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

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.


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

Document

PROCEDURE







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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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PROCEDURE







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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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PROCEDURE







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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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PROCEDURE







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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

Document

PROCEDURE







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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.

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


No. ITEM ACTIVITY

No.

of

step

Resp

JOB STEPS REFERENCE


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.


No. ITEM ACTIVITY

No.

of

step

Resp

JOB STEPS REFERENCE


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

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.

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.

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

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.

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)




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

Performed

Witnessed

Approved

Approved

02_Form 2 _ Pressure test pipes


221304 Indeks/Index

R010/K010 Kunde/Customer



Sak/subject

Cheves HEPP Unit 1 and 2

Side /Page av / of


Dato / Date Sign

Pos. nr /Part No


Del / Part

Pressure tests of misc. pipe lines

Unit No.

Pressure tests of miscellaneous pipe lines

PIPE LINE

PRESSURE (bar)





Acceptance criteria:

Test pressure

bar

Holding time

min

Medium Water

Performed

Witnessed

Approved

Approved

03_Form 3 _ Survey of cabling


221304 Indeks/Index

K500 Kunde/Customer



Sak/subject

Cheves HEPP Unit 1 and 2

Side /Page av / of


Dato / Date Sign

Pos. nr /Part No


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

rp-h-n-i-p-001

Documents

sn power cheves hepp

pelton turbine governors

property of rainpower

rainpower permission

installation steps

issued date

ara000273o1n kh

jensen rev date description