SIST EN IEC 63132-3:2020
(Main)Guidance for installation procedures and tolerances of hydroelectric machines - Part 3: Vertical Francis turbines or pump-turbines (IEC 63132-3:2020)
Guidance for installation procedures and tolerances of hydroelectric machines - Part 3: Vertical Francis turbines or pump-turbines (IEC 63132-3:2020)
IEC 63132-3:2020: The purpose of this this part of IEC 63132 is to establish, in a general way, suitable procedures and tolerances for the installation of a vertical Francis turbine or pump-turbine. This document presents a typical assembly and whenever the word “turbine” is used in this document, it refers to a vertical Francis turbine or a pump-turbine. There are many possible ways to assemble a unit. The size of the machine, design of the machine, layout of the powerhouse or delivery schedule of the components are some of the elements that could result in additional steps, the elimination of some steps and/or assembly sequences.
It is understood that a publication of this type will be binding only if, and to the extent that, both contracting parties have agreed upon it.
This document excludes matters of purely commercial interest, except those inextricably bound up with the conduct of installation.
The tolerances in this document have been established upon best practices and experience, although it is recognized that other standards specify different tolerances.
Wherever this document specifies that documents, drawings or information is supplied by a manufacturer (or by manufacturers), each individual manufacturer will furnish the appropriate information for their own supply only.
Leitfaden für Installations-Prozeduren und -Toleranzen von hydroelektrischen Maschinen – Teil 3: Vertikale Francis- oder Pumpturbinen (IEC 63132-3:2020)
Lignes directrices des procédures et tolérances d'installation des machines hydroélectriques - Partie 3: Turbines ou pompe-turbines Francis verticales (IEC 63132-3:2020)
IEC 63132-3:2020 L’objectif de la présente partie de l'IEC 63132 est d’établir, d’une façon générale, des procédures et des tolérances adéquates pour l’installation des turbines et alternateurs hydroélectriques. Ce document présente un assemblage typique et à chaque fois que le mot "turbine" est utilisé, il signifie une turbine ou pompe turbine Francis verticale. Il y a plusieurs façons possibles pour assembler un groupe. Les dimensions des machines, la conception des machines, le plan de la centrale et l’échéancier des livraisons des différentes composantes sont quelques éléments qui peuvent résulter en l’ajout d’étapes, l’élimination de certaines étapes et/ou des séquences d’assemblages.
Il est entendu que ce type de document sera contraignant seulement si, et dans la mesure où, les deux parties contractuelles l’ont convenu.
Ce document exclut les questions d’intérêt purement commercial, sauf celles inextricablement liées au déroulement de l’installation.
Les tolérances mentionnées dans ce document ont été déterminées selon les meilleures pratiques et l’expérience, bien qu’il soit reconnu que d’autres normes spécifient des tolérances différentes.
Partout où ce document précise que des documents, des dessins ou des renseignements sont fournis par un fabricant (ou par des fabricants), chaque fabricant fournira les informations appropriées pour leur propre approvisionnement seulement.
Navodilo za postopke vgradnje in tolerance hidroelektričnih strojev - 3. del: Vertikalna Francisova turbina ali turbina črpalke (IEC 63132-3:2020)
General Information
Standards Content (Sample)
SLOVENSKI STANDARD
01-oktober-2020
Navodilo za postopke vgradnje in tolerance hidroelektričnih strojev - 3. del:
Vertikalna Francisova turbina ali turbina črpalke (IEC 63132-3:2020)
Guidance for installation procedures and tolerances of hydroelectric machines - Part 3:
Vertical Francis turbines or pump-turbines (IEC 63132-3:2020)
Leitfaden für Installations-Prozeduren und -Toleranzen von hydroelektrischen Maschinen
– Teil 3: Vertikale Francis- oder Pumpturbinen (IEC 63132-3:2020)
Lignes directrices des procédures et tolérances d'installation des machines
hydroélectriques - Partie 3: Turbines ou pompe-turbines Francis verticales (IEC 63132-
3:2020)
Ta slovenski standard je istoveten z: EN IEC 63132-3:2020
ICS:
27.140 Vodna energija Hydraulic energy engineering
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
EUROPEAN STANDARD EN IEC 63132-3
NORME EUROPÉENNE
EUROPÄISCHE NORM
June 2020
ICS 27.140
English Version
Guidance for installation procedures and tolerances of
hydroelectric machines - Part 3: Vertical Francis turbines or
pump-turbines
(IEC 63132-3:2020)
Lignes directrices des procédures et tolérances Leitfaden für Installations-Prozeduren und -Toleranzen von
d'installation des machines hydroélectriques - Partie 3: hydroelektrischen Maschinen - Teil 3: Vertikale Francis-
Turbines ou pompe-turbines Francis verticales oder Pumpturbinen
(IEC 63132-3:2020) (IEC 63132-3:2020)
This European Standard was approved by CENELEC on 2020-06-02. 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 CEN-CENELEC
Management Centre 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 CEN-CENELEC Management Centre has the
same status as the official versions.
CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Croatia, Cyprus, the Czech Republic,
Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the
Netherlands, Norway, Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland,
Turkey and the United Kingdom.
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2020 CENELEC All rights of exploitation in any form and by any means reserved worldwide for CENELEC Members.
Ref. No. EN IEC 63132-3:2020 E
European foreword
The text of document 4/382/FDIS, future edition 1 of IEC 63132-3, prepared by IEC/TC 4 "Hydraulic
turbines" was submitted to the IEC-CENELEC parallel vote and approved by CENELEC as
The following dates are fixed:
• latest date by which the document has to be implemented at national (dop) 2021-03-02
level by publication of an identical national standard or by endorsement
• latest date by which the national standards conflicting with the (dow) 2023-06-02
document have to be withdrawn
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CENELEC shall not be held responsible for identifying any or all such patent rights.
Endorsement notice
The text of the International Standard IEC 63132-3:2020 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 63132-1 NOTE Harmonized as EN IEC 63132-1
IEC 63132-2 NOTE Harmonized as EN IEC 63132-2
IEC 63132-3 ®
Edition 1.0 2020-04
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Guidance for installation procedures and tolerances of hydroelectric machines –
Part 3: Vertical Francis turbines or pump-turbines
Lignes directrices des procédures et tolérances d’installation des machines
hydroélectriques –
Partie 3: Turbines ou pompe-turbines Francis verticales
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 27.140 ISBN 978-2-8322-8103-1
– 2 – IEC 63132-3:2020 IEC 2020
CONTENTS
FOREWORD . 4
1 Scope . 6
2 Normative references . 6
3 Terms and definitions . 6
4 Installation flowchart . 6
4.1 Turbine embedded parts . 6
4.2 Turbine mechanical parts . 8
5 Steps . 10
5.1 Turbine embedded parts . 10
5.1.1 Step 1: Benchmarks set-up . 10
5.1.2 Step 2: Primary embedded pipes and draft tube liner foundation
installation . 10
5.1.3 Step 3: Draft tube liner foundation embedment . 10
5.1.4 Step 4: Draft tube liner foundation and workspace verification . 11
5.1.5 Step 5: Handing over to installation . 11
5.1.6 Step 6: Draft tube liner supports installation . 11
5.1.7 Step 7: Draft tube liner installation . 12
5.1.8 Step 8: Secondary embedded pipes installation around the draft tube
liner . 14
5.1.9 Step 9: Handing over to concreting phase. 14
5.1.10 Step 10: Draft tube liner embedment . 15
5.1.11 Step 11: Concrete voids testing . 15
5.1.12 Step 12: Draft tube liner grout injection . 16
5.1.13 Step 13: Handing over to installation . 16
5.1.14 Step 14: Draft tube liner dimensional inspection after embedment . 16
5.1.15 Step 15: Stay ring and spiral case supports installation . 17
5.1.16 Step 16: Stay ring installation . 17
5.1.17 Step 17: Spiral case installation . 18
5.1.18 Step 18: Pit liner(s) and/or servomotor base plates installation . 20
5.1.19 Step 19: Secondary embedded pipes installation around the spiral case . 21
5.1.20 Step 20: Spiral case pressure test . 21
5.1.21 Step 21: Handing over to concreting phase . 22
5.1.22 Step 22: Embedment up to generator floor . 22
5.1.23 Step 23: Remaining turbine embedded parts grout injection . 22
5.1.24 Step 24: Handing over to installation . 23
5.1.25 Step 25: Spiral case dimensional inspection after concreting . 23
5.1.26 Step 26: Corrosion protection for embedded parts . 23
5.1.27 Step 27: Turbine embedded parts complete . 23
5.1.28 Step 28: Turbine mechanical parts installation . 24
5.2 Turbine mechanical parts . 24
5.2.1 Step 1: Turbine embedded parts complete . 24
5.2.2 Step 2: Stay ring machining (if required) . 24
5.2.3 Step 3: Draft tube cone(s) installation . 24
5.2.4 Step 4: Bottom ring installation . 24
5.2.5 Step 5: Turbine runner installation . 26
5.2.6 Step 6: Turbine shaft installation . 26
5.2.7 Step 7: Turbine runner and shaft coupling . 27
IEC 63132-3:2020 IEC 2020 – 3 –
5.2.8 Step 8: Guide vane installation . 27
5.2.9 Step 9: Head cover installation . 27
5.2.10 Step 10: Shaft seal housing assembly . 29
5.2.11 Step 11: Guide bearing housing assembly . 29
5.2.12 Step 12: Regulating ring installation . 29
5.2.13 Step 13: Servomotors installation . 29
5.2.14 Step 14: Guide vane links and levers installation . 30
5.2.15 Step 15: Turbine shaft free . 30
5.2.16 Step 16: Generator installation . 31
5.2.17 Step 17: Turbine and generator shafts coupling . 31
5.2.18 Step 18: Unit alignment . 32
5.2.19 Step 19: Shaft seal final installation . 33
5.2.20 Step 20: Turbine guide bearing assembly and adjustment . 33
5.2.21 Step 21: Guide vane apparatus final adjustment . 34
5.2.22 Step 22: Remaining turbine parts installation completion . 34
5.2.23 Step 23: Cleaning, painting and inspection before initial tests . 34
5.2.24 Step 24: Turbine mechanical parts complete . 34
5.2.25 Step 25: Commissioning . 34
Bibliography . 35
Figure 1 – Generic installation flowchart – Francis turbine or pumped-turbine
embedded parts . 7
Figure 2 – Generic installation flowchart – Francis turbine or pumped-turbine
mechanical parts . 10
Figure 3 – Draft tube liner installation . 13
Figure 4 – Draft tube liner embedment plan . 15
Figure 5 – Stay ring installation . 18
Figure 6 – Spiral case installation . 20
Figure 7 – Bottom ring installation . 26
Figure 8 – Head cover installation . 28
Figure 9 – Turbine shaft free . 31
Table 1 – Concentricity and junction . 14
Table 2 – Elevation, level and pararellism . 19
Table 3 – Circularity and level . 25
Table 4 – Circularity and concentricity . 28
Table 5 – Runner concentricity, level and elevation . 30
Table 6 – Runner measurements . 32
Table 7 – Shaft measurements . 33
– 4 – IEC 63132-3:2020 IEC 2020
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
GUIDANCE FOR INSTALLATION PROCEDURES
AND TOLERANCES OF HYDROELECTRIC MACHINES –
Part 3: Vertical Francis turbines or pump-turbines
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 itself does not provide any attestation of conformity. Independent certification bodies provide conformity
assessment services and, in some areas, access to IEC marks of conformity. IEC is not responsible for any
services carried out by independent certification bodies.
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 63132-3 has been prepared by IEC technical committee 4: Hydraulic
turbines.
The text of this International Standard is based on the following documents:
FDIS Report on voting
4/382/FDIS 4/392/RVD
Full information on the voting for the approval of this International Standard can be found in the
report on voting indicated in the above table.
This document has been drafted in accordance with the ISO/IEC Directives, Part 2.
A list of all parts in the IEC 63132 series, published under the general title Guidance for
installation procedures and tolerances of hydroelectric machines, can be found on the IEC
website.
IEC 63132-3:2020 IEC 2020 – 5 –
The committee has decided that the contents of this document will remain unchanged until the
stability date indicated on the IEC website under "http://webstore.iec.ch" in the data related to
the specific document. At this date, the document will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
– 6 – IEC 63132-3:2020 IEC 2020
GUIDANCE FOR INSTALLATION PROCEDURES
AND TOLERANCES OF HYDROELECTRIC MACHINES –
Part 3: Vertical Francis turbines or pump-turbines
1 Scope
The purpose of this this part of IEC 63132 is to establish, in a general way, suitable procedures
and tolerances for the installation of a vertical Francis turbine or pump-turbine. This document
presents a typical assembly and whenever the word “turbine” is used in this document, it refers
to a vertical Francis turbine or a pump-turbine. There are many possible ways to assemble a
unit. The size of the machine, design of the machine, layout of the powerhouse or delivery
schedule of the components are some of the elements that could result in additional steps, the
elimination of some steps and/or assembly sequences.
It is understood that a publication of this type will be binding only if, and to the extent that, both
contracting parties have agreed upon it.
This document excludes matters of purely commercial interest, except those inextricably bound
up with the conduct of installation.
The tolerances in this document have been established upon best practices and experience,
although it is recognized that other standards specify different tolerances.
Wherever this document specifies that documents, drawings or information is supplied by a
manufacturer (or by manufacturers), each individual manufacturer will furnish the appropriate
information for their own supply only.
2 Normative references
There are no normative references in this document.
3 Terms and definitions
No terms and definitions are listed in this document.
ISO and IEC maintain terminological databases for use in standardization at the following
addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
4 Installation flowchart
4.1 Turbine embedded parts
Figure 1 shows a generic installation flowchart for Francis turbine or pumped-turbine embedded
parts.
IEC 63132-3:2020 IEC 2020 – 7 –
1 Benchmarks set-up
Primary embedded pipes and draft tube liner foundations
Remaining turbine embedded parts grout injection
installation
Handing over to installation
3 Draft tube liner foundations embedment
Spiral case dimensional inspection after concreting
Draft tube liner foundations and workspace verification
Corrosion protection of embedded parts
Handing over to installation
27 Turbine embedded parts complete
6 Draft tube liner supports installation
28 Turbine mechanical parts installation
7 Draft tube liner installation
Secondary embedded pipes installation around the draft
tube liner
9 Handing over to concreting phase
10 Draft tube liner embedment
11 Concrete voids testing
12 Draft tube liner grout injection
13 Handing over to installation
Draft tube liner dimensional inspection after embedment
15 Stay ring and spiral case supports installation
Stay ring installation
Standard tasks
17 Spiral case installation
Important milestones
Pit liner(s) installation and/or servomotor base plates
Joint effort of turbine and generator
installation
Current flowchart product installation complete
19 Secondary embedded pipes installation around spiral case
Reference to other flowcharts or activities
20 Spiral case pressure test
Handing over to concreting phase
22 Embedment up to generator floor
IEC
Figure 1 – Generic installation flowchart –
Francis turbine or pumped-turbine embedded parts
– 8 – IEC 63132-3:2020 IEC 2020
4.2 Turbine mechanical parts
Figure 2 shows a generic installation flowchart for Francis turbine or pumped-turbine
mechanical parts.
IEC 63132-3:2020 IEC 2020 – 9 –
Turbine mechanical parts complete
Stay ring machining
3 Draft tube cone(s) installation
4 Bottom ring installation
5 Turbine runner installation
Turbine shaft installation
7 Turbine runner and shaft coupling
Guide vanes installation
9 Head cover installation
Shaft seal housing assembly
Guide bearing housing assembly
12 Regulating ring installation
13 Servomotors installation
Guide vane links and levers installation
Turbine shaft free
16 Generator installation
Standard tasks
17 Turbine and generator shafts coupling
Important milestones
Unit alignment
Joint effort to turbine and generator
Shaft seal final installation
Current flowchart product installation complete
20 Turbine guide bearing assembly and adjustment
Reference to other flowcharts or activities
21 Guide vane apparatus final adjustment
22 Remaining turbine parts installation completion
23 Cleaning, painting and inspection before initial tests
Turbine machanical parts complete
25 Commissioning
IEC
NOTE The generator installation is linked to the turbine installation.
– 10 – IEC 63132-3:2020 IEC 2020
Figure 2 – Generic installation flowchart –
Francis turbine or pumped-turbine mechanical parts
5 Steps
5.1 Turbine embedded parts
5.1.1 Step 1: Benchmarks set-up
a) Objective of work in the step
– Set-up benchmarks to be used for starting proper installation of the turbine.
b) Explanation of work
– Sufficient benchmarks should be provided to establish the unit centreline, axis and
elevation.
c) Recommendations
N/A
d) Additional information
Depending on the project delivery system (EPC, design build, etc.), the benchmarks or their
reference points could be provided by the owner, civil contractor, etc. Whoever provides the
benchmarks or reference points is responsible to make sure they are correct.
The benchmark type (x, y, z coordinates, defining axis and elevations, etc.) should be
agreed to prior to the work commencing.
The turbine supplier/intaller should take care to transfer the necessary benchmarks
throughout the installation and/or concreting processes so that the benchmarks remain
accessible as the unit is assembled.
5.1.2 Step 2: Primary embedded pipes and draft tube liner foundation installation
a) Objective of work in the step
– Install the primary embedded pipes and steel foundations in the correct locations.
b) Explanation of work
– Install the primary embedded pipes and supporting systems.
– Install the foundation components of the draft tube liner.
c) Recommendations
Different designs require different tolerances; therefore, it is recommended that the turbine
supplier should provide the tolerances. It is considered as a best practice to perform:
– NDT as applicable (i.e. visual inspections, pressure tests of the piping, test of welding
seams);
– measures to prevent the concrete from entering the pipes or contaminating the machined
surfaces of foundations during concreting.
d) Additional information
The contract should define which party is responsible to install the primary embedded pipes
and/or the draft tube liner foundation components.
5.1.3 Step 3: Draft tube liner foundation embedment
a) Objective of work in the step
– Embed the foundation components of the draft tube liner and the primary embedded
piping in the concrete.
b) Explanation of work
– Embed the foundation components of the draft tube liner.
c) Recommendations
IEC 63132-3:2020 IEC 2020 – 11 –
Care should be taken not to damage any of the embedded components or piping when
pouring concrete.
d) Additional information
N/A
5.1.4 Step 4: Draft tube liner foundation and workspace verification
a) Objective of work in the step
– Confirm that the draft tube liner foundations have been installed in the correct place,
verifying that the draft tube pit for placing the draft tube liner is per the design and there
is sufficient access to the workplace.
b) Explanation of work
– Ensure that the dimensions of the draft tube pit match the design.
– Ensure that there will be no interference between the concrete structures, the reinforcing
steels, the scaffolding, etc., the foundation anchors, the embedded pipes and the draft
tube liner.
Once the workplace is acceptable the turbine installation work can start.
c) Recommendations
Check that the foundation components of the draft tube liner and the primary embedded
pipes were installed within the tolerances provided by the turbine supplier.
d) Additional information
N/A
5.1.5 Step 5: Handing over to installation
a) Objective of work in the step
– Transfer the work space to the turbine supplier/installer.
b) Explanation of work
– There is normally an official transfer of the working area of the draft tube from the civil
contractor to the turbine supplier/installer. Typically, the transfer is documented with
some types of signed form.
c) Recommendations
N/A
d) Additional information
N/A
5.1.6 Step 6: Draft tube liner supports installation
a) Objective of work in the step
– Install the draft tube liner supports.
b) Explanation of work
– Install the supports and installation devices (if required) for fixing the draft tube liner to
the base plates.
c) Recommendations
The following items should be checked:
– NDT of the site welded portion of supports (if applicable);
– dimensional checks of supports.
– 12 – IEC 63132-3:2020 IEC 2020
d) Additional information
In some cases, it will be advantageous for the civil contractor to be able to store the
reinforcement steel that will be installed in the draft tube and/or around the draft tube. It can
be significantly easier to move the reinforcement steel into this area prior to installation of
the draft tube liner. If this is the case, it should be discussed and agreed between parties.
5.1.7 Step 7: Draft tube liner installation
a) Objective of work in the step
– Install the draft tube liner (see Figure 3).
b) Explanation of work
– Transport the draft tube liner segments to the foundation and placing them on the
supports.
– Tack-weld of the draft tube liner segments.
– Inspect the alignment and principal dimensions of the draft tube liner before welding.
– Weld the draft tube liner.
– Inspect the alignment and principal dimensions of the draft tube liner after welding.
c) Recommendations
– The following items should be checked:
• NDT of the welding seams;
• the junction, concentricity of inlet, elevation, level, inclination (if required) and
principal dimensions of the draft tube liner should be checked and be within the
tolerances listed in Step 9: Handing over to concreting phase;
• proper fixation of the draft tube liner.
d) Additional information
The sequence for the installation of the draft tube liner should be provided by the turbine
supplier. See Figure 3.
In some designs, steel pier nose(s) are required and will be installed in this step.
If the downstream concrete portion of the draft tube cannot be completed prior to the
installation of the draft tube liner, the outlet position of the draft tube liner cannot be
determined by the junction method. Therefore, another method will be required to position
the outlet of draft tube liner. The downstream concrete portion would then be adapted to the
draft tube liner outlet.
Adequate supports or bracing are required to prevent the draft tube liner from moving or
changing shape during placing of the secondary concrete.
IEC 63132-3:2020 IEC 2020 – 13 –
Elevation, level and Radial readings on
flatness in line draft tube cone inlet
Theoretical unit axis
L
(Axial distance between steel and concrete)
Elevation, level and flatness in line
Theoretical unit axis
Radial readings on
draft tube cone inlet
Junction between
steel liner and concrete
L
(Axial distance between steel and concrete)
IEC
Figure 3 – Draft tube liner installation
Junction between
steel liner and concrete
– 14 – IEC 63132-3:2020 IEC 2020
5.1.8 Step 8: Secondary embedded pipes installation around the draft tube liner
a) Objective of work in the step
– Install the secondary embedded pipes.
b) Explanation of work
– Install the embedded pipes in the draft tube pit prior to concreting.
c) Recommendations
– The following items should be checked:
• NDT (i.e. visual inspections, pressure tests, test of welding seams);
• dimensional checks of locations of the pipes.
– The following preventive measures should be considered:
• support the pipes so they cannot move or be damaged during concreting;
• cover/block the pipe openings to prevent concrete from entering the pipes during
concreting.
d) Additional information
Secondary embedded pipes could include draft tube/spiral case dewatering piping,
balancing axial thrust piping, pressure tapping connections for testing or monitoring
purposes etc.
5.1.9 Step 9: Handing over to concreting phase
a) Objective of work in the step
– Transfer the work space to the civil contractor.
b) Explanation of work
– The turbine supplier should confirm that the draft tube liner has been installed and
aligned properly and is ready for concreting.
– There is normally an official transfer of the working area of the draft tube from the turbine
supplier/installer to the civil contractor. Typically, the transfer is documented with some
type of signed form.
c) Recommendations
The items showed in Table 1 should be checked.
Table 1 – Concentricity and junction
Item Tolerance Minimum no. of Measurement location
measurements
a
Concentricity of inlet 0,1 % of the runner Top surface
8 when RD < 4 m
diameter (RD)
a
16 when RD ≥ 4 m
Junction ± 5 % of L (mm) 8 when RD < 4 m Difference between the
outlet end of the draft
16 when RD ≥ 4 m
tube liner and the inlet of
the concrete portion of
the draft tube.
NOTE See Figure 3 for the definition of L.
a
If the draft tube liner inlet has a machined flange, then fewer measurements are required because the draft
tube liner stiffness will ensure it remains circular.
In addition to the above requirements, the elevation, level, inclination, circularity, orientation
in plan and principal dimensions should be checked. The values of these tolerances should
be provided by the turbine supplier.
The tolerances of the principal dimensions are defined by hydraulic requirements described
in the appropriate turbine supplier drawings.
IEC 63132-3:2020 IEC 2020 – 15 –
The draft tube liner should be set concentric to the theoretical unit axis (bench mark) and
centreline.
d) Additional information
The tolerances depend on the design of the connection method between the draft tube cone
and the draft tube liner, which can be either welded or bolted.
Level readings can be also used to check the elevation and inclination.
5.1.10 Step 10: Draft tube liner embedment
a) Objective of work in the step
– Embed the draft tube liner.
b) Explanation of work
– Install the reinforcement, placing of the formwork and then concreting.
c) Recommendations
The concrete pour rate, pour/step heights and allowable differential levels should be agreed
among the concerned parties during the early stages of project development, due to the
critical impacts (to schedule and costs) related to the design and installation of the draft
tube liner.
d) Additional information
Care should be taken when pouring concrete not to damage any of the embedded
components or piping.
Figure 4 shows an example of a concreting plan.
Elev. spiral case pit
Elev. draft tube access floor
Elev. V
Elev. IV
Elev. III
Elev. II
Elevation I
Elev. draft
tube pit
Elev.
excavation
Figure 4 – Draft tube liner embedment plan
5.1.11 Step 11: Concrete voids testing
a) Objective of work in the step
– Determine if there are hollow spaces (voids) between the draft tube liner and the
concrete.
b) Explanation of work
– A common method to detect hollow spaces is by tapping the inside surface of the draft
tube liner with a hammer.
– 16 – IEC 63132-3:2020 IEC 2020
c) Recommendations
While there is no established standard for determining the amount of voids that require
2 2
grouting, it is recommended that a single area greater than 0,1 m to 0,2 m depending on
unit size should be grouted. Also, a minimum of 80 % of the liner should be firmly in contact
with the concrete.
d) Additional information
Areas where there is no contact between the draft tube liner and the concrete will sound in
a different tone (resonance) when hit with a hammer.
5.1.12 Step 12: Draft tube liner grout injection
a) Objective of work in the step
– Fill the hollowed spaces between the draft tube liner and the concrete with grout.
b) Explanation of work
– Drill holes and fix connections for injecting grouting material.
– Drill air vents.
– Fill voids with grouting material.
c) Recommendations
Hollow space detection should be repeated after grout filling to ensure that no wide hollow
spaces are left.
d) Additional information
The grouting pressure should be determined during the early stages of project development
due to the impacts (on schedule and costs) of the design of the draft tube. Some owners
will specify the grouting pressure.
Typical hydrostatic pressures for grouting range from 50 kPa to 200 kPa.
5.1.13 Step 13: Handing over to installation
a) Objective of work in the step
– Transfer the work space to the turbine supplier/installer.
b) Explanation of work
– There is normally an official transfer of the working area from the civil contractor to the
turbine supplier/installer. Typically, the transfer is documented with some types of signed
form.
c) Recommendations
N/A
d) Additional information
N/A
5.1.14 Step 14: Draft tube liner dimensional inspection after embedment
a) Objective of work in the step
– Determine if the dimensions and positions of the draft tube liner changed during
concreting.
b) Explanation of work
– Measurements are taken to confirm that the draft tube liner did not distort or move during
placement of the concrete.
c) Recommendations
Confirm, after concreting, that the concentricity is within the tolerance specified in Step 9:
Handing over to concreting phase. The elevation and level should also be checked to
confirm if they are within the tolerances given by the turbine supplier.
IEC 63132-3:2020 IEC 2020 – 17 –
d) Additional information
The centre of the draft tube liner will become the reference centre for installing the stay ring
and bottom ring.
In some cases, depending on the design of the draft tube liner, the centre of the draft tube
liner will not become the reference centre for installing the stay ring. In these cases, the
theoretical unit centre will be the reference centre for the stay ring.
The as-set elevation of the draft tube liner may influence the installation of the remainder of
the turbine and generator.
5.1.15 Step 15: Stay ring and spiral case supports installation
a) Objective of work in the step
– Install the stay ring and spiral case supports.
b) Explanation of work
– Install the supports for the stay ring and the spiral case.
– The nature, number and position of the supports will be determined by the turbine
supplier.
c) Recommendations
The tolerances should be provided by the turbine supplier. The location, elevation and level
of the supports for the stay ring and spiral case may need to be checked depending on the
design.
d) Additional information
Depending on the design of the supports, intermediate concreting may be required.
5.1.16 Step 16: Stay ring installation
a) Objective of work in the step
– Install the stay ring (see Figure 5).
b) Explanation of work
– Assemble the stay ring.
– Install and align (centre, level, elevation, etc.) and then anchor the stay ring.
– Weld the stay ring split lines (if applicable).
c) Recommendations
The following items should be checked:
– the circularity and the dimension of the stay ring should satisfy the tolerances listed in
Step 17: Spiral case installation;
– orientation in plan;
– the deformation of the stay ring from time to time, during welding;
– NDT of the welding seams.
d) Additional information
N/A
– 18 – IEC 63132-3:2020 IEC 2020
Elevation, level and flatness in line
Radial reading on upper stay ring flange
Elevation, level and flatness in line
Radial readings on lower stay ring flange
IEC
Figure 5 – Stay ring installation
5.1.17 Step 17: Spiral case installation
a) Objective of work in the step
– Install the spiral case.
b) Explanation of work
– Assemble and tack-weld the spiral case.
– Weld the spiral case shells.
– Weld the spiral case to the stay ring.
– Weld the connection piece (pipe/penstock) to the spiral case.
– Install the internal reinforcement (if applicable) and the external anchors for the spiral
case.
– Inspect the alignment of the spiral case and stay ring after finishing spiral case welding.
c) Recommendations
The items showed in Table 2 should be checked.
IEC 63132-3:2020 IEC 2020 – 19 –
Table 2 – Elevation, level and parallelism
Item Tolerance Minimum No. of Measurement location
measurements
Stay ring elevation ± 3 mm Half the number of guide Either the upper (head
vanes cover) or lower (bottom
ring) flange or the marked
centre of the stay vanes
depending on the design
a
Stay ring level Half the number of guide Each flange
0,05 mm/m
vanes on each flange
20 % of the total of the Half the number of guide
Parallelism Each flange
guide vane top clearance vanes
and guide vane bottom
clearance (mm)
a
Tolerance based on flange diameter; as an example, for a flange diameter of 5 m, the tolerance on level is
0,25 mm.
In addition to the above requirements, stay ring concentricity, stay ring circularity, spiral
case inlet concentricity, spiral case inclination, stay ring flatness in line, orientation in plan
and spiral case principal dimensions should be checked. The values of these tolerances
should be provided by the turbine supplier.
The stay ring should be installed so that the stay vane centreline is coincident with the
theoretical elevation. The turbine supplier should provide the principal dimensions from the
stay vane centreline to both upper and lower flanges (measured at the shop), even though
the centre mark is put on the stay ring.
The stay ring should be installed concentric to the centre of the embedded draft tube liner.
The spiral case inlet should be installed concentric to the penstock centre. Depending on
the design, the inclination, waviness and junction at the inlet of the spiral case may need to
be checked to ensure proper connection to the penstock or the inlet pipes. See Figure 6.
Check for deformation of the spiral case from time to time during the welding.
NDT of welding seams should be checked.
d) Additional information
The turbine supplier should provide the sequence for the installation of the spiral case.
Depending on the amount of radial adjustment of the bottom ring in the stay ring, the centre
of the stay ring may become the reference for installing the bottom ring. In cases where
there is a lot of radial adjustability between the bottom ring and the stay ring, the centre of
the draft tube liner may remain as the reference centre for installing the bottom ring. The
turbine supplier must determine which component should be the reference centre for the
bottom ring prior to the stay ring installation and communicate the decision prior to stay ring
installation.
In some cases, the outside of the spiral case is protected against corrosion.
In the case of the embedded type of draft tube cone and bottom ring, these may be
embedded together with the spiral case. These components are installed before or after
installing the stay ring and spiral case, depending on the design. The tolerances are the
same as in Step 4: Bottom ring installation in the Turbine mechanical parts.
For the embedded draft tube cone, the following steps are considered:
– to assemble the draft tube cone;
– to install the draft tube cone on the draft tube liner (sometimes temporarily);
– to assemble the bottom r
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