Tailrace Gate O&M Instructions
Tailrace Gate O&M Instructions
Date
  Name
  Date
                                                        REVISION ACCORDING TO LETTER EPDC LTK-C3-
  Name       A.FERRAZ     A.FERRAZ     F.COSTA          99-002 OF FEBRUARY 19, 1999.
COMMENTS:
                                     KINGDOM OF THAILAND
                    ELECTRICITY GENERATING AUTHORITY OF THAILAND
          LAM TA KHONG PUMPED STORAGE PROJECT UNITS 1-4
                          CONTRACT No. EGAT 47/9-32-5611-EGAT-LTK-C3
PROCESS
          165 501
JOB No.
             ABB                          PORTUGAL
                               Asea Brown Boveri S.A.                  KHO.140.OM.01+                 A
                  ABB                                                 TABLE OF CONTENTS                                                  Page 2
II OPERATING INSTRUCTIONS............................................................................................7
    1       OPERATING DESCRIPTION...............................................................................................
            1.1     TAILRACE GATE........................................................................................................
            1.2     ELECTRICAL HOIST..................................................................................................
    2       CONTROL............................................................................................................................
    3       GATE OPERATION.............................................................................................................
            3.1     OPENING....................................................................................................................
            3.2     CLOSING....................................................................................................................
            3.3      STOPPING.................................................................................................................
    4       MAINTENANCE...................................................................................................................
    5       SAFETY DEVICES...............................................................................................................
            5.1     WIRE SLACKNESS....................................................................................................
            5.2     OVERLOAD................................................................................................................ 11
                                                                                                ISSUE                         REVISION
                                LAM TA KHONG
                                TAILRACE GATE
                                                                                               April 2001                        A
           ABB                                             TABLE OF CONTENTS                                                Page 3
IV SPARE PARTS................................................................................................................... 19
V DRAWINGS LIST................................................................................................................ 21
VI ANNEXES - CATALOGUES...............................................................................................22
                                                                                     ISSUE                       REVISION
                       LAM TA KHONG
                       TAILRACE GATE
                                                                                    April 2001                       A
       ABB                                             I - MAIN CHARACTERISTICS                                                  Page 4
1 TECHNICAL DATA
                                                                                        ISSUE                         REVISION
                       LAM TA KHONG
                                                                                        April 2001                         A
                       TAILRACE GATE
       ABB                              I - MAIN CHARACTERISTICS                              Page 5
      Motor specification :
        - asynchronous three phase motors, squirrel gage BROOK-CROMPTON, TEFV
          ARGUS, 3 Kw – 1500 r.p.m. WU-DA 100 LR, B3, class F insulation system,
          temperature rise class B.
      Load cell setting value :
          - minimum value = 1,02 KN
          - maximum value = 41,48 KN
      The tailrace gate allows the closing of tailrace tunnel for maintenance inspection and
      repair work.
      Each tailrace gate consists of two (2) elements of welded construction in St 52.3
      DIN17100, comprising a skin plate reinforced by main horizontal beams, horizontal and
      vertical stiffners and vertical end girders.
Watertightness is achieved by a continuos sealing, fixed by stainless steel bolts and nuts.
      The shapes of the rubber seals are rectangular for the bottom and of the music note type
      for the side and top seals.
      Two (2) by-pass valves 300 mm inner diameter of conical type, located at the upper
      element, are operated by the electrical hoist through the lifting beam in order to balance
      the hydraulic pressure on both sides at the tailrace gate before raising gate.
      Lateral guidance of the gate consists of guide rollers on each side of structure, equipped
      with self lubricating bushings.
      The embedded parts are composed by horizontal sill and frontal beam, two (2) bearing
      plates and two (2) side and posterior guides of welded construction.
From EL. 277.00 up to EL. 283.00 the side guides are of removable type.
All surfaces in contact with the rubber seals are made of stainless steel.
                                                               ISSUE               REVISION
                  LAM TA KHONG
                                                               April 2001             A
                  TAILRACE GATE
       ABB                              I - MAIN CHARACTERISTICS                             Page 6
Both of the resting devices also permit the inspection of the gate leaf.
      The electric hoist is equipped with two drums with spur gears.
      These gears are moved by a reducer with helical gears.
      The hydraulic brake. placed between the reducer and the electric motor, maintain
      the correct position of the hoist.
                                                               ISSUE              REVISION
                  LAM TA KHONG
                                                               April 2001            A
                  TAILRACE GATE
            ABB                           II - OPERATING INSTRUCTIONS                              Page 7
1 OPERATING DESCRIPTION
The operation of the tailrace gate is done by means of an electrical hoist 250 KN, installed         on
          the operation platform at EL. 286.00 m, through one lifting beam.
          The tailrace gate can only be operated under equalized water pressure. For that purpose,
          the two (2) balancing valves located at the top of the upper element, are actuated by the
          first displacement of the lifting beam prior the lifting of the gate.
          All the equipment must be verified in accordance with the instructions presented on
          SECTION VI - CATALOGUES.
2 CONTROL
          Control selection is made by the key switch SA1,SA2 and SA3, with the following positions
          and funtions:
SA1
          Position 0 - DISCONNECTED - In this position it’s not possible the control of the Gate.
          Position 1 - LOCAL CONTROL - In this position the control of the Gate it’s only possible
                                       on the Local Panel.
          Position 2 - REMOTE CONTROL - In this position the control of the Gate it´s only
                                          possible on Remote Control.
          The positions “LOCAL CONTROL” and “DISCONNECTED” are signaled in Local Panel
          and in Remote Control.
SA2
          Position 0 - NORMAL - In this position it´s possible the normal control of the Gate.
          Position 1 - MAINTENANCE - In this position the control of the Gate it´s only possible
                                        on the Pendant Station, at EL. 277.00 or EL. 286.00
The position “MAINTENANCE” are signaled in Local Panel and in Remote Control.
                                                                   ISSUE                REVISION
                       LAM TA KHONG
                                                                    April 2001             A
                       TAILRACE GATE
       ABB                             II - OPERATING INSTRUCTIONS                                 Page 8
3 GATE OPERATION
      The operating description of the Tailrace Gate 1 is equal for Tailrace Gate 2.
      The gate operates normally between EL.247.70 and EL. 276.00.
3.1 OPENING
Pressing the button SB1 exciting relay KA1, acting the contacts :
      The main contacts from KM1 at closing, put working motor M1, in open sense also
      acting the follow auxiliary contact
      When limit switch S11 is actuated, wich close auxiliary circuit from timer KT11,
      acting the contacts.
After Gate equilibrating time, the contactor KM1 is excited restarting operation
      When fully opened the switch S20.1 and S20.2 are actuated at EL. 276.00, exci-
      ting relay KA20 acting the contacts.
3.2 CLOSING
Pressing button SB2, the relay KA4 will be excited, acting their contacts:
      The main contacts of KM2 at closing put working motor M1, in close sense, also
      acting the follow auxiliary contact
      When fully closed, the limit switch S10 is actuated, exciting relay KA10, acting their
      contacts:
                                                                 ISSUE                 REVISION
                  LAM TA KHONG
                                                                  April 2001              A
                  TAILRACE GATE
       ABB                            II - OPERATING INSTRUCTIONS                           Page 10
3.3 STOPPING
      The operation described in 3.1 or 3.2 can be interrupted pressing button SB3.
      In this case, the intermediate position relay KA60 is excited, acting their contacts:
4 MAINTENANCE
      When in Local Control, the selector switch SA2 must be changed to position 1, exciting
      relay KA23, acting the contacts :
5 SAFETY DEVICES
      The operation described in 3.2 can be interrupted when the contacts of load cells
      B1.1 or B2.1 are actuated, exciting relay KA41, acting their contacts :
                                                                  ISSUE              REVISION
                  LAM TA KHONG
                                                                   April 2001           A
                  TAILRACE GATE
       ABB                            II - OPERATING INSTRUCTIONS                         Page 11
5.2 OVERLOAD
      The operation described in 3.1 can be interrupted when the contacts of load cells
      B1.2 or B2.2 are actuated, exciting relay KA42, acting their contacts :
      Measures on own power supply, and measures when all 3 phases are present and have the
      correct phase sequence, exciting relay KA45, acting their contacts :
                                                               ISSUE             REVISION
                  LAM TA KHONG
                                                                April 2001          A
                  TAILRACE GATE
       ABB                          III - MAINTENANCE INSTRUCTIONS                          Page 12
1 BEGINNING OF OPERATION
      After final assembly and before operating the equipments, the following items must be
      checked as mentioned bellow.
.     Any annomaly must be immediatly repaired, in order to get good operating conditions and
      durability of the equipments.
CIRCUIT BREAKERS
                       Q0           50 A            Q7            1A
                       Q3            3A             Q8            2A
                       Q4            1A             Q 10         20 A
                       Q5            6A             Q 11          1A
                       Q6            2A             Q 12          1A
                                                               ISSUE                 REVISION
                  LAM TA KHONG
                                                                 April 2001             A
                  TAILRACE GATE
       ABB                          III - MAINTENANCE INSTRUCTIONS                        Page 13
                       F 10      6 - 10 A
                       F 20     0.63 - 1 A
                      Q1         10 A
                      Q2          2A
                                 MOTOR
      Type :
       Characteristics         Prevue         Registed      Obs.
            Power              3 KW              KW
            Voltage            380 V              V
       Nominal Current         6.6 A              A
          - heating resistance
          - phases power control
          - ilumination
      After assembly and regulation of the Tailrace Gate are finished, the first opening and
      closing movements must be made with care, recording all the results.
      All the registered results will be importants for future maintenance operations and global
      performance of the equipments.
If possible, the first tests must be done without water and later with water
                                                               ISSUE                 REVISION
                  LAM TA KHONG
                                                                 April 2001             A
                  TAILRACE GATE
      ABB                          III - MAINTENANCE INSTRUCTIONS                          Page 15
If possible, the first tests must be done without water and later with water
                                                              ISSUE                 REVISION
                 LAM TA KHONG
                                                                April 2001             A
                 TAILRACE GATE
      ABB                             III - MAINTENANCE INSTRUCTIONS             Page 16
NOTES
ELECTRICAL HOIST
  - Electric motor                                                    see page 17
  - Position Indicator                                                see page 17
  - Load cell                                                         see page 17
  - Limit switch                                                      see page 17
  - Electrical connection                                             see page 17
                                                        ISSUE             REVISION
                     LAM TA KHONG
                                                         April 2001          A
                     TAILRACE GATE
       ABB                         III - MAINTENANCE INSTRUCTIONS                          Page 17
      The gate seals are manufactured from synthetic rubber with a shore hardness of 65 +/- 5.
      If any abnormal leakage occur, the gate seals must be checked in order to find out if
      correcting the position of the seal, the leakage can be stopped. If any distruction is
      detected, the gate seal must be replaced.
                                                              ISSUE                 REVISION
                  LAM TA KHONG
                                                               April 2001              A
                  TAILRACE GATE
       ABB                           III - MAINTENANCE INSTRUCTIONS                          Page 18
2.2.1 REDUCER
      In the reducer, the first oil change must be executed one year after beginning of
      operation.
      The next changes must be carried out whenever the oil analysis present adulteration
      vestiges.
      The oil level shall be keeped constant and whenever necessary it must be done the filling up.
      During all the reparations and maintenance works the joints must be cleaned, before
      closing the reducer with the purpose of assure the oiltight.
      The recommended oil to the reducer, is the “OMALA OIL 220” - SHELL or equivalent
      - see DWG.KHO.144.3355.
      This check operation, must be done yearly at the first two or three years and posteriorly
      every four years.
      Usually it is not necessary to repaint unless fifteen years after beginning of gate operation.
      The original painting schemes are indicated on the drawing KHO.021.000.01.
      The remainder equipment does not need Periodic Maintenance operation, beeing
      only necessary to make repairs or replacements of damage elements whenever
      some working anomalies are detected.
                                                                 ISSUE                REVISION
                  LAM TA KHONG
                                                                  April 2001             A
                  TAILRACE GATE
            ABB                                IV - SPARE PARTS                    Page 19
TAILRACE GATE
GATE LEAF
ELECTRICAL CIRCUIT
ELECTRICAL HOIST
 20            2    Shoe Brakes
KHO.144.000.01
                                                          ISSUE                REVISION
                     LAM TA KHONG
                                                           April 2001             A
                     TAILRACE GATE
          ABB                               V - DRAWINGS LIST                       Page 21
TAILRACE GATE
                                     ASSEMBLY - MASONRIES
KHO.140.000.01   General Assembly
KHO.140.001.01   Groove Section
KHO.140.002.01   Groove Section between EL. 256.00 and 277.00
KHO.140.003.01   Groove Section above EL. 277.00
                                        EMBEDDED PARTS
KHO.141.001.01 Assembly
                                            GATE LEAF
KHO.142.001.01 Assembly
KHO.142.201.01 Lower element
KHO.142.202.01 Upper element
                                       ELECTRICAL HOIST
KHO.144.000.01 Assembly
KHO.144.3355   Assembly - Maintenance
                                        ELECTRICAL EQUIPMENT
KHO.148.001      Electrical circuit (sheets 1 to 13)
KHO.148.002.01   Name plates
KHO.148.003      Control Unit (sheets 1,2)
KHO.148.004.01   Electrical connections
KHO.148.005.01   Cables list
                                            ACESSORIES
KHO.149.000.01 Assembly
ANTI-CORROSION PROTECTION
                                                               ISSUE         REVISION
                    LAM TA KHONG
                                                                April 2001      A
                    TAILRACE GATE
      ABB                               VI - ANNEXES                             Page 22
CATALOGUES
ELECTRICAL HOIST
                                                    ISSUE                 REVISION
            LAM TA KHONG
                                                     April 2001              A
           TAILRACE GATE
      ABB                               VI - ANNEXES                               Page 23
                                                        ISSUE             REVISION
           LAM TA KHONG
                                                         April 2001            A
          TAILRACE GATE
      ABB                                 VI - ANNEXES                                 Page 24
CATALOGUES
ELECTRICAL CIRCUIT
                                                         ISSUE                  REVISION
            LAM TA KHONG
                                                             April 2001            A
           TAILRACE GATE