Economic But High Efficiency Hydro Power Plant Pelton Turbine Generator

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Basic Info.

Origin

China

HS Code

850239000

Origin

China

HS Code

850239000

Product Desciption

Pelton Turbine

2.1 Technical Data

Type	Pelton turbine generator
Model	CJA475-L-74 / 2 * 6
Water head	190 m
Runner diameter	740 mm
Rated flow	0.34 m³ / sec
Rated speed	750 rpm
Runaway speed	1300 rpm
Rated efficiency	89%
Max. parts weight	1.6 ton

2.2 Brief Introduction of Turbine Structure and Main Component

This turbine is vertical Pelton turbine with single runner and double nozzle. It consists of main machine, nozzle apparatus, inlet part, deflector regulating apparatus, reverse nozzle mechanic, etc.

2.2.1 Main Machine: Including Rotary Part (working part) and Machine House

a. Rotary part: including runner, water throw ring, etc. The runner is the heart of turbine. The properties of the runner are critical for the properties of the turbine. This runner is cast by stainless steel. The shape of bucket is like two half-spoon, there is a water dividing edge in the middle. The water dividing edge divide the water flow jetted to the bucket to two sides in order to reduce water collision lost.
There is a notch on the top of the bucket to avoid the bucket hamper the flow impulse
the following bucket. The water throw ring can stop the water overflow along shaft.
b. Machine house including house and cover. The house connects the main part in a whole. One of the bearings for deflector shaft is located on a truncated cone hole near the connection between the house and the distributor. Connect the cover and house by screws and put asbestos pad between them.

2.2.2 Nozzle Apparatus: Consists of Distributing Parts and Connection

Distributing parts include: Jet elbow, needle, nozzle, support, balance piston, etc.
Jet elbow lead the pressure water to nozzle through support, the main function of the
support is to bear needle rod and avoid vortex.
The needle is made into converging stream type to reduce drag resistance to water flow. Pressurized water flow into the nozzle, then the flow speed rise rapidly at the nozzle outlet and push the runner blade by high speed jetting, the pressure energy is converted into speed energy and work on the runner.
Nozzle opening is adjusted through change the section of nozzle outlet by the action of needle servomotor, this can adjust jetting capacity, adapt the change of load. Use the balance piston to balance axial hydraulic force applied on needle, make the action of needle rod free.
The sealing sleeve on jet elbow is another supporting point to bear the needle rod. The
oil immersed asbestos packing and sealing gland are fixed on jet elbow, the former
enclose the water, and the latter clamp and scrape fouling off needle rod, protect the
gasket. There is a hole at the jet elbow side near the support to remove weed and wood stick on the support in the pipe. The nozzle liner ring is made of GX5 CrNi 16-6, located on nozzle outlet to reduce cavitation since the cavitation mostly possibly occurred there because the flow speed is the highest at nozzle outlet.

2.2.3 Inlet Part Includes: Inlet elbow, etc.

Inlet elbow lead the pressurized water to jet elbow, it is also a supporting point of nozzle apparatus.
Expansion joint is used for installation and maintenance of unit for dismantling and
adjusting.
Drain valve is located on lowest part of inlet part. When maintenance or stop the unit for a long term, open the valve to remove accumulated water.
Gate valve is used for cutting the water flow for maintenance or stop the unit for a long term.

2.2.4 Deflector Regulating Apparatus

It consists of deflector, deflector shaft, rocker arm, fork, connecting rod, operation rod, contact board, lifting hook, spring, electromagnet, etc.
The deflector is also named flow diverter, it divert the jetting flow off the blade when the unit suddenly rejects load, to avoid over-speed and water hammer pressure rising too big. The deflector is made of ZG230-450.
Principle of deflector regulating apparatus:
i. Electrical: When the unit suddenly reject load or emergency shut down, the controller receives emergency shut signal, the electromagnet acts, bounce off the contact board, under the force of the spring, the operation rod make the deflector rotate a certain angle to deflect the jetting flow.
ii. Manual: When the unit suddenly reject load or emergency shut down, use hand to pull the lifting hook to rotate a certain angle, the operation rod make the deflector rotate a certain angle to deflect the jetting flow. Before start the unit, use hand to pull the operation rod to reset.

2.2.5 Reverse Nozzle Mechanic:

In order to prevent damage of bearing when shut down the Pelton turbine, the turbine is not permitted to rotate under low speed for long time, but the turbine is difficult to stop when rotate in air, so we locate a reverse nozzle to stop the unit rapidly when normal shut down or emergency shut down the unit.

2.2.6 Bypass Valve Equipped with Bypass Pipe and Gate Valve

Bypass valve if for the bypass of water flow in the front and back of gate valve. Before opening the gate valve, open the bypass valve first, let the pressure water fill the elbow through bypass valve, balance the pressure difference in the front and back of gate valve, reduce the torque for opening the gate valve.

2.3 Installation of Turbine

Installation quality of turbine will directly influence service life and output of turbine, therefore the installation work of turbine shall be done carefully.

2.3.1 Preparation Before Installation

1. Check components, accessories, spare parts and delivered technical data according
to packing list supplied by manufacturer.
2. The installers must be familiar with the drawings of Assembly of turbine, Arrangement of installation and Drawing of component.
3. Prepare tools, measurement instruments, manual hoist, frame level, dial indicator, clearance gauge, fitting tools and special tools needed during installation.
4. Select correct lifting method according to pre-opened lifting hole on main machine or machine house.

2.3.2 Technical Requirements for Installation

1. Permitted levelness error of main shaft: ≤0.02mm/m.
2. Permitted levelness error of turbine house along vertical direction of main shaft:≤
0.05mm/m. Maximum clearance between nozzle outlet and needing when closing: ≤
0.05mm.
3. Lower chord of the deflector is tangent to the center line of the needle when the
needle full closed.

2.3.3 Installation

The customer shall prepare hydraulic design and power house design; pour concrete
foundation according to the drawings of turbine assembly, turbine layout and technical documents of auxiliary equipments. Check whether the concrete foundation, setting level, anchor bolts (or pre-opened holes) are consistent with layout drawing. If there is no problem, start installation after the concrete foundation is complete dry.
A. Install Turbine House
Lift and assemble turbine house on reserved foundation, adjust horizontal plane, then
weld the dowel ribs with the anchor ribs in foundation, secondly pouring concrete. Levelness error of turbine house along vertical direction of main shaft shall be accordance with Technical requirements for installation. Fasten the bolts and nuts.
B. Install the Generator
C. Install Turbine Cover
D. Install Distributor
After the main machine installed, install nozzle, reverse nozzle, deflector regulating
apparatus and water inlet part, then fasten all nuts. Adjust the deflector: The distance between the deflector surface face to the water and the outside surface of nozzle shall be 10mm when the deflector full open. Lower chord of the deflector is tangent to the center line of the needle when the deflector full closed.
E. Install Bypass Valve

2.4 Operation and Maintenance of Turbine

2.4.1 Preparation before operation

a. Check whether the main machine, gate valve, pipes, instruments, ect. are completely installed and fastened or not.
b. Check whether the bearings and all lubricating points have been filled oil or not.
c. Check whether each rotary part and hand wheel can act freely or not. Act needle
actuating apparatus by hand, open and close the needle for several times, check
whether the nozzle apparatus can act freely or not. Then close the needle and gate
valve.
d. Check whether the pipes are clear or not, whether the sealing is in good state or not. e. After checking, fill water in, check whether there is any leakage or not. In case there is leakage, stop filling water immediately, check and solve it. Check whether the static head is reduced or not. Also pay attention to clear the trash rack.

2.4.2 Installation method and procedure:

1. According to the requirement of the arrangement diagram, lift and install the draft tube, then level it. Make sure right position direction flange bolt hole match the drawing then place concrete.
2. Lift and install the host machine of the volute and place it on the draft tube, center and level it. Attention shall be paid to the inlet center and the middle elevation (center of same pressure and tube of force, elevation is relative.) Install the governor and fix the push-and-pull rod, placing concrete in accordance with the requirement of the arrangement diagram.
3. Install the sluice valve and expansion joint: according to the requirement of the
arrangement diagram: lift and install flange of the sluice valve and expansion joint
orderly, and mat all flange faces with rubber gasket, find axis direction of the chief
pipeline and level and elevation of water inlet of the volute. Expansion joint of our product has been welded with the water inlet of the volute main machine. During installation, connect the movable flange and sluice valves and put rubber strip between flange and sluice as required by diagram. (When installing sluice valve and expansion joint, the distance between sluice valve flange surface and expansion joint water inlet surface shall meet the requirement of the diagram.)
4. Lift and install runner and generator
After the solidification of the concrete, the installation of the runner and generator shall perform. Before installation, disconnect the header of the turbine,( In our product, the header and motor frame have been installed on the main machine)trap it on the generator's spindle first, then install the runner and lock the tail cone, lift the generator and install it on the motor frame directly, lock the header bolt, connect the motor frame with the bolt and seal bolt of the device. So far the main machine has been installed completely.

2.4.3 Trial run

2.4.2.1 Pipeline water pressure test
Water pressure test the pipeline section by section according to GB/T15468-2006 Basic Technical Conditions for Turbine Unit.
2.4.2.2 Pipeline filling test
When the unit is fully closed, inform the inlet valve on the upstream to be opened slowly to fill the pipeline section by section. Then open the bypass valve after the pressure inside keep stable. Stop water filling at once as long as leakage or deformation of pipeline was found during the above process.
2.4.2.3 Low speed run test
Open needle slowly when the unit is under manual type, run the unit for 10 ~ 20 min under 50% rated speed to check the unit is stable, no noise, and check the bearing temperature as well. Put it into automatic no load running if everything is ok.
2.4.2.4 Load test
Add load gradually to make the unit run at 25%, 50%, 75% and 100% of rated power separately, there should be stable and no abnormal like frequency waving. Stop the unit to check and repair as long as any problem appeared.
2.4.2.5 Load-rejection test
Load rejection with 25%, 50%, 75% and 100% of rated power of unit to measure speed raising rate and pressure raising rate, where the rotary speed raising rate should not exceed 50% and the pressure raising rate no more than 30%.
2.4.2.6 72 hrs running test under rated working
Running the unit for 72 hrs with the max. output of water head to find all mechanism should run smoothly.
2.4.2.7 During all above running test, the waving, vibrating, bearing temperature, net water pressure, rotary speed changing and so on for each part of unit should be measured and recorded as well.
More attention must be paid to the changing of bearing temperature during the first operation. At the primary stage, check and record it per 5 ~ 10 min, which can be prolong to per hour after the bearing temperature comes to stable. Temperature for bearing shoe is normally under 65ºC and no more than 70ºC max. When the highest temperature being exceeded, the system will alarm or cut off automatically.

2.4.4 Operation precautions

a. The operator shall know the construction, working principle of the turbine, the usage and operation of each hand wheel and switch.
b. All hand wheels shall be on closing position before start the unit.
c. Thoroughly check the unit before filling water into the elbow, only start the unit when there is no abnormal.
d. Add load only after the no load operation is normal.
e. When emergency stop the unit, firstly act the electromagnet valve switch, make the deflector on full close position in a short time to prevent over-speed and water hammer pressure rise too much, then close needle slowly.
f. When stop the unit for a long time or being maintenance, relative parts shall be on close position and open water drainage valve on the bottom of water inlet part to empty the accumulated water.
g. Pay attention to bearing temperature rise, fill oil or replace oil periodically. Also fill oil on each rotary part periodically to ensure free action.
h. Regularly check each drive part to ensure reliable drive.

2.4.5 Stop Turbine

The turbine should be stopped as follows:
a. Close needle.
b. Close the valve if the unit stop for a long time, when stop for longer time, the inlet valve on the upstream of pipeline should be closed first, then open the needle to drain the water inside the pipe, then close the gate vale.
c. Close valve for pressure gauge.
d. Clean the whole unit and inject grease to all lubricate points.

2.4.6 Turbine maintenance

a. Ensure perfect lubrication of each rotary part, check lubrication before shift work. Fill oil regularly. Pay special attention to the two bearings.
b. Lubricating oil in bearing body shall be replaced after first 100 hours operation. After that, it shall not be filled too much, only to medium line of the oil scale, else the bearing may be hot.
c. When stop the unit for a long time or during cold winter, empty the water pipe to prevent frozen and the pipe be broken.
d. Periodically check friction of nozzle, needle and deflector. Replace or repair them by weld when necessary.
e. Periodically check screws, nuts and pins, any loosen shall be handled without delay.
f. Periodically overhaul. New machine shall be checked after operation for one month. Firstly remove the machine cover, check whether the turbine blade is normal, and repair if there is damage. Then apply medium size maintenance once every 3 to 6 months based on actual condition. Check each wear-out part, connecting part contacting water, clean bearings, replace lubricating oil, etc.
g. Annual overhaul (medium): In addition to periodical checking items, the annual overhaul must be like during installation, check all parts, clean pipes, adjust each part to satisfy technical requirements, repair or replace wear-out parts. Paint anti-rust coat
on wet surface, spray paint of suitable color on external surface after all checks completed.
Installation quality of turbine will directly influence service life and output of turbine, therefore the installation work of turbine shall be done carefully.