed so that they are not loose over the years of operation. Bronze bushes
shall be used in all moving joints and suitable nitrile rubber seals will be used to arrest leakage of oil/water.
Suitable arrangement will be provided for limiting the blades movement. The centrifugal force acting on the
blades and trunion will be transmitted to hub through thrust rings of bronze.

The blade turning angles will be engraved on all window covers and Z - axis/zero position mark on blade stubs.

Suitable number of nitrile reinforced rubber `V’ shape or any other suitable shape seals shall be provided
around journals of all blades to prevent leakage of oil outside the system or entry of water into the hydraulic
system.

One drain plug will be provided in the bottom of cone to drain oil. Air bleeding plugs will be provided at
suitable places in hub and cone to release air while filling the oil in runner.

184
 The final assembled runner shall be statically balanced in the works before dispatch. The balancing weights
will be fixed by welding and covered by cover plates to avoid their rotation directly in water.

The runner arrangement shall be designed to permit vertical movement of the shaft to facilitate and
dismantling of the generator thrust bearings, jacking of the unit and clearing male and female portion of the
shaft coupling.

Note: Francis turbine runners for Bhakra Left Bank were cast steel with stainless steel overlay on
water passages. Stainless coating was specified to be not less than (3/16”).

Material: The material selected for new project, or upgrade constructions of hydraulic turbine runners has,
over the years, become, almost exclusively, stainless steel. Martensitic grades of stainless steel (13 to 16%
Chrome, 3 to 5 % Nickle) have been used to a large degree because these materials offer a combination of
good weldability, high strength, and cavitation resistance. Austenitic stainless steel offer excellent
cavittaion resistance and weldability, but tend to have lower strength characteristics. Austenitics (18 to 20%
chrome, 3 to 12% nickel) inherently have better corrosion characteristics than martensitics due to the higher
chrome content. With any stainless, steps should be taken to avoid contamination during manufacturing and
handling.

Deflection: The expansion of the runner crown and band (primarily, the band) for all normal operating
conditions must be checked to ensure that the tight running – seal clearances at the wearing rings will not
contact. This must be checked in combination with the shafting system deflections.

Stress: The crown, band, and blade, or vane, thicknesses should be compatible, particularly at the
discharge edge junction of the blades, or vanes with the crown and band. This allows each component to
carry its share of loads and moments without unnecessary constraint.

Adequate stress transition must be provided between blade, or vane, discharge edges and crown and, to a
lesser extent, the band.

Natural frequency: The runner’s natural frequency should be calculated to ensure that it is sufficiently
separated from the normal operating frequencies of the unit to avoid resonance.

7.10.7 Oil Header

Oil header shall be mounted on the top of the generator and shall incorporate parts for supplying oil to the
runner blade servomotor cavities. It shall be complete with special piping passing down the bore of the
main shaft to the runner, return motion lever and gear.

The blade control apparatus shall be designed to adjust automatically and also manually, the angle of the
runner blades as and when required corresponding to the guide vane opening such that the optimum
efficiency of the turbine is obtained under all conditions of heads and discharges. A device shall be
provided to ensure optimum relation between gate opening and blade angle over the entire range of heads.

7.10.8 Turbine Shaft & Coupling

The turbine shaft shall be designed to operate safely in combination with the generator rotor at any speed up
to the maximum runaway speed without detrimental vibration or objectionable distortion. It shall operate at
the rated speed and maximum specified output without exceeding the maximum allowable stresses. The
couplings for connecting to turbine runner and generator rotor shall be friction type with pre-stressed
coupling bolts. The tightening torque for coupling bolts will clearly be mentioned on drawing. If necessary,
torque transmitting pins will be provided on coupling flanges. Proper size rubber cords shall be used between
coupling joints to avoid leakage of oil/water. Torque tightening wrench will be included in scope of supply under
special tools.

The shafts and coupling bolts of all the units shall be made interchangeable.

185
 The turbine shaft will be 1.5% Mn. steel forging confirming to Indian standard or equivalent International
Standard. It will have integrally forged coupling flanges for coupling to generator shaft at upper end and
turbine runner at lower flange. A central hole will be provided to allow internal non-destructive inspection
and for carrying two concentric pipelines for supplying oil to runner blade servomotor. The shaft is provided
with a bearing belt.

Necessary tackles and devices shall be included and supplied for lowering the shaft with runner in turbine pit and
coupling the same with generator shaft.

7.10.9 Guide Bearing

Self lubricating turbine guide bearing shall preferably be segment type and adequate number of babit lined
segments shall be used along the outer circumference of the bearing belt of the shaft. Arrangement shall be
provided to adjust the bearing gaps and lock the pads in position. Alternatively, shell type bearing can also
be offered.

The babit material of the bearing shell lining will have following composition:

Sn – 90%, Sb – 6.5%, Cu – 3.5%, Pb <0.2%

The bearing body shall be made of mild steel plates and shall be fixed to the cover of turbine with the help of
studs. The guide bearing cooler shall be located on turbine top cover and will cool the guide bearing oil by
water passing through turbine babit lined segments.

Level relay with alarm shall be provided for indicating low oil level in the bearing body. For thermal control
the sensing heads, of two thermo-signalisers and two resistance thermometers shall be provided in the
bearing segments/shell. An Electro-contact flow relay shall be provided for signaling the stoppage of flow of
cooling water supply. .

Note: The adjustable shoe or segment type bearing is self lubricating since it uses a self generated
hydrodynamic fluid pressure distribution enhanced by the pivoting capability of the shoe or segment.

The type of guide bearing that offers adjustability, good combined (oil and structural) stiffness, and the
closest load support to the runner is the adjustable shoe or segment bearing. The resulting close proximity of
the guide bearing to the runner, and, therefore, the shaft seal, limits space and precludes the use of a large oil
basin necessary for a self pumping bearing. Therefore, the benefits of this bearing arrangement are fully
realized when the lubricating oil is pumped from an external sump that includes cooling coils (or heat
exchangers). Controls, redundant pumps and motors.

7.10.10 Turbine Shaft Gland

The turbine shaft gland shall effectively prevent leakage of water along the shaft under all operating and
standstill condition and prevent entry of air. Shaft gland shall be of stuffing box (carbon ring) type with
self-lubricated packing and lantern ring. Any other suitable type of shaft gland will also be considered.
Arrangement of providing clean cooling water supply to the gland at pressure sufficient to stop dirty water
coming up shall be made by the Contractor.

An air inflatable type service seal shall be provided so that sealing rings can be replaced through turbine top
cover without dismantling the guide bearing. A pressure gauge and an Electro-contact flow relay shall be
provided for measuring the pressure in the turbine seal and signaling the stoppage of flow of cooling water
supply. .

Note: - Two versions of the basic “axial” face seal concept have been used: hydrostatic, which requires
clean water injection into the sealing interface, and hydrodynamic, which generators its own interface
liquid film by using the fluid being sealed.

186
 The use of hydrostatic seals is especially advantageous when the following special operation requirements
exist:

• Lowest possible face wear rate;

• Contaminated operating water, particularly when the contaminants are abrasive solids;
• Synchronous condenser operation (with runner operating in air)

The packing-box type of main shaft-seal is the simplest configuration of the mentioned shat seals. The
sealing element is generally a series of square woven packing compressed by a packing gland to provide
sufficient packing pressure on the main shaft to provide controlled leakage through the packing box. It
should be pointed out that packing box seals require a small amount of leakage to cool the seal properly.

For shaft seals where the seal remains submerged even at minimum tailrace water elevation, a separate
maintenance seal is normally specified. This maintenance seal, when actuated, will allow exchanging the
main sealing elements of the shaft seal without dewatering the draft tube.

7.10.11 Mounting Of Shear Pin Contact

The limit switches shall be provided for the shear pins/breaking links to give the alarm signal when any of
the shear pins / breaking links gets broken due to jamming of guide vanes. The cables used for inter-
connecting the limit switches shall be weather proof type and withstand the surrounding moist atmosphere.
The limit switches shall be oil/water tight and special glands be used to prevent entry of water in the limit
switches through the cables.

7.10.12 Plate Form In Turbine Pit & Hatch Covers

Suitable removable type platforms/supports shall be provided on turbine cover for inspection and maintenance
of the equipment.

Suitable hatch covers, ladders and railings shall be provided wherever necessary for easy approach and safety.

7.10.13 Centralised Grease Lubrication System

The centralised grease lubrication system shall be of adequate capacity to pressurise the turbine and inlet
valve grease lubrication points periodically by timer as per requirements. The equipments comprises of an
electric motor driven grease pump, starter, grease reservoir, pressure regulator, solenoid valve, set of
grease dosers and pipes etc.

The control panel with control indicators, manually starting push buttons, fault indicators etc. shall be
supplied. The control panel shall be of wall mounted type. One hand operated transfer pump shall be
supplied for transferring grease from commercial standard grease drums to reservoir of automatic grease
lubrication system.

One number manually operated pump for greasing the points when the automatic system is not in
operation shall be supplied.

7.11 Inlet and Pressure Relief Valves

Inlet valves for closure on shut off are provided on long penstock and where single penstock headers are
branched near powerhouse for individual units. Pipes for underground pumped storage projects have valves
on the upstream and downstream side to the pump turbine.

Turbine inlet valves normally operate under zero flow condition and have bye pass piping for equalizing
pressure before opening and during closing. These are generally operated fully open and fully closed
position. Throttling of these valves for flow control should not be allowed. Design pressure rating should
include the effects of water hammer for capability for emergency closing on full load rejection.

187
 Hydraulic servomotor usually operates inlet valves. In small hydro the practice is to have a common
pressure oil system for closure of turbine wicket gate and inlet valve. These valves especially in SHP are
held in open position by oil pressure and closed by weight on release of oil pressure.

7.11.1 Butterfly Valves

Butterfly valve are commonly used inlet valves being rugged; compact, simple design and low cost. Large
butterfly valves have been used involving heads up to about 100 meter and diameters up to 9 meters. Small
butterfly valves have been used up to 300 meters head.
Pong power plant (60 MW unit size) inlet butterfly valves are of Lattice construction; rated head is 65.5
meter and maximum head including water hammer head is 123.8 m. it is the heaviest assembly to be lifted
by powerhouse crane.

Sobla small hydro power plant inlet valves are for 185 m head. Normally butterfly valves should be larger
than turbine inlet diameter.

7.11.2 Spherical valves

These valves are used up to 1200 meters and diameter up to 4.5 meter.

Dehar power plants are provided with spherical valves. Design Head is 380 m and unit size 165 MW.

7.11.3 Pressure relief valves

These valves of water saving type have been used in Pong power Plant on River Beas Dam. These are
cylindrically balanced type and controlled by the governor and operated by the combined guide vane and
relief valve servomotor.

7.12 Turbine Instrumentation, Control, Safety Devices and Unit Control Board

Each turbine shall be provided with a complete set of instruments, gauges, controls and safety devices on
unit control board provided for monitoring the condition of the unit during normal running and
emergencies. These shall permit the unit to be started and brought up to speed no load position at the
governor location and control during normal running. The instruments and garages for the turbine include,
inter alia, pressure gauges, level indicator, indicating lamps for status indication etc. These shall be placed
near the locations of apparatus or in the Unit Control Board (UCB) or both. The safety devices shall
comprise equipment and devices for sensing abnormal operating conditions, for giving visual and audible
annunciation and shut down the unit, if required. A list of these instruments, controls and safety devices is
given in tables A and B. The items, quantities and location are to suit the requirements for safe and
satisfactory operation of the generating units and the auxiliary systems.

TABLE ‘A’

Schedule of Indicating / Recording instruments for Turbine, Governing and Auxiliaries Equipment

SL Parameter indicated / Type of Location Qty. Remarks

No. recorded Instrument
A Temperature of :
01 Turbine guide bearing pads RTD Turbine Guide 2 Indication /Alarm at UCB &
Bearing SCADA
02 Turbine guide bearing pads TSD - do - 1 Alarm/ Shutdown
03 Turbine guide bearing oil RTD - do - 1 Indication /Alarm at UCB &
SCADA
04 Oil in OPU sump RTD Local 1 Indication/Alarm at UCB

188
B Pressure of :
05 Oil in Pressure Accumulator PG Local 1 Local Indication
06 Oil in Governor Actuator PG Local 1
07 Oil in Servomotor PG TG Panel 2
08 Before guide vanes PG TG Panel 1
O9 Draft Tube PVG TG Panel 1
10 Water in Shaft Seal PG TG Panel 1
11 Air in Shaft Seal PS Local 1
12 Water before inlet valve PG local 1
13 Water after inlet valve PG local 1
14 Water after inlet valve PS local 1
15 Air in HP air receiver PG Local 1
16 Air in LP air receiver PG Local 1
17 Cooling Water PG Local 1
18 Low/Very Low/ Emergency Low DPS Local 3 For control of OPU pumps
Pressure in OPU /emergency shut down
19 Low/Very Low air pressure in DPS Local 2 For control of compressors
HP air receiver
C Levels of :
20 Oil in Turbine Guide Bearing SG Local 1
21 Oil in Turbine Guide Bearing – ELC Local 2 Alarm in UCB
Low/High
22 Oil in OPU sump -High/Low FSW Local 1 Alarm in UCB
23 Oil in Pressure Accumulator – FSW Local 3 Alarm/shut down/ control of
low/very low/high air qty.
24 Oil in oil leakage unit FSW Local 2 Control of pump / alarm
25 Oil in oil leakage unit SG Local 1
26 Leakage water in turbine cover FSW Local 2 Alarm in UCB
27 Water in dewatering sump ELC Local 3 Control of dewatering pumps /
alarm
28 Water in drainage sump ELC Local 3 Control of drainage pumps /
alarm
D Flow of :
29 Cooling water in main line MFR Local 2 Control of Pumps / alarm
30 Cooling water at TGB outlet FR Local 1 Alarm / starting interlock
31 Cooling Water in shaft seal FR Local 1 alarm

189
 E Other Instruments / Indicators
32 Guide Vane Position ( % ) Mech. Governor 1 Duplication at UCB
Indicator Actuator
33 Guide Vane Limiter Position (% ) Elec./Mech. - do - 1 Duplication at UCB
Indicator
34 Runner Blade Position Mech. - do - 1 Duplication at UCB
Indicator
( Degrees)
35 Speed of Generating set ( 0-200 Elec. - do - 1 Duplication at UCB
%) Indicator

36 Control Current in Actuator Elec. - do - 1 Duplication at UCB

Solenoid Indicator
37 Speed Setting Indicator Elec. - do - 1 Duplication at UCB
Indicator
38 Gate setting Indicator Elec. - do - 1 Duplication at UCB
Indicator
39 Servomotor locked / unlocked LS Local 2 Starting Interlock
40 Guide Vanes sear Pins fail LS Local 24 Alarm

RTD - Resistence Thermometer (these will be wired up to Temperature Indicator & Recorder
Instrument mounted on control & Metering Panel)
TSD - Thermo Signaling Device (With two set points for Alarm and Trip commands)
PG - Pressure Gauge
FSW - Float Switch
FR - Flow Relay
MFR - Magnetic Flow Relay
ELC - Electronic Level Controller
TABLE ‘B’

SAFETY DEVICES (FOR ALARM / SHUT DOWN )

SL Parameter Type of Location Qty. Remarks

No. Instrument
01 Turbine guide bearing pads RTD Turbine Guide 2 Alarm
Bearing
02 Turbine guide bearing pads TSD - do - 1 Alarm/ Shutdown
03 Turbine guide bearing oil RTD - do - 1 Alarm
04 Oil in OPU sump RTD Local 1 Alarm
05 Very Low/ Emergency Low Pressure in DPS Local 2 Alarm/ Shut down
OPU
06 Very Low air pressure in HP air receiver DPS Local 2 Alarm
18 Oil in Turbine Guide Bearing – ELC Local 2 Alarm
Low/High
19 Oil in OPU sump -High/Low FSW Local 1 Alarm

190
 20 Oil in Pressure Accumulator – Low/ FSW Local 2 Alarm/Shut down.
Very Low
21 Oil Level in oil leakage unit - High FSW Local 1 Alarm
23 Level of Leakage water in turbine pit - FSW Local 1 Alarm
High
24 Water Level in dewatering sump-High ELC Local 1 Alarm
25 Water Level in drainage sump-High ELC Local 1 Alarm
26 Flow of Cooling water in main line -Low MFR Local 2 Alarm
27 Flow of Cooling water at TGB outlet- FR Local 1 Alarm / starting
Low interlock
28 Flow of Cooling Water in shaft seal - FR Local 1 Alarm
Low
37 Guide Vanes sear Pins fail LS Local 24 Alarm

RTD - Resistence Thermometer ( these will be wired up to Temperature Indicator & Recorder
Instrument mounted on control & Metering Panel )
TSD - Thermo Signaling Device ( With two set points for Alarm and Trip commands )
DPS - Differential Pressure Switch
FSW - Float Switch
FR - Flow Relay
MFR - Magnetic Flow Relay
ELC - Electronic Level Controller

7.13 Governing System and Accessories

Governing System And Accessories

Scope of Supply : Each governing system shall comprise of :

• Electro-hydraulic Governor consisting of Electronic cubicle and E-H Actuator

• Speed signal generator (SSG)
• Centrifugal type over speed switch
• Restoring mechanism
• Oil Pressure Unit
• Leakage oil unit
• Oil piping

7.13.1 Electro Hydraulic Governor

7.13.1.1 Rating, Performance And Basic Provisions Of Governor

The governor shall be Digital electronic type with electronic speed sensing, electronic hydraulic
transducer, and oil-pressure actuator. It shall have adequate capacity to operate the wicket gate
servomotor through a complete opening or closing stroke in desired time under maximum operating head
and with minimum permissible oil pressure in oil pressure accumulator.

The governor shall meet the requirements of IEEE –125 “Recommended Specification for Speed
Governors of Hydraulic Turbines”.

191
Stability (Current Practice)

The governor operation shall be deemed stable:

If peak to peak magnitude of the sustained load oscillation caused by the governor, with 4% or more speed
droop setting, does not exceed ± 0.15% of the rated capacity - the generator being connected to the grid
with sustained load demand.

The governor shall control, with stability, the turbine at any speed between 85 and 105% of rated speed
when operating isolated from the system and while connected to the system at any load between zero and
the load corresponding to maximum opening of the guide vanes.

With the turbine running at its rated speed, the total amplitude of speed variations not resulting in any
measurable difference in the guide apparatus servomotor position shall not exceed 0.02% of the rated speed
at any gate opening.

Dead Band - The dead band adjustment range shall be 0 to ± 3Hz. The governor dead time shall not
exceed 0.2 seconds with a sudden load change of 10% or more of the capacity of the turbine.

The adjustment of permanent speed droop shall have a range from 0 to 10%.

The governor adjustments shall enable synchronizing over the range of 85 to 105% of rated speed and shall
be adaptable for automatic synchronizing and automatic load or frequency control.

Governor shall have provision for local-manual, local-fully automatic and remote fully automatic control
of the turbine. These auxiliary devices shall permit transfer from one method of control to the other,
without disturbing the operation of the turbine. Transfer from local to remote control will be initiated by a
two-way position selector switch located in UCB (Unit Control Board).

The electronic regulation panel shall be micro-processor based digital system of proven design. Governor
shall use PID (Proportional Integral Derivative) loop control in which three derivatives of speed are used
for speed stabilization.

Control modules of governor regulator shall be suitable for following auxiliary supply voltages:
AC : 415 Volts AC + 10%
DC : 110 Volts DC –20% to +20%

Starting and stopping of the generating unit shall be possible locally from the governor panel and also
remotely from Microprocessor based DACS and auto start/stop control system (Unit control boards).

Governing shall be fail-safe on the failure of the speed sensing element, loss of oil pressure or defect in the
actuating system so that under any of these conditions, the machine shall be automatically shutdown, with
alarm and indication.

Relationship between runner blade angle and wicket gate opening at all working heads shall be achieved
digitally in micro-processor. The governor regulator cubicle shall be capable of accepting independent
analogue signal (4 to 20 mA) from head race and tail race water level sensors and signal for gross head.
The combinatory relationship i.e. runner blade angle Vs Wicket gate opening will be adjusted as per gross
head signal. The electronic gate limit shall also be applied as per head signal.

Provision for level controlled units e.g. canal etc.

Provision shall be made in each governor regulator to control wicket gate opening based on water level in
power channel so as to utilize available water for power generation and avoid flowing through bypass
gates. Sufficient flexibility will be provided in control philosophy to choose control of any of the unit using
192
 load-frequency control, gate limit control, manual control and control as per water level in power channel.
This point has to be clarified specifically in the Bid.

Hand control device for stroking of governor shall be provided.

Partial Shutdown / Controlled Action Shutdown device shall be used for automatically shutting down the
turbine to the speed-no-load position by the operation of certain protective devices.

7.13.1.2 Performance Requirements as follows were generally specified earlier.

Stability: The governor system shall be capable of controlling with stability the speed of the turbine when
operated at rated speed and no load or when operated at rated speed with isolated load at all power outputs
to and including maximum output of the turbine. The governor system shall also be capable of controlling
with stability the power output of the turbine at all power outputs between zero and maximum power output
of the turbine at all power outputs between zero and maximum power output inclusive when the generator
is operating in parallel with other generators in a plant or in a transmission system. The governor system
should be deemed stable, if the hydraulic system of turbine and water conduit is inherently stable, when:

a) The magnitude of the sustained speed oscillation caused by the governor does not exceed 0.3% of
rated speed with the generator operating at rated speed and no load or operating at rated speed and
isolated sustained load and with the governor speed droop set at from two to five percent inclusive.

b) the magnitude of the sustained power output oscillation caused by the governor does not exceed
three percent of the rated capacity of the turbine with the generator operating under sustained load
demand in parallel with other generators which are themselves capable of operating in parallel with
other generators and with the governor speed droop set at from two to 5% inclusive.

Dead Time: The elapsed time from the initial speed change the turbine servomotor for a sudden load
change of more than 10% of the full load rating of the turbine shall be not more than 0.25 second as
demonstrated during field tests.

Dead Band: The total magnitude of the sustained speed change within which there is no resulting
measurable change in the position of the turbine gate servomotors at rated speed of the turbine shall not
exceed 0.02% of the rated speed of the turbine at any gate opening as demonstrated by shop tests. For
purpose of determining compliance with guaranteed characteristics, the minimum speed change in % of
turbine speed to which the governor will respond is defined as one-half the measured dead band.

Runner Blade Lost Motion: The runner blade position shall be maintained in the proper relation to the gate
position with a minimum of lost motion. The steady state position of the runner blades as measured by the
position of the top of the inner oil pipe at the oil head for any given cam position following a movement in
the opening direction shall not vary more than one-eighth of an inch from the steady date position of the
runner blades following a movement in the closing direction to the same cam position.

Speed response Elements: The speed of the speed responsive element shall vary directory with the speed
of the main shaft of the turbine for all rates of acceleration and declaration. The governor drive shall not be
affected by variations in the voltage or current of the main generator or exciter or of the power system to
which the main generator is connected.

7.13.1.3 Working Principle

Working principle of Governor Controller will be as follows:

The speed signal will be derived from Speed Signal Generator (SSG). This signal will be converted to a
DC signal by a pulse converter and a frequency to voltage converter. Feedback signal corresponding to
gate position will be obtained form a variable resistor or a LVDT. The subsequent stages of control and
regulation will be carried out in the micro-processor hardware. The required transfer function for the
controller will be realized in software by using suitable function block language. The reference values

193
 (Speed setting, Gate setting, Gate limiter position etc.) and parameter values of PID controller, temporary
and permanent droop functions will be set in the processor.

The reference values to be varied using raise/lower switches in the panel and parameters to be set during
commissioning using programming tool. The output of the regulation function block will be fed to an
analog output module. This signal will be further amplified by a booster amplifier and fed to electro-
hydraulic transducer in actuator cubicle.

7.13.1.4 Constructional Features

The governor electronic cubicle should have the following features:

- Modular, bus based architecture which will allow flexibility in hardware configuration.
- Inter module communication through serial bus .
- Module level self diagnostics to be ensured. Each module shall contain circuits for monitoring its
most important functions. If a fault occurs, the type and possible location to be indicated by light
emitting diodes and output signals
- Non-volatile RAM (read only memory) to be made available on the processor module for retaining
important parameter values even when power failure occur.
- Power supply requirement: Station battery 110 /24 V DC.

Software:

A complete set of programme and data base files and software configuration and programming tools
shall be provided for all digital devices installed in the system as per IEEE 125.

Interface to other plant systems shall be provided as follows:

Interface to unit controllers, plant controller central control room, plant monitoring system and remote
terminal unit for offsite control as required.

- PID/temporary droop control scheme for regulation.

- Start up and Shutdown logic.
- Speed relays.
- Electronic limit.
- Function block programming language to be used same as in Unit Control panels
- The digital modules used in the controller belong to the same family hardware which are also being
used in unit Control Panels.

The cubicle shall be a steel cabinet with doors for convenient adjustment, test and maintenance. Micro
terminal for indications and control shall be mounted on the front rack with transparent cover. The cubicle
shall be mounted at a suitable location along with unit control board panels.

All electrical wiring shall be neatly concealed inside the cubicle and terminated in readily accessible
terminals. Cable entry shall be from below the cubicle.

All settings like speed droop, temporary droop on line/ off line, temporary droop time constant on line/ off
line, dead band, permanent speed droop and sensitivity etc shall be achieved through digital type micro
terminal. It should be possible to change the once adjusted values through password only.

Governor shall accept digital set commands from unit control panels for various controls i.e. speed / gate
setting, limit setting, start, stop, main circuit breaker position, shutdown, and other signals necessary for
proper operation and as per logic control scheme approved by purchaser.

Following analogue/digital output signals shall be provided as input for unit control panels:

194
 • Speed , Wicket gate position and gate mechanical limit position, Wicket gate electrical limit,
• Actuator balance current, Speed setting, Gate setting, Speed relay signals,
• Position of various limit switches, position of various solenoids and any other signal considered
necessary for ensuring proper control
Command signals at the following speeds shall be available at regulator output terminals:
ƒ At speeds above 120 % of rated speed to cause unit shut down through the shutdown solenoid via
protection circuits
ƒ At 90 % of the rated speed for initiating excitation and synchronising functions.
ƒ At 80 % of the rated speed for changing over the governor to auto speed regulation.
ƒ At 25 % of the rated speed activate the generator brake application.
ƒ At zero speed to indicating unit standstill.
ƒ At 150 % speed to announce emergency condition and drop intake gates.
7.13.1.5 Electro-Hydraulic Actuator

The electro-mechanical transducers, pilot valves, main distributing valve for wicket gates and runner
blades control, auto clean strainers for transducers / pilot valves, shut-down solenoid, terminal blocks and
other accessories necessary for the hydraulic actuator shall be housed in a suitable cabinet. Following
indicators shall be mounted on the front panel of the actuator:

• Wicket gate position and gate mechanical limit position indicator

• Speed Indicator (with marking as 0 to 200 %)
• Actuator balance current indication
• Speed setting indicator ( with marking as 45 Hz to 55 Hz )
• Gate setting indicator ( with marking 0 to 100 % )
• Runner Blade angle indicator (with marking – min. to max blade angle)
• Pressure gauge for oil pressure in transducer
Following controls shall be provided on the actuator cubicle:
Gate limit control device which can be operated manually at the actuator and electrically from the unit control
board (suiting to 110 volts DC). Manual gate control should be possible by this device when control changed
over to `Manual’. Push button for Auto/Manual Changeover for Gate Control. Device for Manual Control of
Runner Blades during maintenance Emergency shut down device which can be operated manually at the
actuator, electrically by remote control or by emergency shut down signal from Unit Control Panels.

Auto clean double element filter set shall be provided in governor actuator to ensure that impurities of 10
microns or above are avoided. The change over to standby filter and cleaning of clogged filter must be
possible while unit is under operation.

The control mechanism shall be equipped with means of independent adjustment of the opening and
closing times of the guide vanes and runner. The adjustments shall be secured and will not be liable to
change at its own under any circumstance. The time for the gate closure under full load throw off shall be
adjustable to limit the speed rise and pressure rise within guaranteed values.

All bearings in the governor actuator cubicle shall be grease packed or self-lubricated.

Gate Position Switches

A bank of switches / master switch assembly will be provided in actuator cubicle or on the restoring
system. Its switches shall be adjustable independently corresponding to different positions of wicket gates
as desired for fulfilling the requirement of control sequence. At least two switches will be provided for gate
full closed position and two switches for slightly higher position than no load gate position.

195
7.13.1.6 Speed Signal Generator (SSG)

A toothed wheel type speed signal generator shall feed speed signal to the governor electronic cubicle for
regulation and speed relays. The toothed wheel shall be mounted on the turbine shaft and two magnetic
pick-ups shall be mounted near the toothed wheel. One of the two pickups will work as redundant. The
square wave output of the magnetic pick-up shall be fed to the frequency-to voltage converter module in
the governor electronic cubicle. The output of this converter shall be fed to the governor analogue input
signal module.

The capacity and characteristics of the SSG shall fully match with the requirement of speed responsive
elements and governor regulation and control system. It shall be designed to withstand satisfactorily the
maximum runaway speed of the turbine.

The digital governor shall have the provision of speed sensing through a potential transformer. The PT
shall be included in the scope and provision of its mounting in the LAVT cubicle. The VA burden and
classification of PT shall be as per IEEE.125.

7.13.1.7 Over Speed Device

A centrifugal type over speed protection device with provisions for electrical and mechanical tripping,
shall be mounted on the turbine shaft above the guide bearing. The tripping points shall be adjustable
independently for speed higher than the maximum speed the turbine can develop with loss of full load. The
mechanical tripping device shall directly actuate the governor actuator shut-down valve through a
hydraulic connection. The electrical tripping contact shall be wired to the turbine terminal cubicle. The
rotating parts of the over speed protection shall be protected by a guard.

7.13.1.8 Restoring Mechanism

Restoring mechanism – solid rod & levers, wire rope with pulleys or fully electronic, will be provided to
feed position of wicket gate and runner servomotors to governor for stabilizing and indication. Design of
restoring mechanism should ensure minimum backlash to achieve overall sensitivity of the governor.
Mechanism shall be provided to monitor the health of restoring mechanism so as to give emergency shut
down signal in case of its failure.

7.13.1.9 Oil Pressure System

Each turbine will be provided one independent oil pressure unit to supply oil under desired pressure to
guide apparatus servomotor through governor hydraulic actuator. Oil pressure system shall consist of oil
pumping unit and an air-oil pressure accumulator. The operating oil pressure shall be not less than 40 kg/cm2.
The bidder may offer higher operating pressure if the runner operating mechanism permits so. While selecting
the operating oil pressure, care should be taken that servomotor should be capable of closing the wicket gates
under all operating conditions at the emergency low pressure.

In SHP Oil Pressure system of higher rated pressure with Nitrogen Cylinders can be offered as
ALTERNATIVE offer with explanation of advantage and cost benefits.

Oil Pumping Unit

Oil pumping unit shall consist of one sump tank with two numbers oil screw pumps driven by a 3 phase
415 VAC electric motors, check valves, idler and relief valves, oil level indicator and transmitter, oil filters
at the suction of pumps and oil temperature detector. The sump tank shall have adequate capacity to drain
the entire governor oil system including servomotors. It shall be provided with a manhole and oil
centrifuging and drain connections.

The oil pump shall be screw type and have a capacity sufficient to operate the complete governor hydraulic
system but not less than 200 l/m when operating under the recommended pressure. The main duty pumps
shall be operating continuously even when the required pressure in oil pressure accumulator has been built
up.

The electric motors shall be direct connected 3 phase AC motor, 415 volts + 10%, 50 Hz completely
enclosed frame, squirrel cage rotor type with class F insulation.
196
 The motor starter panel housing contactors, switch fuse units and meters etc. shall be mounted on the wall
near the sump and wired complete with leads labeled. The connections to each motor shall be arranged so
that either pump may be removed for repair or replacement without interfering with the continuous
operation of the other.

A complete pump logic control system shall be provided in the main PLC system of turbine control. It will
permit the selection of either pump, as the main unit with the other pump acting as a standby, which will
cut in automatically to supply the oil and close a set of alarm contacts. Suitable number of adjustable
differential pressure switches will be used to obtain the desired logic.

Oil Pressure Accumulator

The capacity of the pressure accumulator shall be sufficient to operate the servomotors of the turbine, with
minimum pressure of normal operating range and under other normal operating conditions, through three
complete servomotor strokes (3 x sum of guide apparatus and runner servomotor volumes) with the oil
pumps not operating. Design calculation of capacity of oil pressure system shall be furnished. .

The pressure tank shall be constructed in accordance with part UW of the ASME Code for Unfired
Pressure Vessels, Section VIII, for the maximum working pressure of the governing system.

Following safety / control features shall be provided on the accumulator:

• Air pressure relief device, mounted on or near the top of the tank.
• Two low oil level devices with independently adjustable closing contacts
- One low oil level device shall be set to operate an alarm when there is sufficient oil under
pressure to provide only two full strokes of all servomotors.
- The other low level device shall be set to shutdown the unit when there is sufficient oil under
pressure for approximately 1-½ strokes.
• Two oil level devices with independent adjustable contacts for control of high pressure air
replenishment.
• Sight oil level gauge with guard, shut off valves and automatic shutoff device.
• Connection for compressed air line with shutoff valve and check valve.
• Air blow off valve, pressure gauge, manhole, drain connection, lifting lugs, anchor bolts, and all
necessary equipment for a complete assembly.

i) Oil Leakage Unit

One oil leakage unit will be provided to collect leakage oil from servomotor, oil distributing head and other
governing elements. Provision shall be made to drain oil pipelines and servomotor through oil leakage unit
and pump it to oil handling system or OPU sump.

Oil leakage unit should consist of one oil tank of at least 100 liters, one pump motor set with set of valves,
oil level relay and sight gage glass.

ii) Oil Pipe Lines

Oil pipe lines of adequate size along with necessary valves, connecting flanges, fittings and fasteners shall
be supplied for interconnection between different hydraulic elements. Sufficient joints will be foreseen in
pipelines for their easy dismantling and cleaning. Pipelines shall be fabricated at site to suit the civil
structure of the power house and provide neat layout. All weld joints in pipelines shall be done by Tag
welding and inside surfaces of pipes will be cleaned by metal wire brush and acid pickling and flushed to
metallic shine. All pipes above 15 mm internal diameter shall be carbon steel seamless pipes and up to
15mm size, these will be stainless steel pipes. Pipes shall be rigidly clamped on walls, floors or trenches
with suitable clamps to avoid their vibrations. Covers for trenches shall be included in the pipeline scope of
work.

Isolating valve in pressure oil pipeline between pressure accumulator and governor actuator cubicle shall
be hydraulically operated through a solenoid valve.
197
 References

IEC: 61362 (1998) - Guide to specification of hydraulic turbine control systems

IEC: 61366 - Hydraulic turbine
IEC: 61366-1 (1998) - Part 1: General and Annexes
IEC: 61366-2 (1998) - Part 2: Guidelines for technical specifications for Francis turbines
IEC: 61366-2 (1998) - Part 3: Guidelines for technical specifications for Pelton turbine
IEC: 61366-2 (1998) - Part 4: Guidelines for technical specifications for Kaplan and
Propeller turbines
IEC: 61366-2 (1998) - Part 5: Guidelines for technical specifications for Tubular turbines
IEC: 61366-2 (1998) - Part 5: Guidelines for technical specifications for pump turbines
IEC: 61116 (1992) - Electro- mechanical equipment guide for small hydro electric
Installations
IEEE: 125-2007 - IEEE recommended practice for preparation of equipment specifications for speed
governing of hydraulic turbines intended to drive electric generators

198