Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.

3.5 DESIGN & MATERIALS

3.5.1 General Design Requirements

In addition to the requirements set forth in the General Technical Specifications, the
following requirements shall apply for the spherical valves:

+ All components must be designed to withstand the loads likely to be

encountered during operation.

Even in case of unusual stresses, caused for example by a pipe rupture

downstream of a valve, the valve shall be able to safety close and no
damage shall occur.

The rotation for closing movement of the valve rotor shall be performed in a
way that the hydraulic force of the valve body acts downwards.

The servomotor cylinders shall be fixed to the valve body, thus allowing the
reaction torque to be directly transmitted to the valve body.

+ By the arrangement of the required dismantling joint with sliding flange

connection downstream of the valve, all axial forces have to be transmitted
by the valve to the penstock branch pipe. Therefore, the valve's anchorage
must be provided in a way allowing the valve to axially slide on its
foundation.

+ The controls shall be built in such a way that dangerous accumulation of air
is prevented under all circumstances. All possibilities of creating
disadvantageous water hammer effects and resonance phenomena shall be
excluded.

3.5.2 Loading Conditions

1. Water level conditions

Water levels are outlined in Clause 3.4.1.

2. Water flow

Design flow is set forth in Clause 3.4.1 and emergency free flow of the valve
shall be filled in by the Contractor in the Technical Schedule 'E".

3. Loads

a) Allowance shall be made for the weights, buoyancy, hydrodynamic

loads and loads generated by valve movement (such as friction
forces).

b) Earthquake forces

The spherical valves and associated equipment shall be desiqned

to safely withstand an earthquake force of 0.25 9 acting in any
direction; design basic earthquake forces (DBE).

Volume-IV: Particular Technical Specifications 3-4 Section-3: Main Inlet Valves

 Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

c) Hydraulic transients

Pressure surges generated by turbine load rejections, by load

acceptance or by the closure of valves shall be taken into account.

d) Load combinations

Usual loading conditions

Each of the following conditions shall be considered for normal

loading of valves; the head water level is FSL.

(i) Valve closed:

The effect of the following loads shall be combined:

Hydrostatic load corresponding to the water level

acting on the valve, no water on the downstream
side

Pressure surge due to power station maximum

transients.

(ii) Valve open or at any point of travel:

Hydrostatic load corresponding to the piezometric

level acting on both sides of the valve

Hydrodynamic loads corresponding to the closure

undei rated flow of turbine.

Unusual Loading Conditions

Unusual conditions for valves result from one of the following

com binations:

Usual conditions (as above) with the operating basis

earthquake forces (OBE)

Usual conditions under exceptional reservoir level instead

of FSL

Overloads generated by trunnion friction or stuck seals,

combined with any usual loading condition

Load applied during manufacture, transport and installation

Emergency loading conditions

Incidents assumed to be the direct or indirect consequence

of an earthquake.

Hydrodynamic loads corresponding to the valve closure

under free discharge in an extreme case of pipe rupture
downstream of the valve.

3.5.3 Design Stresses

Under usual loading, the maximum equivalent stress shall not exceed 50% of the
yield strength.

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Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

Under unusual loading and hydrostatic test pressure, the maximum equivalent
stress shall not exceed 75% of the yield strength.

Under emergency loading conditions, the maximum equivalent stress shall not
exceed 90% of the yield strength.

3.6 PARTICULAR REQUIREMENTS

3.6.1 Valve Body

The valve body shall be made of stress relieved cast steel or welded plate steel or of
both. It shall be rigidly built and adequately ribbed to minimize distortion under full
load. The body shall be divided, but the splitting shall not cross the trunnion
bearings. All valve body parts shall be normalized before machining.

The body shall be provided with two horizontal trunnion bearings of self-lubricated
metal. The bearing housings shall be integral with the valve body.

The supporting feet of the valve body shall be designed to transmit the total vertical
load (weight of complete valve with operating mechanism, flanged connections and
contained water volume) to the base plates secured in the concrete pedestals.

The supporting feet and base plates must be designed, machined and surface-
treated suitably to allow axial movement of the spherical valves within the range of
elastic extension of penstock manifold branch and upstream transition pipe.

The valve body downstream of the maintenance seal shall be provided with suitable
flange connections for the by-pass line, braking nozzle line, drain line, etc.

3.6.2 Valve Rotor

The valve rotor shall be of cast steel or welded plate steel, equipped with
replaceable trunnions and seal rings for the downstream (service) seal and the
upstream (maintenance) seal. The waterway shall be shaped and finished to
minimise flow disturbances and head losses.

3.6.3 Trunnions and Bearings

The trunnions of forged steel shall be arranged horizontally and designed for bolted
connection to the valve rotor. The bolts shall be of corrosion-resistant steel. The
sealing areas of the trunnions shall be of corrosion-resistant material.

The bearings of self-lubricated metal shall permit all necessary adjustments to be

madeoutside of the bearing housings. The trunnions shall be balanced hydraulically.
A mechanical indicating device for the valve rotor position shall be provided.
-.-...._
Thetrunnlon seals shall prevent water from entering the bearings.

3.6.4 Valve Seals

The spherical valve shall be provided with removable and replaceable upstream and
downstream seals. The seals shall be made of corrosion- and erosion-resistant
'-~m~crt;rial. The seat rings and seal rings shall be of different materials with different
hardness.

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Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

The upstream seal shall serve as a maintenance seal. Closing of the maintenance
seal allows inspection, repairs and exchange of the service seal components without
emptying of the pressure tunnel and penstocks of the three(3) units. The upstream
seal shall be controlled manually and operated by pressure water and shall be drip-
tight in the closed position. The position of the manually controlled valve shall be
lockable by a padlock in both positions, i.e. "opened" and "closed".

The downstream seal shall serve as the service seal, controlled by filtered water
from the decanting tank. The seat ring and seal ring shall be replaceable without
removing the valve body. On the contact line between seat and seal one of the rings
may be equipped with a rubber packing (or other suitable non-metallic material) to
improve the tightness.

3.6.5 Control Water System

For the control of the service and maintenance seals, the preference is given to the
following procedure:

Service seal:

Operated with water pressure, control valve operated with oil pressure.

Maintenance seal:

Operated with water pressure, control valve hand-operated.

In general, each control system shall have the following features:

+ The control elements shall be built to prevent under all circumstances any
dangerous accumulation of air. All possibilities of creating disadvantageous
water hammer effects or resonances by swinging of the rotating body shall
be excluded.

+ The control valves shall be interlocked in order to prevent any kind of faulty
operation of the spherical valve; in particular it shall be impossible to move
the sealing rings to the closed position, unless the valve rotor is in the
closed position. On the other hand, it shall also be impossible to turn the
valve rotor towards the open position unless the seal rings are unsealed.

+ The service seal shall be operated by decanted pressure water taken from
the water decanting tank.

+ The maintenance seal shall be operated by pressure water taken from the
<opstream transition pipe. A filter shall avoid impurities from entering into the
. '.
movable parts of the seal.
--....
+ . The· ?ontrol system shall include a hand pump for closing the maintenance
seal 'in the case of filling the pressure shaft.

+ Special emphasis shall be given to a simple and rugged design of the

throttling device for the adjustment of the closing and opening time.
Especially, unintentional wrong adjustment of the device, for instance after
overhauls, shall be made impossible.

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Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

For safety purposes, each spherical valve shall have its own control system, which is
working completely independently from the control system of the neighbouring valve.

The Contractor shall submit hydraulic operating diagram with appropriate

description.

The water decanting tank supplied by the Contractor for the seal service shall be
installed on the valve gallery. The decanting tank shall be of welded construction for
a design pressure of 5Mpa.

The tank shall be provided with the necessary isolating and flushing valves.

On the decanting tank outlet side a strainer shall be installed. The interior part of the
strainer shall be exchangeable and shall consist of a perforated stainless steel
basket, tested and guaranteed to withstand full pressure with the basket entirely
clogged. Replacement of the basket shall be possible without interrupting the
service of the spherical valves.

The size of the decanting tank shall be determined in accordance with the control
water requirements. It shall have enough capacity to provide decanting and filtered
water for 2 consecutive opening/closing movements of the service seal.

All necessary control pipes and isolating valves between upstream transition pipe
and decanting tank respectively, decanting tank and control panel, as well as from
the oil supply unit to control panel, and spherical valves shall be included.

In addition, all pipe fixation material, emptying and flushing pipes shall form part of
the supply.

All water pipes shall be made of stainless steel and shall in order to reduce, as far
as possible, the time for installation be prefabricated in the workshop. They shall be
welded except where flange connections are necessary for possible future
dismantling.

All piping shall be hydrostatically tested at a pressure of 100% greater than the
maximum working pressure. As far as possible, the pressure test shall partly be
carried out at the Contractor's workshop. However, the entire pipe arrangement shall
be subject to the pressure test after complete assembly at site.

The pipes shall, where practicable, be laid in specially prepared concrete ducts to be
covered by checkered plates. The pipes shall be fixed on anchor plates to be placed
in the above-mentioned ducts. The arrangement of the pipes, in particular on the

_.- va~~;z.itself, shall be made in an aesthetically perfect manner.

"-
For safety purposes, the point where the control water is taken from the upstream
_..transitiQn pipe has to be equipped with two isolating valves to be arranged in series.
:'. : ~
/
/'
'. ..•.... - '.') ,
3".6',/ "Op~raH~~~Mechanism
( '~;: ,'·ih~~oP:eiaji.~g mechanism shall mainly consist of two servomotors, one on either
\. .:':":.~-.~i~e_?f
th~}alve body, and connection levers between servomotor piston and valve
',.
'"..:. __ --.~
rotor truml(on. The servomotor
-.... .....
cylinders shall be made of stress-relieved cast steel

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 Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

and be fixed to the valve body, thus allowing the reaction torque to be directly
transmitted to the valve body.

Besides of the connections for the control pipes, the servomotors shall be equipped
with flushing valves on their lowest point, as well as with suitable tappings on their
highest point for air venting.

The servomotor piston shall be provided with oil-resistant V-type pressure gaskets.
The piston rod shall be stainless steel or protected by a hard-chromium overlay,
approximately 0.04 mm in thickness. The piston rod bushing shall be bronze.

The connection levers of cast steel together with the connections between pistons
and levers shall represent a sturdy design in order to safely transmit the torque
under any operating conditions. The transmission of the torque from the connection
levers to the rotor trunnion shall preferably be made by a key-seated connection.

All bushes of movable linkages shall be of self-lubricated metal.

The servomotors shall have sufficient capacity and safety reserve to open and close
the spherical valve under the operating conditions outlined in Clause 3.4.1. The
pressure oil shall be taken from the pressure oil unit.

The minimal closing time and opening time is specified in Clause 3.4.2. Replaceable
. )
orifices shall be provided to permit adjustment of the closing and opening times in
the range of 30 to 80 seconds and for two velocity ranges of the stepped
characteristic of the servomotor stroke. The movement of the servomotor pistons
shall be cushioned before reaching the opened or closed end position. Valve
opening may be initiated when the upstream and downstream pressure of the valve
have almost equalized after preceding opening of the bypass.

A mechanical locking device shall be provided to hold the servomotors in the closed
or open position, preventing accidental movement of the valve rotor during
inspection, maintenance, etc. Each locking device shall have provisions for the use
of a padlock.

A mechanical position indicator shall be mounted on the valve operating mechanism

with indication signs for the open and closed position, as well as a scale with
indication of the degrees giving the intermediate positions of the rotor.

3.6.7 Pressure Oil System & Local Control Panel

",<~:~~~~~uipment shall mainly include the following units:

\\ '.~
!
.• 'Oil accumulator

.• - . ---'"Oil sump tank with pumps, filters, control valves, etc.

-' '" ~'\\
• Local control panel, preferably mounted on top of the oil sump tank.
,--::_ .
The arrangement of oil sump tank, oil piping and control valves shall be such that
... ' f
-the servomotors remain full of oil despite of leakages from glands, piston seals or
_"

control valves.

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Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

One pressure oil accumulator shall supply sufficient pressure oil to ensure one
closing, one opening and one closing movement of the spherical valve, without
operation of the pumping set. This pressure oil tank shall be automatically recharged
by the oil pumping sets.

(1) Pressure Accumulator

The pressure accumulator shall be of the bladder or piston type with

provision of nitrogen and air column. The maximum oil pressure shall in the
range of 70-100 bar approximately. The accumulator should be designed
for vertical arrangement adjacent to the oil sump tank.

The pressure accumulator shall be fabricated from pressure vessel steel.

The accumulator shall be equipped with stainless steel piping, hydraulically
actuated main oil valve preventing oil leakage through distribution valves
during stand-still, guard valves, pressure gauges, pressure switches, water-
in-oil detector, oil-in-water detector, stroke transmitter and limit switches.

(2) Oil Sump Tank

The oil sump tank shall be made of welded steel plates duly stiffened with
steel sections. Its capacity shall be at least 50% greater than the total oil
quantity contained in all oil circuits. All oil drainage, leakage and/or exhaust
pipes shall be conveyed to the oil sump tank.

The sump tank shall be equipped with a manhole of at least 600 mm

diameter, level indicator, filtered air vent, connections for filling and draining
and magnetic filters. Tapping points with check valve, shut-off valves and
caps for hose connections to the oil treatment system.

Tapping point with isolating valve and blank flange for temporary hose
connections to the oil filtration plant.

(3) Pumps

For the pressure oil supply, two screw pumps (max. speed 1500 rpm) shall
be installed in the sump tank. The pumps shall be electric motor driven (400
V, 3-phase, 50Hz). Combined pump capacity shall be sufficient to refill the
total active accumulator volume in at least 100 seconds.

Each pump shall be equipped with check valve, unloader valve, safety valve
_~~
. \
pressure switch and all other accessories necessary for reliable operation .
-,
')The pumps shall operate intermittently to replenish the accumulator volume.
_.
~",
" The pump control shall be outlined for lead/lag mode with manual switch-
~,,·bver. On receipt of a switch on signal, both pumps will start simultaneously.
The standby pump will shortly thereafter stop. if the on-duty pump operates
satisfactorily.

Provisions shall be made to allow the complete disconnection of either

pump from the system for maintenance without affecting the system
operation.

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Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

A hand-operated piston oil pump for emergency operation shall be mounted

on top of the oil sump tank.

(4) Filters

Twin full-flow magnetic and mesh cartridge filters shall be provided and shall
allow, by means of three-way valves, the cleaning or replacement of the
mesh carriage from one filter side without interruption of the filtering
procedure. A differential pressure indicator with alarm contacts shall be
provided. The filter shall be arranged on or within the oil sump tank in such a
way that maintenance works can be done easily.

(5) Control Valves

The control of bypass valve, service seal operation and spherical valve
servomotors shall be accomplished by pressure oil. The set of control
valves shall include solenoid valves, pilot valves and distribution valves.

(6) Local Control Panel

The panel shall be mounted in the valve gallery or near the oil unit at the
turbine floor. It shall be designed as mentioned in the General Technical
Conditions and for protection class IP 65. The control panel shall
accommodate the control equipment, rectifier, a set of terminals with 20%
spare arranged on a terminal strip, electric switch box heating, and vapour-
tight type lighting inside 01 the switch box to facilitate maintenance work.

The control equipment shall include the following components:

One key-operated selector switch with three positions, "Off", "Local"

and "Automatic", for the main inlet valve control system.

Push buttons "On" and "Off" for the pumps.

Push buttons "Opening", "Stop" and "Closing" for the main valve
and bypass valve

Control relays for the local control.

Indication lamps "On", "Off" and "Failure" for the pumps, and
"Open", "Closed" and "Failure" for the valves
" ...
,
Operating hour counters for the oil pumps.

Manual selector switch "No.1" and "No.2" for the oil pumps.

Output of individual alarm signals for recording by sequence

.\ .
recorder.

Collective alarm output

3.6.8 'By-pass Line

A by-pass line of 200 mm diameter shall be arranged for filling the turbine manifold
and for balancing the pressure on both sides of the valve rotor as much as possible

Volume-IV: Particular Technical Specifications 3 - 11 Section-3: Main Inlet Valves

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Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

before opening the spherical valve. The by-pass line shall be connected upstream
and downstream of the service seal to the spherical valve body. In order to minimize
erosion, the connection of the by-pass pipe to the valve body shall be made under
an angle of 45 degree.

The by-pass pipe shall be made of seamless stainless steel. The by-pass pipe shall
be equipped with strong bracings in order to prevent any vibrations.

The by-pass valve shall be provided with a needle valve operated by pressurized oil
taken from the oil pressure unit. The valve body shall be made of cast steel; the
needle, seat and piston rod of stainless steel. Provisions shall be made to prevent
water entering into the oil system of the servomotor and vice versa.

The by-pass valve must be capable of opening and closing under a balance
pressure of 43.9 bar and to operate under all opening positions without undue
vibrations and cavitation.

The whole system shall be subjected to a test pressure of 7.8 MPa.

The by-pass valve shall close automatically after opening of the spherical valve and
remain in the closed position even If the oil pressure fails on the closing side of the
servomotor with the spherical valve in open position.

The operating position of the by-pass valve shall be shown by an indicator. A pilot
valve shall be provided for 10c?1control and automatic remote control. A set of
adjustable limit switches shall be provided to control the valve opening to any
position from closed to fully open.

Both limit switches for the "open" and "closed" positions shall be provided with at
least two electrically independent contacts.

One manually operated guard valve shall be provided upstream of the by-pass
valve. The guard valve shall be directly fixed to the spherical valve body. The guard
valve body shall be made of cast steel and the seats and spindle of stainless steel.
The valve shall be equipped with a strong gear allowing to be operated under
unilateral maximum working pressure.

3.6.9 Upstream Transition Pipe

Each spherical valve shall be provided with an upstream transition pipe of 1.2 m
inside diameter. It shall be welded of fine grain plate steel (St 690 or A8TM 516
Gr.70, Normalized) .

. . 'The downstream end shall be equipped with a forged, ready-machined weld neck
flange matching the upstream flange of the valve body.

The weld joint between downstream end of penstock branch pipe and upstream end
\ .
of the upstream transition pipe shall be a field weld joint in order to allow for
correction of any misalignment between spherical valve and penstock manifold
branch pipes.

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Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

Furthermore, the upstream end portion of the upstream transition pipe shall have an
allowance in length of +300 mm. The making-up of the connection pipe and welding
of the joint shall be performed by the Contractor. The upstream transition pipe shall
be welded to the penstock branch pipe at site according to the stipulations in the
ASME Boiler & Pressure Vessel Code. The physical properties of the material shall
be similar to those used for the penstock. The connecting ends of the weld joint shall
have their welding edges beveled. Prior to site welding the Contractor shall submit a
copy of relevant site welding methods, material used, non-destruction detection and
mechanical testing methods and procedures to the Engineer for approval. Welding
seams shall be smoothly ground.

All transition pipes shall be provided with flanged tappings for control water for the
decanting tanks and Station Services.

3.6.10 Dismantling/Expansion Pipe

The dismantling/expansion pipe shall be arranged between the downstream flange

of the spherical valve and the upstream flange of the turbine manifold. It will be
supplied within the scope of the turbine supply, specified in Section 1 of the
Particular Technical Specifications

3.6.11 Piping

3.6.11.1 Brake Nozzle Line

A manually operated neadte valve directly attached to the relevant flange on

the spherical valve body downstream of the maintenance seal shall serve as
the guard valve of the brake nozzle line.

Needle and seat ring, movable parts and bushing of the guard valve shall be
made of stainless steel; the valve case shall be made of cast steel. The
seamless stainless steel pipe from the guard valve to the brake nozzle will
supply the required brake water. Steel pipe and valves shall pass a hydro-
static pressure test at 7.S Mpa. The brake jet assembly is specified in
Section 1, Clause 1.8.11 (Hydraulic Turbines).

3.6.11.2 Drain Line

A draining line 80 mm in diameter for the removal of sand and silt

accumulated on the bottom of the spherical valve shall be routed from the
spherical valve bottom to the turbine pit below the turbine runner. The line
'f.
i'.
1 \.••. _....
shall be equipped with two manually operated valves in series, i.e. the guard
valve directly attached to the spherical valve body followed by the blow-off
valve. Both valves shall be ball-type valves. The valve casings shall be
./
-. made of cast steel, the seals, bushing and movable parts of corrosion-
'resistant metal. The drain pipe shall be made of stainless steel.
'1 ',-
3:6.12 .. Control Devices <f~ ~."

/ l" ~ ('
\ -,, : ~~....-B~i8es, the control devices specified in the Clauses 3.6.5 to 3.6.8, the supply for
~.... ., "~t'~ '. • ",,.i

" ..-~:"each Main Inlet Valve shall also include the following control devices:

Volume-IV: Particular Technical Specifications 3 - 13 Section-3: Main Inlet Valves

 Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

(a) One (1) PLC for the control of the bypass valve and spherical valve
operation, as a subroutine of the turbine start / stop sequence control.

(b) One (1) set control devices for the electro-hydraulic control of bypass valve
operation, including solenoid valve, pilot valve and distribution valve.

(c) Limit switches for the monitoring of bypass valve positions.

(d) One (1) set control devices for the electro-hydraulic control of the spherical
valve operation, including solenoid valves, pilot valves and distribution
valves.

(e) One (1) set control devices for the electrical and mechanical interlocking of
seal operation and servomotor operation, to ensure the reliable correlation
of the valve operations

The correlation between seal operation and rotor movement shall be

supervised by pressure switches and mechanical-cam controlled limit
switches.

(f) One set limit switches for spherical valve positions "open", "closed" and
"pre-start condition for turbine".

(g) Pressure gauges, pressure switches and pressure transducers for the
control and monitoring of the water pressure upstream and downstream of
the spherical valve.

(h) Pressure switches and pressure transducers for the control and monitoring
of the water pressure of service seal and maintenance seal.

(i) Terminal box at the spnencal valve foundation for the cabling and wiring of
limit switches and pressure switches. The terminal box shall include 20%
spare terminals for possible future devices.

(j) One (1) PLC for the control of the pressure oil system.

(k) Pressure gauges and pressure switches for the monitoring and control of oil
pump operation.

3.6.13 Foundation Plates

The valve body legs shall stand on foundation plates, which shall permit the body to
"s[id.ein direction of the water conduit, however, omit a lateral sliding and an uplifting.
\ '-._.
'(he sliding faces shall be provided with grease grooves and with greasing nipples.

].:he foundation plates shall be provided with stiffening ribs and anchor bolts and with
all necessary devices to facilitate level and position adjustment.
J I
3.6.1.4
'._
Mrseellaneous Material
• ~- :.S:·~ ..

~~.l~.~heSkered plates with frames, made of hot-dip galvanized steel for cable
..'):,;i",.,tc "
<, :~__:-and
. tube trenches between valve and control cabinet or pumping set

3 - 14

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Volume-IV: Particular Technical Specifications Section-3: Main Inlet Valves
Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

+ Grated floors, handrails, supports, and ladders, made of hot-dip galvanized

steel, for easy access and maintenance of the equipment, such as by-pass
valve, valve trunnion bearing limit switches, position transmitter and
manhole opening.

3.7 ASSEMBLY AND TESTS IN THE WORKSHOP

3.7.1 Material Tests

For the relevant extent of material tests, test procedures and limits of acceptance
refer to General Technical Specifications. Based on these requirements, the
Contractor shall prepare a list showing all components of the supply to be tested and
the corresponding tests to be performed.

The Engineer, however, reserves the right to request further tests, if he deems such
tests necessary.

3.7.2 Workshop Assembly and Workshop Tests

All parts of the supply shall generally be assembled in the Contractor's factory to the
extent necessary for the purpose of inspection, testing and otherwise, to ensure that
the equipment will function satisfactorily.

Exceptions may be permitted, if approved by the Engineer.

All parts shall be correctly doweled and match marked to facilitate the assembly at
site.

At least, the following parts of each spherical valve shall be assembled at the
Contractor's workshop and be presented to the Engineer:

+ Complete assembly of spherical valve with operating mechanism, including

attachment of upstream transition pipe

+ Complete assembly of by-pass system

+ Complete assembly of oil accumulator, pressure oil system and local control
panel

+ Assembly of control piping as far as practicable.

In the above-mentioned assembled condition, the following shop tests shall be

performed on the valve by the Contractor in the presence of the Engineer:

+ Pressure test at 7.8 MPa of the completely assembled spherical valve. The
pressure shall be applied for an hour at least.

• '. Pressure test at 7.8 MPa on the upstream transition pipe, the pressure shall
be applied for an hour at least.

+ " Tightness test of service seal and maintenance seal at design pressure of
':0:(' 5.2 MPa for an hour on each. The pressure for both seals shall be applied
on their upstream side with the downstream side empty for control of the
tightness.

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 Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

+ Pressure test with 150% of the applied working pressure of closing and
opening cylinder of the operating servomotors. On each cylinder, the
pressure shall be applied for an hour at least.

+ Functional test of the spherical valve with performance of opening and

closing movements as well as application of the seals.

• Pressure and tightness test of the entire by-pass system with the same
pressures and times as indicated above for the main inlet valve.

• Pressure test of the hydraulic part of the control cabinet, including piston
accumulator, with double the normal working pressure; pressure to be
applied during one hour at least.

+ Hydraulic and electrical function tests of the control panel under maximum
and minimum working pressure.

+ Pressure test of the control piping at double the normal working pressure as
far as practicable.

Required Performance:

The valve and operating mechanism must be free of abnormal friction or other
power consuming deficiencies.

All seals must be driptight.

3.8 FIELD INSTALLATION AND TESTS AT SITE

3.8.1 Installation Requirements

In addition to the General Technical Specifications, the following particular

requirements shall apply for the installation of the spherical valves:

The valves shall be brought to the final installation place by means of the
powerhouse bridge crane. There the valves shall be placed, perfectly aligned and
prepared for embedment of the base plates and for field welding of the upstream
transition pipe to the penstock branch pipe, and connection of the dismantling pipe
to the turbine manifold. Making-up and welding of the upstream field joint shall be
done by the Contractor.

After final placement of the spherical valve the complete installation of the control
equipment and piping, including welding of the pipe work, shall be performed. The
scope of installation activities comprises also the supervision of the embedment of
the base plates (to be embedded by the Civil Contractor) and site painting.

For !he issue of the "Complete and Ready for Commissioning Certificate", the
followinq checks shall be performed:
I.
!;~
.• ': \. "Verification of all parts of the supply.
:~ t

<

+ "Verification of perfect alignment of the spherical valve and dismantling pipe.

+ Check of all important clearances with particular view to the dismantling

flange system.

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Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

• Non-destructive testing of the field welding and material testing shall be in

accordance with the General Technical Specifications. The field welding
shall be checked by radiographic examination on its total length, i.e. 100%.

• Performance of pressure testing of the control piping with double the normal
working pressure.

• Check of the pre stressing, perfect locking and securing of all nuts.

3.8.2 Commissioning Tests

The Contractor shall supervise and direct the following commissioning tests, as
applicable to ensure that the equipment has been correctly installed, all necessary
adjustments and settings are made, and that it is in sound condition to operate.

The tests listed hereafter are divided in preliminary tests, operation and performance
tests.

Commissioning of the equipment shall take place, together with the corresponding
generating unit according to the commissioning program agreed by the Engineer.

3.8.3 Preliminary Tests (Dry Tests)

• Electrical control of CO! rect wiring and cabling of all control, alarm and
auxiliary power circuits.

• Testing and setting of ali relays, limit switches, etc.

• Function test of the spherical valve control system

• Dry check of automatic start and stop sequences in conjunction with the
Pelton turbine.

• Dry check of opening and closing movements, preliminary adjustment of

opening and closing time of spherical valve rotor and bypass valve.

3.8.4 Operation and Periormance Tests

• Application of the maintenance seal of the spherical valves of the penstock

system, using the supplied hand pump or by mechanical tightening device.

• Filling of penstock manifold and upstream conduit. Subsequent filling and

deaeration of all control pipes and control valves.

• Tightness test of the valve seal at pressurized penstock.

• Performance of various opening and closing sequences of the by-pass

valve.

• Checking of opening and closing time of spherical valve rotor and automatic
by-pass valve under dead water conditions.

• Various opening and closing movements under dead water conditions

order to check the correct functioning of the control system, spherical valve
in

and bypass system in local and remote control.

Volume-IV: Particular Technical Specifications 3 -17 Section-3: Main Inlet Valves

Golen Gol Hydropower Project Contract Documents: Contract LOT: 3.2

+ Checking of the flushing installations of valve body and water de-cantering

tanks.

+ Definite adjustment of limit switches and verification of the correct

functioning of the various pressure measuring instruments.

+ Any additional tests required by the Engineer to ensure the completeness

and safety of the equipment when operated.

Following the tests listed above, the subsequent performance tests shall be carried
out:

+ Closing of the spherical valve under 25, 50, 75 and 100% of the maximum
turbine discharge, in order to prove the vibration-free and safe closing of the
valve.

For each closing, the closing time and the corresponding pressure rise shall be
measured and recorded.

The details of the measurement methods, the conditions and performance of the
tests at site shall be agreed upon between Engineer and Contractor, and laid down
in a separate program, defining the sequence of the tests, the equipment
preparation and the correspono.nq operation procedure.

Including a multi channel recorder for the recording of the pressure rise, all
measuring equipment shall be t.rovided by the Contractor.

After successful termination of all tests on completion the spherical valves shall be
subject to a trial run operation period.

Should by mutual agreement between the Engineer and the Contractor one or
several performance tests be postponed, this should not prevent beginning of the
trial operation.

3.8.5 Trial Operation

Trial operation shall be carried out under the supervision and responsibility of the
Contractor, in accordance with the Contract Conditions. During this period, the
Employer's staff shall be made fully familiar with the operation and the routine
maintenance of the plant.

The "Taking-Over Certificate" shall be issued after satisfactory trial run operation in
accordance with the provisions of the General Conditions.

~ Within one month after commencement of trial operation the valve shall be tested to
)) "ll .... determine its ability to close tightly against the maximum specified flow and head or
I:,.._---.::-.:..~ maximum flow and head obtainable, if less than specified.

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Volume-IV: Particular Technical Specifications 3 - 18 Section-3: Main Inlet Valves