Download - RP-H-N-I-P-001
-
RAINPOWER AS
0 2013-03-15 Issued first time E. Larsen J. Jensen
Rev Date Description Written by Dept Appr
R:\Kjeller\Projects\Cheves.pel\Order-2010\16 Site and HMS\Installation procedures\Gov & OPS\RP-H-N-I-P-001_Rev 0 Gov
installation.doc
PROCEDURE FOR INSTALLATION OF THE GOVERNOR
SN POWER CHEVES HEPP
PELTON TURBINE Unit 1 and 2
Document No.: RP-H-N-I-P-001 ARA000273-O1N
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Document
PROCEDURE
SN POWER Cheves HEPP - Pelton turbine unit 1 and 2
Document no.: ARA000273-O1N
KH doc. no.: Revision No.: 0
Page 2 of 11 Subject: Installation procedure for governor
First issued date: 2013-03-15
This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.
R:\Kjeller\Projects\Cheves.pel\Order-2010\16 Site and HMS\Installation procedures\Gov & OPS\RP-H-N-I-P-001_Rev 0 Gov
installation.doc
Order no.
221304 Index R010
Customer
SN Power Project Doc. No.
Activity
Code Site
Cheves HEPP Pelton Turbine File Name
CONTENT
1 PURPOSE ........................................................................................................ 3
2 DEFINITIONS ................................................................................................. 3
3 RESPONSIBILITY AND ROLES ................................................................. 4
4 DESCRIPTION ............................................................................................... 5
4.1 Instruction manual ............................................................................................. 5
4.2 EHS (Environmental Health and Security) ....................................................... 6
5 REFERENCES ................................................................................................ 6
5.1 Drawings ............................................................................................................ 7
5.2 Site Installation Control Forms ......................................................................... 7
6 DEVIATIONS .................................................................................................. 7
7 ENCLOSURES ................................................................................................ 7
8 INSTRUCTION MANUAL ............................................................................ 8
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Document
PROCEDURE
SN POWER Cheves HEPP - Pelton turbine unit 1 and 2
Document no.: ARA000273-O1N
KH doc. no.: Revision No.: 0
Page 3 of 11 Subject: Installation procedure for governor
First issued date: 2013-03-15
This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.
R:\Kjeller\Projects\Cheves.pel\Order-2010\16 Site and HMS\Installation procedures\Gov & OPS\RP-H-N-I-P-001_Rev 0 Gov
installation.doc
1 PURPOSE
The procedure describes the installation steps for the Pelton turbine governors
supplied by Rainpower AS, hereafter named RP, for SN Power - Cheves HEPP
turbine 1 and 2, hereafter named SNP.
The procedure is designed to ensure that the installation will be performed in
accordance with Contractual requirements and to a high standard of
workmanship. Sketches and diagrams are included to support the installation
sequences described herein.
The procedure is made for the 1st unit, and may be revised for the next unit if
changes are regarded as favourable for the progress of work.
2 DEFINITIONS
Site Installation Control Form (SICF) forms to verify and record performance of the installation steps. Tolerances, as built dimensions from
drawings and measured dimensions at site are included in the forms as
appropriate. The sheets are designated as Form 1, Form 2, etc.
Control comparison with specified requirements to verify compliance.
Technical information documents that specify detailed requirements. This may be the Contract, drawings and other relevant information in order to
secure the performance of the installation work.
Inspection Plan (TP) document describing the various inspections to be performed during site installation with reference to the Installation Procedure
and applicable SICF.
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Document
PROCEDURE
SN POWER Cheves HEPP - Pelton turbine unit 1 and 2
Document no.: ARA000273-O1N
KH doc. no.: Revision No.: 0
Page 4 of 11 Subject: Installation procedure for governor
First issued date: 2013-03-15
This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.
R:\Kjeller\Projects\Cheves.pel\Order-2010\16 Site and HMS\Installation procedures\Gov & OPS\RP-H-N-I-P-001_Rev 0 Gov
installation.doc
3 RESPONSIBILITY AND ROLES
RP is responsible to provide its subsuppliers and SNP with appropriate information to perform the installation work
RP acts as supervisor for the installation company, hereafter named IC who is performing the installation work
The RP supervisor is located at site as long as deemed necessary to terminate the installation work and in accordance with contractual
obligations
RP is responsible to see that all SICF are filled in and approved by IC after accomplishment of each step whenever recording is required
RP shall witness and approve the SICF
RP may hand the SICF to SNP for review and approval
If some changes in installation sequences are requested by RP, the changes shall be submitted to SNP for his approval during site meetings whenever
meetings are carried out on regularly basis. A design amendment may be
issued and signed by the two (2) parties
RP is responsible for issuing this procedure, and for preparation of revisions to the document as necessary to capture any changes or corrections to the
procedure
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Document
PROCEDURE
SN POWER Cheves HEPP - Pelton turbine unit 1 and 2
Document no.: ARA000273-O1N
KH doc. no.: Revision No.: 0
Page 5 of 11 Subject: Installation procedure for governor
First issued date: 2013-03-15
This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.
R:\Kjeller\Projects\Cheves.pel\Order-2010\16 Site and HMS\Installation procedures\Gov & OPS\RP-H-N-I-P-001_Rev 0 Gov
installation.doc
4 DESCRIPTION
4.1 Instruction manual
The sequences of the installation work are given in the Instruction Manual that
is included in the procedure refer section 8.
The Instruction Manual expresses the specific steps of work for installation of
the equipment, and provides reference to relevant documents and SICF as
appropriate.
The Instruction Manual includes columns for:
The actual item and activity number
The specific activity to be carried out with number
The company responsible for the activity
Detailed description of the activity
Sketches and references to relevant drawings, documents and SICF
To avoid confusion or conflicts, no design values or tolerances that are stated on the drawings are repeated in the manual, however nominal
values and tolerances may be included in the SICF
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Document
PROCEDURE
SN POWER Cheves HEPP - Pelton turbine unit 1 and 2
Document no.: ARA000273-O1N
KH doc. no.: Revision No.: 0
Page 6 of 11 Subject: Installation procedure for governor
First issued date: 2013-03-15
This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.
R:\Kjeller\Projects\Cheves.pel\Order-2010\16 Site and HMS\Installation procedures\Gov & OPS\RP-H-N-I-P-001_Rev 0 Gov
installation.doc
4.2 EHS (Environmental Health and Security)
The section is addressing only particular risks (if applicable) related to the
tests and work explained in this procedure.
For details how to mitigate risks, refer to applicable procedures and site safety
plan issued by RP. Safety plan issued by SNP overrules the RP plan whenever
interpretations about the understanding are raised.
Note that pre-work hazard assessments should be performed prior to any task
to determine any and all safety issues and their elimination, control or
mitigation with special care to:
Rotating equipment/machinery
Electrical hazards
Flood/drowning hazards
Pressurized substances (oil, nitrogen, air, water)
Fire (cable/electrical fire, oil fire)
Noise
Overhead/lifting hazards
For safety purposes SNP should check, test or certify, as appropriate, all
handling and lifting equipment to be used during the installation work.
This equipment is supposed to be permanent equipment installed at site.
IC shall present valid certificates for handling of lifting tools for SNP and RP.
5 REFERENCES
Contract between SN Power and the Consortium Rainpower AS, Jeumont and
ABB.
General requirements for welded constructions, RP doc. No. 30103.
Procedure for flushing of oil pipes to governor and main inlet valve MIV RP doc. 24993
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Document
PROCEDURE
SN POWER Cheves HEPP - Pelton turbine unit 1 and 2
Document no.: ARA000273-O1N
KH doc. no.: Revision No.: 0
Page 7 of 11 Subject: Installation procedure for governor
First issued date: 2013-03-15
This document and the design is the property of Rainpower and must not be used nor disclosed to any third party without Rainpower
permission.
R:\Kjeller\Projects\Cheves.pel\Order-2010\16 Site and HMS\Installation procedures\Gov & OPS\RP-H-N-I-P-001_Rev 0 Gov
installation.doc
5.1 Drawings
INDEX TITLE DRAWING NUMBER
R670 Mech./Hydraulic Over Speed Device RP-D-N-I-P-014
R510 Piping Arrangement RP-D-N-I-P-001
R010 Hydraulic diagram RP-D-N-I-P-013
5.2 Site Installation Control Forms
Title
Form No
Verification of cleanliness and shooting plastic bullets 1
Pressure Oil Pipes - Test Result 2
Cable check 3
6 DEVIATIONS
None.
7 ENCLOSURES
None.
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Cheves HEPP Instruction for installation of the governor
No. ITEM ACTIVITY
No.
of
step
Resp
JOB STEPS REFERENCE
R:\Kjeller\Projects\Cheves.pel\Order-2010\16 Site and HMS\Installation procedures\Gov & OPS\RP-H-N-I-P-001_Rev 0 Gov installation.doc
8 INSTRUCTION MANUAL
1 INSTALLA-
TION OF THE
GOVERNOR
1-1 Preconditions 1 SNP/
CW
The erection area shall be cleaned and drained for water.
All civil works shall be finished, and if required floors, walls
roofs etc. shall be painted prior to start installation of the
governor system.
2 SNP/
CW
The erection area shall be lighted, electric power supply and
compressed air shall be available.
3 RP/
SNP
Components will be received and stored in/out-door according
to instruction/agreement between RP and SNP.
The components will be moved to the erection areas according
to Contractual schedule and installation sequences.
1-2 General 1 IC/RP All bolt threads will be lubricated prior to inserting bolts/nuts.
All bolt connections will be tightened according to torque
values indicated on applicable drawings.
2 OIL PRESSURE
UNIT (OPS)
WITH
ACCUMULA_
TOR
2-1 Preparations 1 RP/IC/
CW
The OPS shall be moved to the machinery hall floor in order to
be reached by the machinery hall over-head crane.
The floor where the OPS shall be installed shall be inspected
and prepared to installation of the OPS.
Prepare as necessary caterpillars to move the OPS on the floor.
2-2 Installation The OPS shall be lowered by means of the machinery hall over-head crane through the hoisting hatch to final level
Prior to off loading the OPS, the caterpillars, if needed, shall be placed underneath the OPS. The OPS will be
moved to the correct position on the floor
The OPS will be fastened to the floor using concrete anchor bolts drilled in the floor.
All outlets are plugged and they shall remain plugged until the installation of the piping is completed
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Cheves HEPP Instruction for installation of the governor
No. ITEM ACTIVITY
No.
of
step
Resp
JOB STEPS REFERENCE
R:\Kjeller\Projects\Cheves.pel\Order-2010\16 Site and HMS\Installation procedures\Gov & OPS\RP-H-N-I-P-001_Rev 0 Gov installation.doc
3 OVERSPEED
DEVICE
3-1 Preparations
1 RP/IC The combined shaft system is aligned.
3-2 Installation 1 IC/RP The over speed device assembly shall be installed according to
drawing.
4 PIPING 4-1 Preparations 1 RP/IC The necessary amount of pipes and couplings shall be present
prior to installation.
The same applies to special tools for couplings according to the
Walform system.
Installation Procedure for Walform Tube Fittings.
Drawing No. RP-D-N-I-P-001 Piping Arrangement.
4-2 Installation 1 RP/IC The necessary amount of pipes and couplings shall be present
prior to installation, drawing RP-D-N-I-P-001.
The couplings shall be of the Walform type and assembled in
accordance with the Walform Tube Fittings procedure Special tools for couplings connections according to
instructions from the Walform system shall be present.
Every single coupling shall be check for proper assembly prior
to pressurizing the pipe lines. The check shall be verified with
mark-up each coupling.
4-3 Cleaning 1 RP/IC The cleaning will be carried out in two (2) steps:
1 Bullet cleaning 2 Flushing
4-4 Bullet cleaning 1 RP/IC A high pressure Plastic gun shoots plastic bullets through the different parts of the piping
Cleaning shall be verified in SICF, Form 1
4-5 Flushing 1 RP/IC The second step cleaning shall be carried out by the hydraulic
flushing method. The flushing shall be carried out in
accordance with written procedure. The cleanliness values shall
be recorded in SICF, Form 1.
Procedure for flushing and pressure test of the oil piping
system - RP 24993
SICF, Form 1 Verification of cleaning.
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Cheves HEPP Instruction for installation of the governor
No. ITEM ACTIVITY
No.
of
step
Resp
JOB STEPS REFERENCE
R:\Kjeller\Projects\Cheves.pel\Order-2010\16 Site and HMS\Installation procedures\Gov & OPS\RP-H-N-I-P-001_Rev 0 Gov installation.doc
4-6 Pressure testing 1 RP/IC The pressure testing shall be performed with the same loop
arrangement as for the flushing.
The pressure test shall be carried out in accordance with written
procedure.
The result of the pressure test shall be recorded on SICF,
Form 2
SICF, Form 2 Pressure Test Result.
5 OIL TANK 5-1 Cleaning 1 RP/IC The cleanliness of the oil sump tank is verified during FAT in
workshop.
However the tank may be inspected at site by removing the
inspection hatch and visually check inside prior to oil filling.
5-2 Oil type 1 RP/IC Recommended oil for operation of the OPS and flushing shall
be hydraulic oil according to ISO-VG 46.
5-3 Oil filling 1 RP/IC Filling the oil tank shall be done in accordance with the
governor O&M manual.
New oil will be filled through a filtration unit. It is assumed that
no samples for cleanliness documentation should be regarded as
necessary.
The mobile filtration unit shall be used when filling all units.
6 ELECTRONIC
AND CONTROL
CUBICLES
6-1 Installation 1 RP/IC The governor electronic cubicle is located together with the
panels for unit local control and shall be installed according to
drawing.
The control cubicle is installed according to drawing.
7 CABLING 7-1 Installation and
test
1 RP/IC
Cabling and labels shall in principle be installed according the
relevant wiring diagrams.
Ensure that all connections are properly connected to the
terminals in the cabinets.
Crimping sleeves shall be adapted to all cables.
Cable check shall be done by hook-up in the wiring/cable
diagrams and verified in SICF, Form 3.
SICF, Form 3 Verification of cabling
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QUALITY INSPECTION PLAN GOVERNOR
Dok. nr. / Doc. No.
ARA000273-PRI
Rev.
0
Side / Page
1 av / of
5 Sign. dato / Date
Retten til utnyttelse av denne beskrivelse tilhrer Rainpower ASA og m ikke kopieres, utleveres eller forelegges uvedkommende uten tillatelse fra Rainpower. This document and the design is the property of Rainpower ASA and must not be used nor disclosed to any part without Rainpowers permission.
Ordre nr. / Order No.
400409 Kunde / Customer
SN Power Prosj. dok. nr. / Proj. Doc. No.
RP-Q-N-I-P-001 Indeks / Index
R010 Anlegg / Site
Cheves Filnavn / File Name
ARA000273-PRI Rainpower and Rainpowers customer shall be able to inspect all stages in the process at supplier and sub-suppliers. These inspections might happen any time at any location. All NDT shall be reported, also indications that has been repaired.
0 05.01.12 First Issue TFa Rev. Dato / Date Beskrivelse / Description Sign. Avd. / Dept. Godkj. / Appr.
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QUALITY INSPECTION PLAN
1 2 3 4 5 6 7 8 9 10 11
Index Name, drwg. No. & item No. Production stage Inspection Procedure Location
Respons-ible Witness
Report form RC Remarks
R010 Governor Assembled FINAL Commissioning procedure SITE RP CLIENT PROT x Drytest on site.
R490 GOPS 600 Hydraulic controls
Assembled VI FUNCT PRESSURE
FAT Report SUPL RP CLIENT PROT x Assembled test. FAT
R450 Accumulators Assembled VI FUNCT PRESSURE
FAT Report SUPL RP CLIENT PROT x Assembled test. FAT
R620 Electronic governor HY14P Assembled VI FUNCT FAT Report SUPL RP CLIENT PROT x
Assembled test FAT
R670 Overspeed trip device Assembled VI FUNCT FAT Report SUPL RP CLIENT PROT x
Calibrated before test at site.
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3 of 5
Enclosure to document no. ARA000273-PRI The enclosure gives guidelines for filling in as well as explanations for use of the inspection plan. The paragraph numbers refer to column number. 1 INDEX Numbering of inspection activity and/or item designation according to Rainpower project index list. 2 NAME, DRAWING AND ITEM NO. The name of the part or the parts. Drawing and item number has to be specified when it is suitable to identify the part or parts 3 PRODUCTION STAGE E.g., designed, welded, machined. 4 INSPECTION Inspection or testing to be performed. The following abbreviations are used: CA = Chemical analysis
MAT = Material test
TT = Tensile testing
CIT = Charpy impact test
HT = Heat treatment
BT = Bend test
CR = Contract review
PQR = Welding procedures qualification
WPS = Welding procedure
WELDER = Qualification of welders
NDT-OP = Qualification of NDT inspectors
CALC = Checking and approval of calculations
RESSTR = Residual stress analysis
DRAW = Checking and approval of drawings and specifications
PURCH = Review of purchase orders
RECEIPT = Receiving inspection
CERT = Certificate check
VI = Visual inspection
NDT = Extent of non-destructive testing
ACCEPT = Acceptance criteria
UT = Ultrasonic testing
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RT = Radiographic testing
MT = Magnetic particle testing
PT = Penetrant testing
HB = Hardness test
DT = Dimension and form control
BAL = Balancing
PRESSURE = Pressure testing
LEAKAGE = Tightness inspection
FUNCT = Function testing
FINAL = Final testing
5 PROCEDURE Reference to the document which describes the inspection or testing procedure. 6 LOCATION Location for the inspection or test. MS = Machine shop
SFS = Steel fabrication shop
SUPPL = Supplier's workshop
SITE = Erection site
STOCK = Warehouse department
7 RESPONSIBILITY The letter designation, possible group number for the organization unit, who is responsible for the inspection or test performance. SUPPL = Suppliers workshop
RP = Rainpower
BUYER = The customer
8 WITNESSING Representation, if any, by a party other than he who performs the inspection test. Internal party is given by the letter designation, external as follows: RP = Rainpower
CONS = Consultant or classification society
CLIENT = The customers representative
_____ = Hold point, i.e. the process must not proceed until passed by the witness
-
as indicated by underlining.
9 REPORT FORM Reference to form numbers. PROCESS = Signature in Process Description
PROT = Inspection record
10 REPORT TO BUYER Cross for reports to be forwarded to the buyer.
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Performed
Witnessed
Approved
Approved
01_Form 1 _ Cleaning pipes
Site Installation Control Form Ordre Nr. /Order No
221304 Indeks/Index
R010/K010 Kunde/Customer
SN Power Rapport nr./report no.
Form 1 Byggested/Fab. site
Sak/subject
Cheves HEPP Uni 1 and 2
Side /Page av / of
1 1 Tegn. nr. /Drwg. No.
Dato / Date Sign
Pos. nr /Part No
MIV and Governor during installation
Del / Part
Survey of pipe cleaning with plastic bullets and oil
Unit No.
Cleaning with plastic bullets PIPE LINE
CLEANING RESULT
Other pipe lines No. 1 (to be determined at site)
Other pipe lines No. 2 (to be determined at site)
Other pipe lines No. 3 (to be determined at site)
Other pipe lines No. 4 (to be determined at site)
Flushing with oil LOOP SERVOMOTORS
RESULT CLEANLINESS TEMPERATURE LEVEL
Servo 1
Servo 2
Other pipe lines (to be determined at site)
Other pipe lines (to be determined at site)
Acceptance criteria:
Cleanliness level
NAS 1638 class 7
Temperature for VG 64 oil
60 65
Velocity
6 m/s
Pump capacity (6 m/s and internal pipe dia. 8mm)
300 l/min
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Performed
Witnessed
Approved
Approved
02_Form 2 _ Pressure test pipes
Site Installation Control Form Ordre Nr. /Order No
221304 Indeks/Index
R010/K010 Kunde/Customer
SN Power Rapport nr./report no.
Form 2 Byggested/Fab. site
Sak/subject
Cheves HEPP Unit 1 and 2
Side /Page av / of
1 1 Tegn. nr. /Drwg. No.
Dato / Date Sign
Pos. nr /Part No
MIV and Governor during installation
Del / Part
Pressure tests of misc. pipe lines
Unit No.
Pressure tests of miscellaneous pipe lines
PIPE LINE
PRESSURE (bar)
Other pipe lines No. 1 (to be determined at site)
Other pipe lines No. 2 (to be determined at site)
Other pipe lines No. 3 (to be determined at site)
Other pipe lines No. 4 (to be determined at site)
Acceptance criteria:
Test pressure
bar
Holding time
min
Medium Water
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Performed
Witnessed
Approved
Approved
03_Form 3 _ Survey of cabling
Site Installation Control Form Ordre Nr. /Order No
221304 Indeks/Index
K500 Kunde/Customer
SN Power Rapport nr./report no.
Form 3 Byggested/Fab. site
Sak/subject
Cheves HEPP Unit 1 and 2
Side /Page av / of
1 1 Tegn. nr. /Drwg. No.
Dato / Date Sign
Pos. nr /Part No
MIV and Governor during installation
Del / Part
Survey of cabling
Unit No.
Survey of cabling
WIRING DIAGRAM
RESULT
Wiring Diagram SSG
Wiring Diagram Turbine and MIV Equipment
Wiring Diagram OPS
Wiring Diagram Governor