SIST EN 62256:2017
(Main)Hydraulic turbines, storage pumps and pump-turbines - Rehabilitation and performance improvement (IEC 62256:2017)
Hydraulic turbines, storage pumps and pump-turbines - Rehabilitation and performance improvement (IEC 62256:2017)
This document covers turbines, storage pumps and pump-turbines of all sizes and of the
following types:
• Francis;
• Kaplan;
• propeller;
• Pelton (turbines only);
• bulb turbines.
This document 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 document is to assist in identifying, evaluating and executing rehabilitation
and performance improvement projects for hydraulic turbines, storage pumps and pumpturbines.
This document 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.
This document 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 to be addressed in the decision processes.
This document is not intended to be a detailed engineering manual nor a maintenance
document.
Wasserturbinen, Speicherpumpen und Pumpturbinen - Modernisierung und Verbesserung der Leistungseigenschaften (IEC 62256:2017)
Turbines hydrauliques, pompes d'accumulation et pompes turbines - Réhabilitation et amélioration des performances (IEC 62256:2017)
NEW!IEC 62256:2017 est disponible sous forme de IEC 62256:2017 RLV qui contient la Norme internationale et sa version Redline, illustrant les modifications du contenu technique depuis l'édition précédente.
Vodne turbine, akumulacijske črpalke in črpalne turbine - Prenavljanje in izboljšanje delovanja (IEC 62256:2017)
Ta dokument zajema turbine, črpalke za shranjevanje in črpalne turbine vseh velikosti in naslednjih tipov:
• Francis;
• Kaplan;
• propeler;
• Pelton (samo turbine);
• turbine bučke.
Ta dokument tudi brez podrobne razprave prepozna drugo gonilno opremo, ki bi lahko vplivala na turbino, črpalko za shranjevanje ali sanacijo črpalne turbine ali pa bi te lahko vplivale nanjo.
Cilj tega dokumenta je pomagati pri prepoznavanju, vrednotenju in izvajanju projektov sanacije in izboljšanja delovanja hidravličnih turbin, črpalk za shranjevanje in črpalnih turbin.
Ta dokument lahko uporabljajo lastniki, svetovalci in dobavitelji za opredelitev:
• potreb in poslovanja za sanacijo in izboljšanje delovanja;
• področja uporabe dela;
• specifikacij;
• ovrednotenja rezultatov.
Ta dokument je namenjen za:
• pomoč v procesu odločanja;
• obširen vir informacij o sanaciji;
• opredelitev ključnih mejnikov v procesu sanacije;
• opredelitev točk, ki jih je treba obravnavati v procesih odločanja.
Ta dokument ni namenjen kot podroben inženirski priročnik niti dokument za vzdrževanje.
General Information
Relations
Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Wasserturbinen, Speicherpumpen und Pumpturbinen - Modernisierung und Verbesserung der Leistungseigenschaften (IEC 62256:2017)Turbines hydrauliques, pompes d'accumulation et pompes turbines - Réhabilitation et amélioration des performances (IEC 62256:2017)Hydraulic turbines, storage pumps and pump-turbines - Rehabilitation and performance improvement (IEC 62256:2017)27.140Vodna energijaHydraulic energy engineeringICS:Ta slovenski standard je istoveten z:EN 62256:2017SIST EN 62256:2017en01-oktober-2017SIST EN 62256:2017SLOVENSKI
STANDARDSIST EN 62256:20081DGRPHãþD
SIST EN 62256:2017
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 62256
September 2017 ICS 27.140
Supersedes
EN 62256:2008
English Version
Hydraulic turbines, storage pumps and pump-turbines - Rehabilitation and performance improvement (IEC 62256:2017)
Turbines hydrauliques, pompes d'accumulation et pompes turbines - Réhabilitation et amélioration des performances (IEC 62256:2017)
Wasserturbinen, Speicherpumpen und Pumpturbinen - Modernisierung und Verbesserung der Leistungseigenschaften (IEC 62256:2017) This European Standard was approved by CENELEC on 2017-07-04. 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, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, 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: Avenue Marnix 17,
B-1000 Brussels © 2017 CENELEC All rights of exploitation in any form and by any means reserved worldwide for CENELEC Members.
Ref. No. EN 62256:2017 E SIST EN 62256:2017
EN 62256:2017 2 European foreword The text of document 4/323/FDIS, future edition 2 of IEC 62256, prepared by IEC TC 4 "Hydraulic turbines" was submitted to the IEC-CENELEC parallel vote and approved by CENELEC as EN 62256:2017. The following dates are fixed: • latest date by which the document has to be implemented at national level by publication of an identical national standard or by endorsement (dop) 2018-04-04 • latest date by which the national standards conflicting with the document have to be withdrawn (dow) 2020-07-04
This document supersedes EN 62256:2008. 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 62256:2017 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. IEC 60193 NOTE Harmonized as EN 60193. IEC 60609 (Series) NOTE Harmonized as EN 60609 (Series). IEC 60994 NOTE Harmonized as EN 60994. IEC 62097 NOTE Harmonized as EN 62097. IEC 62364 NOTE Harmonized as EN 62364.
SIST EN 62256:2017
IEC 62256 Edition 2.0 2017-05 INTERNATIONAL STANDARD
Hydraulic turbines, storage pumps and pump-turbines – Rehabilitation and performance improvement
INTERNATIONAL ELECTROTECHNICAL COMMISSION
ICS 27.140
ISBN 978-2-8322-4340-4
® Registered trademark of the International Electrotechnical Commission ®
Warning! Make sure that you obtained this publication from an authorized distributor. SIST EN 62256:2017 colourinside
– 2 – IEC 62256:2017 © IEC 2017 CONTENTS FOREWORD . 7 INTRODUCTION . 9 1 Scope . 10 2 Normative references . 10 3 Terms, definitions and nomenclature . 10 4 Reasons for rehabilitating . 12 4.1 General . 12 4.2 Reliability and availability increase. 14 4.3 Life extension and performance restoration . 14 4.4 Performance improvement . 14 4.5 Plant safety improvement . 14 4.6 Environmental, social and regulatory issues . 15 4.7 Maintenance and operating cost reduction . 15 4.8 Other considerations . 15 5 Phases of a rehabilitation project . 15 5.1 General . 15 5.2 Decision on organization . 17 5.2.1 General . 17 5.2.2 Expertise required . 17 5.2.3 Contract arrangement . 17 5.3 Level of assessment and determination of scope . 18 5.3.1 General . 18 5.3.2 Feasibility study – Stage 1 . 19 5.3.3 Feasibility study – Stage 2 . 19 5.3.4 Detailed study. 19 5.4 Contractual issues . 23 5.4.1 General . 23 5.4.2 Specification requirements . 24 5.4.3 Tendering documents and evaluation of tenders . 24 5.4.4 Contract award(s) . 25 5.5 Execution of project . 25 5.5.1 Model test activities . 25 5.5.2 Design, construction, installation and testing . 25 5.6 Evaluation of results and compliance with guarantees . 26 5.6.1 General . 26 5.6.2 Turbine performance evaluation. 26 5.6.3 Generator performance evaluation . 27 5.6.4 Penalties and/or bonuses assessment . 27 6 Scheduling, cost analysis and risk analysis . 27 6.1 Scheduling . 27 6.1.1 General . 27 6.1.2 Scheduling – Assessment, feasibility and detailed study phases . 28 6.1.3 Evaluating the scheduling component of alternatives . 28 6.1.4 Scheduling specification and tendering phase . 29 6.1.5 Scheduling project execution phases . 29 6.2 Economic and financial analyses . 29 SIST EN 62256:2017
IEC 62256:2017 © IEC 2017 – 3 – 6.2.1 General . 29 6.2.2 Benefit-cost analysis . 30 6.2.3 Identification of anticipated benefits . 31 6.2.4 Identification of anticipated costs and benefits . 32 6.2.5 Sensitivity analysis . 33 6.2.6 Conclusions . 34 6.3 Risk analysis. 34 6.3.1 General . 34 6.3.2 Non-achievement of performance risk . 34 6.3.3 Risk of continued operation without rehabilitation . 35 6.3.4 Extension of outage risk . 35 6.3.5 Financial risks . 35 6.3.6 Project scope risk . 36 6.3.7 Other risks . 36 7 Assessment and determination of scope of the work . 37 7.1 General . 37 7.2 Assessment of the site . 37 7.2.1 Hydrology . 37 7.2.2 Actual energy production . 38 7.2.3 Environmental, social and regulatory issues . 38 7.3 The assessment of the turbine . 39 7.3.1 General . 39 7.3.2 Turbine integrity assessment . 39 7.3.3 Residual life. 52 7.3.4 Turbine performance assessment . 61 7.4 The assessment of related equipment . 83 7.4.1 General . 83 7.4.2 Generator and thrust bearing . 84 7.4.3 Turbine governor . 84 7.4.4 Turbine inlet and outlet valves, pressure relief valve . 85 7.4.5 Auxiliary equipment . 85 7.4.6 Equipment for erection, dismantling and maintenance . 86 7.4.7 Penstock and other water passages . 86 7.4.8 Consequences of changes in plant specific hydraulic energy (head) . 86 7.4.9 Grid integration . 87 8 Hydraulic design and performance testing options . 87 8.1 General . 87 8.2 Computational hydraulic design . 88 8.2.1 General . 88 8.2.2 The role of CFD . 88 8.2.3 The process of a CFD cycle . 89 8.2.4 The accuracy of CFD results . 89 8.2.5 How to use CFD for rehabilitation . 90 8.2.6 CFD versus model tests . 91 8.3 Model tests . 91 8.3.1 General . 91 8.3.2 Model test similitude . 92 8.3.3 Model test content . 93 8.3.4 Model test application . 93 SIST EN 62256:2017
– 4 – IEC 62256:2017 © IEC 2017 8.3.5 Model test location . 95 8.4 Prototype performance test . 96 8.4.1 General . 96 8.4.2 Prototype performance test accuracy . 97 8.4.3 Prototype performance test types . 97 8.4.4 Evaluation of results . 98 9 Specifications . 99 9.1 General . 99 9.2 Reference standards . 99 9.3 Information to be included in the tender documents . 100 9.4 Documents to be developed in the course of the project . 101
(informative)
Check-list for evaluation of existing turbine . 103 Annex A (informative)
Assessment examples . 136 Annex BB.1 General . 136 B.2 Runner (applicable to Francis, Kaplan, propeller and Pelton) . 136 B.2.1 Documentation – available data . 136 B.2.2 Design review . 137 B.2.3 Inspection items . 137 B.2.4 Assessment of inspection results . 138 B.2.5 Current condition assessment . 140 B.2.6 Scope of work . 140 B.3 Stay ring . 142 B.3.1 Documentation – available data . 142 B.3.2 Design review . 142 B.3.3 Inspection items . 142 B.3.4 Assessment of inspection results . 143 B.3.5 Current condition assessment . 143 B.3.6 Scope of work (possible action to be taken) . 144 B.4 Guide vanes . 144 B.4.1 Documentation –
Available data. 144 B.4.2 Design review . 145 B.4.3 Inspection items . 145 B.4.4 Assessment of inspection results . 146 B.4.5 Current condition assessment . 147 B.4.6 Scope of work . 147 B.5 Real life example:
Pelton runner with severe crack . 148 B.5.1 Data of the Pelton runner . 148 B.5.2 Fatigue analysis . 148 B.5.3 Fracture-mechanics analysis . 150 B.5.4 Results for the Pelton runner . 150
(informative)
Checklist for evaluation of related equipment . 152 Annex CBibliography . 156
Figure 1 – Flow diagram depicting the logic of the rehabilitation process . 16 Figure 2 – Critical zones for cracks “A” and “B” in Pelton runner buckets . 51 Figure 3 – Bathtub curve . 53 Figure 4 – Process of residual life estimation . 54 Figure 5 – Schematic behaviour for the different stages in the fatigue process . 55 SIST EN 62256:2017
IEC 62256:2017 © IEC 2017 – 5 – Figure 6 – Start-up and full load strain gauge signal on Francis blade . 60 Figure 7 – Relative efficiency versus relative output – Original and new runners . 63 Figure 8 – Relative efficiency versus output – Original and new runners – Outardes 3 generating station . 64 Figure 9 – Efficiency and distribution of losses versus specific speed for Francis turbines (model) in 2005 . 65 Figure 10 – Relative efficiency gain following modification of the blades on the La Grande 3 runner, in Quebec, Canada . 67 Figure 11 – Potential efficiency improvement for Francis turbine rehabilitation . 71 Figure 12 – Potential efficiency improvement for Kaplan turbine rehabilitation . 72 Figure 13 – Cavitation and corrosion-erosion in Francis runner . 74 Figure 14 – Back side erosion of the entrance into a Pelton bucket . 75 Figure 15 – Leading edge cavitation erosion on a Francis pump-turbine caused by extended periods of operation at very low loads . 76 Figure 16 – Severe particle erosion damage in a Francis runner . 78
Table 1 – Expected life of a hydropower plant and its subsystems before major work . 13 Table 2 – Typical routine inspections . 41 Table 3 – Example of a rating system for the inspection results . 58 Table 4 – Example of a typical list of turbine components for Francis and Kaplan
with different weight factors X1 to X7 based on relative importance . 59 Table 5 – Example of rating of a single component
assessment including three assessment criteria . 59 Table 6 – Francis turbine potential efficiency improvement (%) for runner profile modifications only . 66 Table 7 – Potential impact of design and condition of runner seals on Francis turbine efficiency with new replacement runner or rehabilitated runner (%) . 69 Table 8 – 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 . 69 Table 9 – Potential additional efficiency improvement by rehabilitation/replacement of other water passage components on a Francis turbine (%) . 70 Table A.1 – Assessment of turbine embedded parts – Stay ring . 103 Table A.2 – Assessment of turbine embedded parts – Spiral or semi-spiral case . 104 Table A.3 – Assessment of turbine embedded parts – Discharge ring . 105 Table A.4 – Assessment of turbine embedded parts – Draft tube . 107 Table A.5 – Assessment of turbine non-embedded, non-rotating parts – Headcover . 109 Table A.6 – Assessment of turbine non-embedded, non-rotating parts – Intermediate and inner headcovers . 112 Table A.7 – Assessment of turbine non embedded, non-rotating parts – Bottom ring . 113 Table A.8 – Assessment of turbine non embedded, non-rotating parts – Guide vanes . 115 Table A.9 – Assessment of turbine non embedded, non-rotating parts – Guide vane operating mechanism . 117 Table A.10 – Assessment of turbine non embedded, non-rotating parts – Operating ring . 118 Table A.11 – Assessment of turbine non embedded, non-rotating parts – Servomotors . 119 Table A.12 – Assessment of turbine non embedded, non-rotating parts – Guide bearings. 120 SIST EN 62256:2017
– 6 – IEC 62256:2017 © IEC 2017 Table A.13 – Assessment of turbine non embedded, non-rotating parts – Turbine shaft seal (mechanical seal or packing box) . 122 Table A.14 – Assessment of turbine non embedded, non-rotating parts – Thrust bearing support . 122 Table A.15 – Assessment of turbine non embedded, non-rotating parts – Nozzles . 123 Table A.16 – Assessment of turbine non embedded, non-rotating parts – Deflectors and energy dissipation . 124 Table A.17 – Assessment of turbine rotating parts – Runner . 125 Table A.18 – Assessment of turbine rotating parts – Runner . 128 Table A.19 – Assessment of turbine rotating parts – Runner . 130 Table A.20 – Assessment of turbine rotating parts – Turbine shaft . 131 Table A.21 – Assessment of turbine rotating parts – Oil head and oil distribution pipes . 132 Table A.22 – Assessment of turbine auxiliaries – Speed and load regulation system (governor) . 133 Table A.23 – Assessment of turbine auxiliaries – Turbine aeration system . 134 Table A.24 – Assessment of turbine auxiliaries – Lubrication system (guide vane mechanism) . 135 Table C.1 – Assessment of related equipment – Governor . 152 Table C.2 – Assessment of related equipment – Generator and thrust bearing . 153 Table C.3 – Assessment of related equipment – Penstock and turbine inlet valves . 154 Table C.4 – Assessment of related equipment – Civil works . 155 Table C.5 – Assessment of related equipment – Crane, erection equipment . 155
SIST EN 62256:2017
IEC 62256:2017 © IEC 2017 – 7 – 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
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