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2、ehabilitation and performance improvementICS 27.140Hydraulic turbines, storage pumps and pump-turbines BRITISH STANDARDBS EN 62256:2008BS EN 62256:2008Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 17/12/2008 00:19, Uncontrolled Copy, (c) BSIThis British Standard was published under the auth
3、ority of the Standards Policy and Strategy Committee on 29 August 2008 BSI 2008ISBN 978 0 580 54882 6Amendments/corrigenda issued since publicationDate Commentscontract. Users are responsible for its correct application.Compliance with a British Standard cannot confer immunity from legal obligations
4、.National forewordThis British Standard is the UK implementation of EN 62256:2008. It is identical to IEC 62256:2008. The UK participation in its preparation was entrusted to Technical Committee MCE/15, Hydraulic turbines.A list of organizations represented on this committee can be obtained on reque
5、st to its secretary.This publication does not purport to include all the necessary provisions of a EUROPEAN STANDARD EN 62256 NORME EUROPENNE EUROPISCHE NORM May 2008 CENELEC European Committee for Electrotechnical Standardization Comit Europen de Normalisation Electrotechnique Europisches Komitee f
6、r 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 ICS 27.140 English version Hydraulic turbines, storage pumps and pump-turbine
7、s - Rehabilitation and performance improvement (IEC 62256:2008) Turbines hydrauliques, pompes daccumulation et pompes turbines - Rhabilitation et amlioration des performances (CEI 62256:2008) Wasserturbinen, Speicherpumpen und Pumpturbinen - Modernisierung und Verbesserung der Leistungseigenschaften
8、 (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 an
9、d 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 respon
10、sibility 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,
11、 Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom. Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 17/12/2008 00:19, Uncontrolled Copy, (c)
12、BSIForeword 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 implemente
13、d 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
14、 CENELEC as a European Standard without any modification. _ BS EN 62256:2008 2 Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 17/12/2008 00:19, Uncontrolled Copy, (c) BSICONTENTS INTRODUCTION.7 1 Scope and object8 2 Nomenclature .8 3 Reasons for rehabilitating.9 3.1 General .9 3.2 Reliabilit
15、y and availability increase 11 3.3 Life extension and performance restoration .12 3.4 Performance improvement.12 3.5 Plant safety improvement 12 3.6 Environmental, social and regulatory issues 12 3.7 Maintenance and operating cost reduction.13 3.8 Other considerations .13 4 Phases of a rehabilitatio
16、n project13 4.1 General .13 4.2 Decision on organization .15 4.2.1 General .15 4.2.2 Expertise required .15 4.2.3 Contract arrangement16 4.3 Level of assessment and determination of scope.16 4.3.1 General .16 4.3.2 Feasibility study Stage 1.17 4.3.3 Feasibility study Stage 2.17 4.3.4 Detailed study
17、.17 4.4 Contractual issues.23 4.4.1 General .23 4.4.2 Specification requirements 23 4.4.3 Tendering documents and evaluation of tenders23 4.4.4 Contract Award(s)24 4.5 Execution of project.24 4.5.1 Model test activities.24 4.5.2 Design, construction, installation and testing .25 4.6 Evaluation of re
18、sults and compliance with guarantees .25 4.6.1 General .25 4.6.2 Turbine performance evaluation 26 4.6.3 Generator performance evaluation.26 4.6.4 Penalties and/or bonuses assessment.26 5 Scheduling, cost analysis and risk analysis 26 5.1 Scheduling 26 5.1.1 General .26 5.1.2 Scheduling Assessment,
19、feasibility and detailed study phases27 5.1.3 Evaluating the scheduling component of alternatives.27 5.1.4 Scheduling specification and tendering phase .28 5.1.5 Scheduling project execution phases.29 5.2 Economic and financial analyses.29 BS EN 62256:2008 3 Licensed Copy: Wang Bin, ISO/EXCHANGE CHI
20、NA STANDARDS, 17/12/2008 00:19, Uncontrolled Copy, (c) BSI5.2.1 General .29 5.2.2 Benefit-cost analysis .30 5.2.3 Identification of anticipated benefits.31 5.2.4 Identification of anticipated costs and benefits.32 5.2.5 Sensitivity analysis 33 5.2.6 Conclusions.34 5.3 Risk analysis .34 5.3.1 General
21、 .34 5.3.2 Non-achievement of performance risk35 5.3.3 Risk of continued operation without rehabilitation 35 5.3.4 Extension of outage risk 35 5.3.5 Financial risks .36 5.3.6 Project scope risk36 5.3.7 Other risks.37 6 Assessment and determination of scope of the work.37 6.1 General .37 6.2 Assessme
22、nt of the site 38 6.2.1 Hydrology38 6.2.2 Actual energy production .38 6.2.3 Environmental social and regulatory issues .39 6.3 The assessment of the turbine 40 6.3.1 General .40 6.3.2 Turbine integrity assessment .69 6.3.3 Residual life 78 6.3.4 Turbine performance assessment 79 6.4 The assessment
23、of related equipment .101 6.4.1 General .101 6.4.2 Generator and thrust bearing.106 6.4.3 Turbine governor .108 6.4.4 Turbine inlet and outlet valves, pressure relief valve108 6.4.5 Auxiliary equipment .108 6.4.6 Equipment for erection, dismantling and maintenance .109 6.4.7 Penstock and other water
24、 passages 109 6.4.8 Consequences of changes in plant specific hydraulic energy (head)110 7 Hydraulic design and performance testing options110 7.1 General .110 7.2 Computational hydraulic design.111 7.2.1 General .111 7.2.2 The role of CFD.112 7.2.3 The process of a CFD cycle.112 7.2.4 The accuracy
25、of CFD results .113 7.2.5 How to use CFD for rehabilitation 114 7.2.6 CFD versus model tests 114 7.3 Model tests115 7.3.1 General .115 7.3.2 Model test similitude116 7.3.3 Model test content .116 7.3.4 Model test application117 7.3.5 Model test location 119 BS EN 62256:2008 4 Licensed Copy: Wang Bin
26、, ISO/EXCHANGE CHINA STANDARDS, 17/12/2008 00:19, Uncontrolled Copy, (c) BSI7.4 Prototype performance test .120 7.4.1 General .120 7.4.2 Prototype performance test accuracy.121 7.4.3 Prototype performance test types 122 7.4.4 Evaluation of results 122 8 Specifications.123 8.1 General .123 8.2 Refere
27、nce standards .123 8.3 Information to be included in the tender documents.124 8.4 Documents to be developed in the course of the project126 Bibliography128 Figure 1 Flow diagram depicting the logic of the rehabilitation process 14 Figure 2 Critical zones for cracks “A” and “B” in Pelton runner bucke
28、ts 77 Figure 3 Relative efficiency versus relative output Original and new runners.81 Figure 4 Relative efficiency versus output Original and new runners Outardes 3 generating station .82 Figure 5 Efficiency and distribution of losses versus specific speed for Francis turbines (model) in 2005 .83 Fi
29、gure 6 Relative efficiency gain following modification of the blades on the La Grande 3 runner, in Quebec, Canada.85 Figure 7a Potential efficiency improvement for Francis turbine rehabilitation90 Figure 7b Potential efficiency improvement for Kaplan turbine rehabilitation 91 Figure 8 Cavitation and
30、 corrosion-erosion in Francis runner.92 Figure 9 Back side erosion of the entrance into a Pelton bucket.93 Figure 10 Leading edge cavitation erosion on a Franis pump-turbine caused by extended periods of operation at very low loads94 Figure 11 Severe particle erosion damage in a Francis runner.96 Ta
31、ble 1 Expected life of a hydropower plant and its subsystems before major work .11 Table 2 Assessment of turbine embedded parts Stay ring .42 Table 3 Assessment of turbine embedded parts Spiral or semi-spiral case43 Table 4 Assessment of turbine embedded parts Discharge ring 44 Table 5 Assessment of
32、 turbine embedded parts Draft tube45 Table 6 Assessment of turbine non-embedded, non-rotating parts Headcover.46 Table 7 Assessment of turbine non-embedded, non-rotating parts Intermediate and inner headcovers 49 Table 8 Assessment of turbine non embedded, non rotating parts Bottom ring50 Table 9 As
33、sessment of turbine non embedded, non rotating parts Guide vanes 52 Table 10 Assessment of turbine non embedded, non rotating parts Guide vane operating mechanism54 Table 11 Assessment of turbine non embedded, non rotating parts Operating ring55 Table 12 Assessment of turbine non embedded, non rotat
34、ing parts Servomotors 56 Table 13 Assessment of turbine non embedded, non rotating parts Guide bearings 57 BS EN 62256:2008 5 Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 17/12/2008 00:19, Uncontrolled Copy, (c) BSITable 14 Assessment of turbine non embedded, non rotating parts Turbine sha
35、ft seal (mechanical seal or packing box) 59 Table 15 Assessment of turbine non embedded, non rotating parts Thrust bearing support .59 Table 16 Assessment of turbine non embedded, non rotating parts Nozzles .60 Table 17 Assessment of turbine non embedded, non rotating parts Deflectors and energy dis
36、sipation.60 Table 18a Assessment of turbine rotating parts Runner 61 Table 18b Assessment of turbine rotating parts Runner 64 Table 18c Assessment of turbine rotating parts Runner 65 Table 19 Assessment of turbine rotating parts Turbine shaft .66 Table 20 Assessment of turbine rotating parts Oil hea
37、d and oil distribution pipes67 Table 21 Assessment of turbine auxiliaries Speed and load regulation system (governor).67 Table 22 Assessment of turbine auxiliaries Turbine aeration system .68 Table 23 Assessment of turbine auxiliaries Lubrication system (guide vane mechanism) 69 Table 24 Francis tur
38、bine potential efficiency improvement (%) for runner profile modifications only .84 Table 25 Potential impact of design and condition of runner seals on Francis turbine efficiency with new replacement runner or rehabilitated runner (%).87 Table 26 Potential total gain in efficiency from the replacem
39、ent of a Francis turbine runner including the blade profile improvements, the restoration of surface condition and the reduction of seal losses88 Table 27 Potential Additional Efficiency Improvement by Rehabilitation/Replacement of Other Water Passage Components on a Francis Turbine (%)88 Table 28 A
40、ssessment of related equipment - Governor 103 Table 29 Assessment of related equipment Generator and thrust bearing .104 Table 30 Assessment of related equipment Penstock and turbine inlet valves.105 Table 31 Assessment of related equipment Civil works .106 Table 32 Assessment of related equipment C
41、rane, erection equipment.106 BS EN 62256:2008 6 Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 17/12/2008 00:19, Uncontrolled Copy, (c) BSIINTRODUCTION Hydro plant owners make significant investments annually in rehabilitating plant equipment (turbines, generators, transformers, penstocks, g
42、ates 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
43、 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
44、acknowledges that the IEA document provided a good foundation upon which to build this IEC document. BS EN 62256:2008 7 Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 17/12/2008 00:19, Uncontrolled Copy, (c) BSIHYDRAULIC TURBINES, STORAGE PUMPS AND PUMP-TURBINES REHABILITATION AND PERFORMANC
45、E 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 gu
46、ide, 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 rehabi
47、litation. 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 rehabi
48、litation 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 t
49、he points that should be addressed in the decision processes. The Guide is not intended to be a detailed engineering manual nor a maintenance guide. 2 Nomenclature For the purpose of this document, the term “rehabilitation” is defined as some combination of: restoration of equipment capacity and/or equipment efficiency to near “as-new” levels; BS EN 62256:200
