Installation Steps for a 5MW Hydropower Generation System

Installation Steps for a 5MW Hydropower Generation System
1. Pre-installation Preparation
Construction Planning & Design:
Review and verify the hydropower plant design and installation blueprints.
Develop a construction schedule, safety protocols, and installation procedures.
Equipment Inspection & Delivery:
Inspect and check all delivered equipment, including turbines, generators, and auxiliary systems.
Verify parts, dimensions, and specifications against the technical requirements.
Foundation Construction:
Construct the concrete foundation and embedded components as per the design.
Cure the concrete properly to achieve the required strength before installation.
2. Main Equipment Installation
Turbine Installation:
Prepare the turbine pit and install the base frame.
Install the turbine components, including the stay ring, runner, guide vanes, and servomotors.
Perform initial alignment, leveling, and centering adjustments.
Generator Installation:
Install the stator, ensuring precise horizontal and vertical alignment.
Assemble and install the rotor, ensuring uniform air gap distribution.
Install bearings, thrust bearings, and adjust shaft alignment.
Auxiliary System Installation:
Install the governor system (such as hydraulic pressure units).
Set up the lubrication, cooling, and control systems.
3. Electrical System Installation
Power System Installation:
Install the main transformer, excitation system, control panels, and switchgear.
Route and connect power cables, followed by insulation and grounding tests.
Automation & Protection System Installation:
Set up the SCADA system, relay protection, and remote communication systems.
4. Commissioning & Testing
Individual Equipment Testing:
Conduct a no-load test of the turbine to check mechanical performance.
Perform generator no-load and short-circuit tests to verify electrical characteristics.
System Integration Testing:
Test the synchronization of all systems, including automation and excitation control.
Trial Operation:
Conduct load tests to assess stability and performance under operational conditions.
Ensure all parameters meet design requirements before official commissioning.
Following these steps ensures safe and efficient installation, leading to long-term, reliable operation of the 5MW hydropower plant.