SIST EN 62256:2008
(Main)Hydraulic turbines, storage pumps and pump-turbines - Rehabilitation and performance improvement
Hydraulic turbines, storage pumps and pump-turbines - Rehabilitation and performance improvement
The scope of this International Standard covers turbines, storage pumps and pump-turbines of all sizes and of the following types: Francis; Kaplan; propeller; Pelton (turbines only); Bulb. Wherever turbines or turbine components are referred to in the text of this guide, they shall be interpreted also to mean the comparable units or components of storage pumps or pumpturbines as the case requires. The Guide also identifies without detailed discussion, other powerhouse equipment that could affect or be affected by a turbine, storage pump, or pump-turbine rehabilitation. The object of this guide is to assist in identifying, evaluating and executing rehabilitation and performance improvement projects for hydraulic turbines, storage pumps and pump-turbines. This guide can be used by owners, consultants, and suppliers to define: needs and economics for rehabilidation and performance improvement; scope of work; specifications; evaluation of results. The Guide is intended to be: an aid in the decision process; an extensive source of information on rehabilitation; an identification of the key milestones in the rehabilitation process; an identification of the points that should be addressed in the decision processes. The Guide is not intended to be a detailed engineering manual nor a maintenance guide.
Wasserturbinen, Speicherpumpen und Pumpturbinen - Modernisierung und Verbesserung der Leistungseigenschaften
Turbines hydrauliques, pompes d'accumulation et pompes turbines - Réhabilitation et amélioration des performances
Fournir une aide à l'identification, à l'évaluation et à l'exécution de projets de réhabilitation et d'amélioration des performances de turbines hydrauliques, de pompes d'accumulation et de pompes-turbines de toutes tailles et des types suivants: Francis; Kaplan; hélice; Pelton (turbines seulement); bulbe.
Vodne turbine, akumulacijske črpalke in črpalne turbine - Vodilo za prenavljanje in izboljšanje delovanja (IEC 62256:2008)
General Information
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Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN 62256:2008
01-september-2008
9RGQHWXUELQHDNXPXODFLMVNHþUSDONHLQþUSDOQHWXUELQH9RGLOR]DSUHQDYOMDQMHLQ
L]EROMãDQMHGHORYDQMD ,(&
Hydraulic turbines, storage pumps and pump-turbines - Rehabilitation and performance
improvement
Wasserturbinen, Speicherpumpen und Pumpturbinen - Modernisierung und
Verbesserung der Leistungseigenschaften
Turbines hydrauliques, pompes d'accumulation et pompes turbines - Réhabilitation et
amélioration des performances
Ta slovenski standard je istoveten z: EN 62256:2008
ICS:
27.140 Vodna energija Hydraulic energy engineering
SIST EN 62256:2008 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST EN 62256:2008
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SIST EN 62256:2008
EUROPEAN STANDARD
EN 62256
NORME EUROPÉENNE
May 2008
EUROPÄISCHE NORM
ICS 27.140
English version
Hydraulic turbines, storage pumps and pump-turbines -
Rehabilitation and performance improvement
(IEC 62256:2008)
Turbines hydrauliques, pompes Wasserturbinen, Speicherpumpen
d'accumulation et pompes turbines - und Pumpturbinen -
Réhabilitation et amélioration Modernisierung und Verbesserung
des performances der Leistungseigenschaften
(CEI 62256:2008) (IEC 62256:2008)
This European Standard was approved by CENELEC on 2008-04-16. CENELEC members are bound to comply
with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard
the status of a national standard without any alteration.
Up-to-date lists and bibliographical references concerning such national standards may be obtained on
application to the Central Secretariat or to any CENELEC member.
This European Standard exists in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CENELEC member into its own language and notified
to the Central Secretariat has the same status as the official versions.
CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Cyprus, the
Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and the United Kingdom.
CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung
Central Secretariat: rue de Stassart 35, B - 1050 Brussels
© 2008 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Ref. No. EN 62256:2008 E
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SIST EN 62256:2008
EN 62256:2008 - 2 -
Foreword
The text of document 4/231/FDIS, future edition 1 of IEC 62256, prepared by IEC TC 4, Hydraulic
turbines, was submitted to the IEC-CENELEC parallel vote and was approved by CENELEC as
EN 62256 on 2008-04-16.
The following dates were fixed:
– latest date by which the EN has to be implemented
at national level by publication of an identical
national standard or by endorsement (dop) 2009-02-01
– latest date by which the national standards conflicting
with the EN have to be withdrawn (dow) 2011-05-01
__________
Endorsement notice
The text of the International Standard IEC 62256:2008 was approved by CENELEC as a European
Standard without any modification.
In the official version, for Bibliography, the following notes have to be added for the standards indicated:
IEC 60041 NOTE Harmonized as EN 60041:1994 (modified).
IEC 60193 NOTE Harmonized as EN 60193:1999 (not modified).
IEC 60609 NOTE Harmonized in EN 60609 series (not modified).
IEC 60994 NOTE Harmonized as EN 60994:1992 (not modified).
__________
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SIST EN 62256:2008
IEC 62256
Edition 1.0 2008-01
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Hydraulic turbines, storage pumps and pump-turbines – Rehabilitation and
performance improvement
Turbines hydrauliques, pompes d'accumulation et pompes turbines –
Réhabilitation et amélioration des performances
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
XF
CODE PRIX
ICS 27.140 ISBN 2-8318-9332-1
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SIST EN 62256:2008
– 2 – 62256 © IEC:2008
CONTENTS
FOREWORD.6
INTRODUCTION.8
1 Scope and object.9
2 Nomenclature .9
3 Reasons for rehabilitating.10
3.1 General .10
3.2 Reliability and availability increase .12
3.3 Life extension and performance restoration .13
3.4 Performance improvement.13
3.5 Plant safety improvement .13
3.6 Environmental, social and regulatory issues .13
3.7 Maintenance and operating cost reduction.14
3.8 Other considerations .14
4 Phases of a rehabilitation project.14
4.1 General .14
4.2 Decision on organization .16
4.2.1 General .16
4.2.2 Expertise required .16
4.2.3 Contract arrangement.17
4.3 Level of assessment and determination of scope.17
4.3.1 General .17
4.3.2 Feasibility study – Stage 1.18
4.3.3 Feasibility study – Stage 2.18
4.3.4 Detailed study .18
4.4 Contractual issues.24
4.4.1 General .24
4.4.2 Specification requirements .24
4.4.3 Tendering documents and evaluation of tenders.24
4.4.4 Contract Award(s).25
4.5 Execution of project.25
4.5.1 Model test activities.25
4.5.2 Design, construction, installation and testing .26
4.6 Evaluation of results and compliance with guarantees .26
4.6.1 General .26
4.6.2 Turbine performance evaluation .27
4.6.3 Generator performance evaluation.27
4.6.4 Penalties and/or bonuses assessment.27
5 Scheduling, cost analysis and risk analysis .27
5.1 Scheduling .27
5.1.1 General .27
5.1.2 Scheduling – Assessment, feasibility and detailed study phases.28
5.1.3 Evaluating the scheduling component of alternatives .28
5.1.4 Scheduling specification and tendering phase .29
5.1.5 Scheduling project execution phases .30
5.2 Economic and financial analyses.30
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SIST EN 62256:2008
62256 © IEC:2008 – 3 –
5.2.1 General .30
5.2.2 Benefit-cost analysis .31
5.2.3 Identification of anticipated benefits.32
5.2.4 Identification of anticipated costs and benefits.33
5.2.5 Sensitivity analysis .34
5.2.6 Conclusions.35
5.3 Risk analysis .35
5.3.1 General .35
5.3.2 Non-achievement of performance risk.36
5.3.3 Risk of continued operation without rehabilitation .36
5.3.4 Extension of outage risk .36
5.3.5 Financial risks .37
5.3.6 Project scope risk .37
5.3.7 Other risks.38
6 Assessment and determination of scope of the work.38
6.1 General .38
6.2 Assessment of the site .39
6.2.1 Hydrology .39
6.2.2 Actual energy production .39
6.2.3 Environmental social and regulatory issues .40
6.3 The assessment of the turbine .41
6.3.1 General .41
6.3.2 Turbine integrity assessment .70
6.3.3 Residual life .79
6.3.4 Turbine performance assessment .80
6.4 The assessment of related equipment .102
6.4.1 General .102
6.4.2 Generator and thrust bearing.107
6.4.3 Turbine governor .109
6.4.4 Turbine inlet and outlet valves, pressure relief valve. 109
6.4.5 Auxiliary equipment .109
6.4.6 Equipment for erection, dismantling and maintenance . 110
6.4.7 Penstock and other water passages .110
6.4.8 Consequences of changes in plant specific hydraulic energy (head).111
7 Hydraulic design and performance testing options .111
7.1 General .111
7.2 Computational hydraulic design. 112
7.2.1 General .112
7.2.2 The role of CFD.113
7.2.3 The process of a CFD cycle.113
7.2.4 The accuracy of CFD results .114
7.2.5 How to use CFD for rehabilitation .115
7.2.6 CFD versus model tests .115
7.3 Model tests.116
7.3.1 General .116
7.3.2 Model test similitude.117
7.3.3 Model test content .117
7.3.4 Model test application.118
7.3.5 Model test location .120
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7.4 Prototype performance test .121
7.4.1 General .121
7.4.2 Prototype performance test accuracy. 122
7.4.3 Prototype performance test types . 123
7.4.4 Evaluation of results .123
8 Specifications .124
8.1 General .124
8.2 Reference standards .124
8.3 Information to be included in the tender documents.125
8.4 Documents to be developed in the course of the project. 127
Bibliography.129
Figure 1 – Flow diagram depicting the logic of the rehabilitation process .15
Figure 2 – Critical zones for cracks “A” and “B” in Pelton runner buckets .78
Figure 3 – Relative efficiency versus relative output – Original and new runners.82
Figure 4 – Relative efficiency versus output – Original and new runners – Outardes 3
generating station .83
Figure 5 – Efficiency and distribution of losses versus specific speed for Francis
turbines (model) in 2005 .84
Figure 6 – Relative efficiency gain following modification of the blades on the
La Grande 3 runner, in Quebec, Canada.86
Figure 7a – Potential efficiency improvement for Francis turbine rehabilitation.91
Figure 7b – Potential efficiency improvement for Kaplan turbine rehabilitation .92
Figure 8 – Cavitation and corrosion-erosion in Francis runner.93
Figure 9 – Back side erosion of the entrance into a Pelton bucket.94
Figure 10 – Leading edge cavitation erosion on a Françis pump-turbine caused by
extended periods of operation at very low loads.95
Figure 11 – Severe particle erosion damage in a Francis runner .97
Table 1 – Expected life of a hydropower plant and its subsystems before major work .12
Table 2 – Assessment of turbine embedded parts – Stay ring .43
Table 3 – Assessment of turbine embedded parts – Spiral or semi-spiral case.44
Table 4 – Assessment of turbine embedded parts – Discharge ring .45
Table 5 – Assessment of turbine embedded parts – Draft tube.46
Table 6 – Assessment of turbine non-embedded, non-rotating parts – Headcover.47
Table 7 – Assessment of turbine non-embedded, non-rotating parts – Intermediate and
inner headcovers .50
Table 8 – Assessment of turbine non embedded, non rotating parts – Bottom ring.51
Table 9 – Assessment of turbine non embedded, non rotating parts – Guide vanes .53
Table 10 – Assessment of turbine non embedded, non rotating parts – Guide vane
operating mechanism.55
Table 11 – Assessment of turbine non embedded, non rotating parts – Operating ring.56
Table 12 – Assessment of turbine non embedded, non rotating parts – Servomotors .57
Table 13 – Assessment of turbine non embedded, non rotating parts – Guide bearings .58
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62256 © IEC:2008 – 5 –
Table 14 – Assessment of turbine non embedded, non rotating parts – Turbine shaft
seal (mechanical seal or packing box) .60
Table 15 – Assessment of turbine non embedded, non rotating parts – Thrust bearing
support .60
Table 16 – Assessment of turbine non embedded, non rotating parts – Nozzles .61
Table 17 – Assessment of turbine non embedded, non rotating parts – Deflectors and
energy dissipation.61
Table 18a – Assessment of turbine rotating parts – Runner .62
Table 18b – Assessment of turbine rotating parts – Runner .65
Table 18c – Assessment of turbine rotating parts – Runner .66
Table 19 – Assessment of turbine rotating parts – Turbine shaft .67
Table 20 – Assessment of turbine rotating parts – Oil head and oil distribution pipes.68
Table 21 – Assessment of turbine auxiliaries – Speed and load regulation system
(governor).68
Table 22 – Assessment of turbine auxiliaries – Turbine aeration system .69
Table 23 – Assessment of turbine auxiliaries – Lubrication system (guide vane
mechanism) .70
Table 24 – Francis turbine potential efficiency improvement (%) for runner profile
modifications only .85
Table 25 – Potential impact of design and condition of runner seals on Francis turbine
efficiency with new replacement runner or rehabilitated runner (%).88
Table 26 – Potential total gain in efficiency from the replacement of a Francis turbine
runner including the blade profile improvements, the restoration of surface condition
and the reduction of seal losses.89
Table 27 – Potential Additional Efficiency Improvement by Rehabilitation/Replacement
of Other Water Passage Components on a Francis Turbine (%).89
Table 28 – Assessment of related equipment - Governor .104
Table 29 – Assessment of related equipment – Generator and thrust bearing .105
Table 30 – Assessment of related equipment – Penstock and turbine inlet valves.106
Table 31 – Assessment of related equipment – Civil works .107
Table 32 – Assessment of related equipment – Crane, erection equipment .107
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SIST EN 62256:2008
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INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
HYDRAULIC TURBINES, STORAGE PUMPS AND PUMP-TURBINES –
REHABILITATION AND PERFORMANCE IMPROVEMENT
FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,
Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC
Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested
in the subject dealt with may participate in this preparatory work. International, governmental and non-
governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely
with the International Organization for Standardization (ISO) in accordance with conditions determined by
agreement between the two organizations.
2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
interested IEC National Committees.
3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC
Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any
misinterpretation by any end user.
4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications
transparently to the maximum extent possible in their national and regional publications. Any divergence
between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in
the latter.
5) IEC provides no marking procedure to indicate its approval and cannot be rendered responsible for any
equipment declared to be in conformity with an IEC Publication.
6) All users should ensure that they have the latest edition of this publication.
7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and
members of its technical committees and IEC National Committees for any personal injury, property damage or
other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and
expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC
Publications.
8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 62256 has been prepared by IEC technical committee 4: Hydraulic
turbines.
The text of this standard is based on the following documents:
FDIS Report on voting
4/231/FDIS 4/234/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
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SIST EN 62256:2008
62256 © IEC:2008 – 7 –
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
This standard is intended as a guide.
The committee has decided that the contents of this publication will remain unchanged until
the maintenance result date indicated on the IEC web site under "http://webstore.iec.ch" in
the data related to the specific publication. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
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SIST EN 62256:2008
– 8 – 62256 © IEC:2008
INTRODUCTION
Hydro plant owners make significant investments annually in rehabilitating plant equipment
(turbines, generators, transformers, penstocks, gates etc.) and structures in order to improve
the level of service to their customers and to optimize their revenue. In the absence of
guidelines, owners may be spending needlessly, or may be taking unnecessary risks and
thereby achieving results that are less than optimal. This guide is intended to be a tool in the
optimisation and decision process.
IEC TC 4 wishes to thank IEA for providing its document “Guidelines on Methodology for
Hydroelectric Francis Turbine Upgrading by Runner Replacement” as a starting point for the
writing of this document. IEC TC 4 appreciates this contribution and acknowledges that the
IEA document provided a good foundation upon which to build this IEC document.
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SIST EN 62256:2008
62256 © IEC:2008 – 9 –
HYDRAULIC TURBINES, STORAGE PUMPS AND PUMP-TURBINES –
REHABILITATION AND PERFORMANCE IMPROVEMENT
1 Scope and object
The scope of this International Standard covers turbines, storage pumps and pump-turbines
of all sizes and of the following types:
• Francis;
• Kaplan;
• propeller;
• Pelton (turbines only);
• Bulb.
Wherever turbines or turbine components are referred to in the text of this guide, they shall be
interpreted also to mean the comparable units or components of storage pumps or pump-
turbines as the case requires.
The Guide also identifies without detailed discussion, other powerhouse equipment that could
affect or be affected by a turbine, storage pump, or pump-turbine rehabilitation.
The object of this guide is to assist in identifying, evaluating and executing rehabilitation and
performance improvement projects for hydraulic turbines, storage pumps and pump-turbines.
This guide can be used by owners, consultants, and suppliers to define:
• needs and economics for rehabilitation and performance improvement;
• scope of work;
• specifications;
• evaluation of results.
The Guide is intended to be:
• an aid in the decision process;
• an extensive sourc
...
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