IEC 60545:2021
(Main)Guidelines for commissioning and operation of hydraulic turbines, pump-turbines and storage pumps
Guidelines for commissioning and operation of hydraulic turbines, pump-turbines and storage pumps
The purpose of IEC 60545:2021 is to establish, in a general way, suitable procedures for commissioning and operation of hydraulic machines and associated equipment, and to indicate how such machines and equipment should be commissioned and operated. Commissioning and operation of the associated equipment are not described in detail in this document but is considered in the commissioning and operation procedure as a separate step. Machines of up to about 15 MW and reference diameters of about 3 m are generally covered by IEC 62006. It is understood that a guideline of this type will be binding only if the contracting parties have agreed upon it. The guidelines exclude matters of purely commercial interest, except those inextricably connected with the conduct of commissioning and operation. The guidelines are not concerned with waterways, gates, drainage pumps, cooling-water equipment, generators, motor-generators, electrical equipment (e.g. circuit breakers, transformers) etc., except where they cannot be separated from the hydraulic machinery and its equipment. Wherever the guidelines specify that documents, drawings or information are supplied by a supplier (or by suppliers), each individual supplier should furnish the appropriate information for its own supply only. This second edition cancels and replaces the first edition published in 1976 and the first edition of IEC 60805 published in 1985. This edition constitutes a technical revision. This edition includes the following significant technical changes with respect to the previous edition:
a) the focus is on the commissioning and operation of the hydraulic machine. Interfaces to the electric machine are mentioned only for a better understanding of the context;
b) the definitions of tests for commissioning and adjustable speed are updated to state of the art;
c) the record sheets ‘measurements during erection’ are excluded (see IEC 63132 (all parts));
d) the maintenance is excluded (see IEC 62256).
Lignes directrices pour la mise en service et l'exploitation des turbines hydrauliques, des pompes-turbines et des pompes d'accumulation
IEC 60545:2021 Le présent document a pour objet d’établir, d’une manière générale, des procédures appropriées pour la mise en service et l’exploitation des machines hydrauliques et des équipements associés, et d’indiquer la façon dont il convient de mettre en service et d’exploiter ces machines et équipements.
La mise en service et l’exploitation des équipements connexes ne sont pas décrites en détail dans le présent document, mais sont prises en compte dans la procédure de mise en service et d’exploitation comme une étape distincte.
Les machines d’une puissance pouvant atteindre environ 15 MW et présentant des diamètres de référence d’environ 3 m sont généralement couvertes par l’IEC 62006.
Il est entendu qu’une ligne directrice de ce type n’est contraignante que si un accord a été conclu entre les parties contractantes.
Les lignes directrices excluent les questions d’intérêt purement commercial, sauf celles qui sont étroitement liées à la conduite de la mise en service et de l’exploitation.
Les lignes directrices ne couvrent pas les adductions, les vannes, les pompes de drainage, les équipements de refroidissement à eau, les alternateurs, les générateurs-moteurs, les équipements électriques (par exemple les disjoncteurs, les transformateurs), etc., sauf lorsqu’ils ne peuvent pas être séparés de la machinerie hydraulique et de ses équipements.
Lorsque les lignes directrices précisent que les documents, les plans ou les informations sont mis à disposition par un ou plusieurs fournisseurs, il convient que chaque fournisseur fournisse les informations appropriées, concernant uniquement sa propre production.
Cette seconde édition annule et remplace la première édition parue en 1976 et la première édition de l’IEC 60805 parue en 1985. Cette édition constitue une révision technique.
Cette édition inclut les modifications techniques majeures suivantes par rapport à l’édition précédente:
a) les aspects traités sont essentiellement la mise en service et l’exploitation de la machine hydraulique. Les interfaces avec la machine électrique ne sont mentionnées que lorsqu’elles permettent une meilleure compréhension du contexte;
b) les définitions des essais pour la mise en service et la vitesse variable ont été actualisées selon l’état de l’art;
c) les feuilles d’enregistrement "mesures pendant le montage" ont été exclues (voir l’IEC 63132 (toutes les parties);
d) la maintenance a été exclue (voir l’IEC 62256).
General Information
Frequently Asked Questions
IEC 60545:2021 is a standard published by the International Electrotechnical Commission (IEC). Its full title is "Guidelines for commissioning and operation of hydraulic turbines, pump-turbines and storage pumps". This standard covers: The purpose of IEC 60545:2021 is to establish, in a general way, suitable procedures for commissioning and operation of hydraulic machines and associated equipment, and to indicate how such machines and equipment should be commissioned and operated. Commissioning and operation of the associated equipment are not described in detail in this document but is considered in the commissioning and operation procedure as a separate step. Machines of up to about 15 MW and reference diameters of about 3 m are generally covered by IEC 62006. It is understood that a guideline of this type will be binding only if the contracting parties have agreed upon it. The guidelines exclude matters of purely commercial interest, except those inextricably connected with the conduct of commissioning and operation. The guidelines are not concerned with waterways, gates, drainage pumps, cooling-water equipment, generators, motor-generators, electrical equipment (e.g. circuit breakers, transformers) etc., except where they cannot be separated from the hydraulic machinery and its equipment. Wherever the guidelines specify that documents, drawings or information are supplied by a supplier (or by suppliers), each individual supplier should furnish the appropriate information for its own supply only. This second edition cancels and replaces the first edition published in 1976 and the first edition of IEC 60805 published in 1985. This edition constitutes a technical revision. This edition includes the following significant technical changes with respect to the previous edition: a) the focus is on the commissioning and operation of the hydraulic machine. Interfaces to the electric machine are mentioned only for a better understanding of the context; b) the definitions of tests for commissioning and adjustable speed are updated to state of the art; c) the record sheets ‘measurements during erection’ are excluded (see IEC 63132 (all parts)); d) the maintenance is excluded (see IEC 62256).
The purpose of IEC 60545:2021 is to establish, in a general way, suitable procedures for commissioning and operation of hydraulic machines and associated equipment, and to indicate how such machines and equipment should be commissioned and operated. Commissioning and operation of the associated equipment are not described in detail in this document but is considered in the commissioning and operation procedure as a separate step. Machines of up to about 15 MW and reference diameters of about 3 m are generally covered by IEC 62006. It is understood that a guideline of this type will be binding only if the contracting parties have agreed upon it. The guidelines exclude matters of purely commercial interest, except those inextricably connected with the conduct of commissioning and operation. The guidelines are not concerned with waterways, gates, drainage pumps, cooling-water equipment, generators, motor-generators, electrical equipment (e.g. circuit breakers, transformers) etc., except where they cannot be separated from the hydraulic machinery and its equipment. Wherever the guidelines specify that documents, drawings or information are supplied by a supplier (or by suppliers), each individual supplier should furnish the appropriate information for its own supply only. This second edition cancels and replaces the first edition published in 1976 and the first edition of IEC 60805 published in 1985. This edition constitutes a technical revision. This edition includes the following significant technical changes with respect to the previous edition: a) the focus is on the commissioning and operation of the hydraulic machine. Interfaces to the electric machine are mentioned only for a better understanding of the context; b) the definitions of tests for commissioning and adjustable speed are updated to state of the art; c) the record sheets ‘measurements during erection’ are excluded (see IEC 63132 (all parts)); d) the maintenance is excluded (see IEC 62256).
IEC 60545:2021 is classified under the following ICS (International Classification for Standards) categories: 23.100.10 - Pumps and motors. The ICS classification helps identify the subject area and facilitates finding related standards.
You can purchase IEC 60545:2021 directly from iTeh Standards. The document is available in PDF format and is delivered instantly after payment. Add the standard to your cart and complete the secure checkout process. iTeh Standards is an authorized distributor of IEC standards.
Standards Content (Sample)
IEC 60545 ®
Edition 2.0 2021-06
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Guidelines for commissioning and operation of hydraulic turbines,
pump-turbines and storage pumps
Lignes directrices pour la mise en service et l’exploitation des turbines
hydrauliques, des pompes-turbines et des pompes d’accumulation
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IEC 60545 ®
Edition 2.0 2021-06
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Guidelines for commissioning and operation of hydraulic turbines,
pump-turbines and storage pumps
Lignes directrices pour la mise en service et l’exploitation des turbines
hydrauliques, des pompes-turbines et des pompes d’accumulation
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 23.100.10 ISBN 978-2-8322-9923-4
– 2 – IEC 60545:2021 © IEC 2021
CONTENTS
FOREWORD . 5
1 Scope . 7
2 Normative references . 7
3 Terms and definitions . 7
3.1 Machine and equipment . 7
3.2 Tests, periods, operating modes . 9
4 Information on operating conditions . 11
4.1 General . 11
4.2 Documents, data and instructions . 11
4.3 Final stage of erection, before commissioning . 13
5 Commissioning . 13
5.1 General . 13
5.1.1 Overview . 13
5.1.2 Commissioning period . 14
5.1.3 Operating conditions during commissioning . 14
5.1.4 Measurements during commissioning . 14
5.1.5 Grid and hydraulic conditions . 15
5.1.6 Pre-conditions for commissioning . 15
5.1.7 Health and safety during the commissioning . 16
5.2 Commissioning co-ordinator and organisation . 16
5.3 Pre-start tests . 17
5.3.1 General . 17
5.3.2 Prior to filling waterways . 17
5.3.3 Filling waterways . 18
5.3.4 Prior to filling machine . 18
5.3.5 Filling machine . 19
5.3.6 Using the machine as a pump for initial filling of the penstock. 20
5.4 Initial run . 20
5.5 Test operation period . 21
5.5.1 General . 21
5.5.2 No-load tests . 21
5.5.3 First synchronizing . 23
5.5.4 Load rejection and load run . 23
5.5.5 Additional tests for adjustable (variable) speed hydraulic machinery in
combination with a double fed generator/motor-generator . 27
5.5.6 Operation modes and mode changes . 28
5.5.7 Control modes . 29
5.5.8 Operation modes with particular functions . 29
5.5.9 Field tests for runaway speed . 30
5.5.10 Other tests . 30
5.6 End of commissioning . 30
6 Operation . 31
6.1 General . 31
6.2 Test service period . 31
6.2.1 General . 31
6.2.2 Responsibilities . 31
6.2.3 Outages and interruptions . 31
6.2.4 Observations and records . 31
6.2.5 End of test service period . 32
6.3 Commercial service . 32
6.3.1 Guarantee period . 32
6.3.2 Post guarantee period . 34
6.3.3 Special operating conditions . 34
Annex A (informative) Description of different modes of operation of a reversible
pump-turbine . 39
A.1 General . 39
A.2 From standstill (ready to operate) to standstill (auxiliary systems in
operation) (01 and 10) . 39
A.3 From standstill (auxiliary systems in operation) to no-load (synchronized) (12) . 39
A.4 From no-load (synchronized) to standstill (21). 39
A.5 From no-load to turbine operation (23) . 40
A.6 From turbine operation to no-load (synchronized) (32) . 40
A.7 From no-load to synchronous condenser operation (turbine direction) (24) . 40
A.8 From synchronous condenser operation (turbine direction) to no-load (42) . 41
A.9 From synchronous condenser operation (turbine direction) to turbine
operation (43:= 42 and 23) . 41
A.10 From turbine operation to synchronous condenser operation (turbine
direction) (34:= 32 and 24) . 41
A.11 From standstill (auxiliary systems in operation) to synchronous condenser
operation (turbine direction) 14 or (12 and 24) . 41
A.12 From synchronous condenser operation (turbine direction) to standstill (41) . 41
A.13 From standstill (auxiliary system in operation) to SCO (pump direction) (15) . 42
A.14 From synchronous condenser operation (pump direction) to pump operation (56) . 42
A.15 From pump operation to synchronous condenser operation (pump direction) (65) . 42
A.16 From synchronous condenser operation (pump direction) to standstill (51) . 42
A.17 From operation (pump direction) to standstill (61) . 42
A.18 From standstill to pump operation (16) . 42
A.19 From turbine – full load to pump operation (36) . 43
A.20 From pump operation to turbine full load – quick change over (63) . 43
A.21 Hydraulic short circuit . 43
Annex B (informative) Tests for adjustable (variable) speed hydraulic machinery in
combination with a double fed generator/motor-generator . 44
B.1 Operating zone and test condition . 44
B.1.1 General . 44
B.1.2 Pumping operation . 44
B.1.3 Generation operation . 44
B.1.4 Test conditions . 45
B.2 Test items . 45
B.2.1 Step response test by power setter . 45
B.2.2 Guide vane opening vs. power characteristic measurement in pump and
turbine operation . 45
B.2.3 Confirmation of preventive control of the speed deviation from the
defined speed range . 46
B.2.4 Load (input/output) rejection test . 46
Annex C (informative) Commissioning program . 47
Bibliography . 48
– 4 – IEC 60545:2021 © IEC 2021
Figure 1 – Commissioning procedure . 14
Figure 2 – Example of organisation chart for commissioning . 17
Figure 3 – Modes of operation of a reversible pump-turbine . 29
Figure B.1 – Pumping operation zone . 44
Figure B.2 – Generation operation zone . 45
Table C.1 – Example for a commissioning procedure programme . 47
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
GUIDELINES FOR COMMISSIONING AND OPERATION OF HYDRAULIC
TURBINES, PUMP-TURBINES AND STORAGE PUMPS
FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
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indispensable for the correct application of this publication.
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rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 60545 has been prepared by IEC technical committee 4: Hydraulic
turbines.
This second edition cancels and replaces the first edition published in 1976 and the first edition
of IEC 60805 published in 1985. This edition constitutes a technical revision.
This edition includes the following significant technical changes with respect to the previous
edition:
a) the focus is on the commissioning and operation of the hydraulic machine. Interfaces to the
electric machine are mentioned only for a better understanding of the context;
b) the definitions of tests for commissioning and adjustable speed are updated to state of the
art;
c) the record sheets ‘measurements during erection’ are excluded (see IEC 63132 (all parts);
d) the maintenance is excluded (see IEC 62256).
– 6 – IEC 60545:2021 © IEC 2021
The text of this International Standard is based on the following documents:
FDIS Report on voting
4/407/FDIS 4/420/RVD
Full information on the voting for its approval can be found in the report on voting indicated in
the above table.
The language used for the development of this International Standard is English.
This document was drafted in accordance with ISO/IEC Directives, Part 2, and developed in
accordance with ISO/IEC Directives, Part 1 and ISO/IEC Directives, IEC Supplement, available
at www.iec.ch/members_experts/refdocs. The main document types developed by IEC are
described in greater detail at www.iec.ch/standardsdev/publications.
The committee has decided that the contents of this document will remain unchanged until the
stability date indicated on the IEC website under webstore.iec.ch in the data related to the
specific document. At this date, the document will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
IMPORTANT – The "colour inside" logo on the cover page of this document indicates
that it contains colours which are considered to be useful for the correct understanding
of its contents. Users should therefore print this document using a colour printer.
GUIDELINES FOR COMMISSIONING AND OPERATION OF HYDRAULIC
TURBINES, PUMP-TURBINES AND STORAGE PUMPS
1 Scope
The purpose of this document is to establish, in a general way, suitable procedures for
commissioning and operation of hydraulic machines and associated equipment, and to indicate
how such machines and equipment should be commissioned and operated.
Commissioning and operation of the associated equipment are not described in detail in this
document but is considered in the commissioning and operation procedure as a separate step.
Machines of up to about 15 MW and reference diameters of about 3 m are generally covered
by IEC 62006.
It is understood that a guideline of this type will be binding only if the contracting parties have
agreed upon it.
The guidelines exclude matters of purely commercial interest, except those inextricably
connected with the conduct of commissioning and operation.
The guidelines are not concerned with waterways, gates, drainage pumps, cooling-water
equipment, generators, motor-generators, electrical equipment (e.g. circuit breakers,
transformers) etc., except where they cannot be separated from the hydraulic machinery and
its equipment.
Wherever the guidelines specify that documents, drawings or information are supplied by a
supplier (or by suppliers), each individual supplier should furnish the appropriate information
for its own supply only.
2 Normative references
There are no normative references in this document.
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminological databases for use in standardization at the following
addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
3.1 Machine and equipment
3.1.1
hydraulic machinery
turbines, storage pumps, pump-turbines, valves, guide and thrust bearings used in hydroelectric
power and pumped storage stations
Note 1 to entry: The term hydraulic machinery includes hydraulic torque converter and all type of main inlet valves.
– 8 – IEC 60545:2021 © IEC 2021
Note 2 to entry: Terms related to hydro turbine governing systems are not included; refer to IEC 60308.
[SOURCE: IEC TR 61364:1999, 3.1, modified – Addition of Note 1 to entry.]
3.1.2
hydraulic machine
hydraulic impulse and reaction turbines, storage pumps and pump-turbines
[SOURCE: IEC TR 61364:1999, 3.1]
3.1.3
turbine
machine for transforming hydraulic energy into mechanical energy
Note 1 to entry: The term turbine includes a pump-turbine functioning as a turbine.
Note 2 to entry: The term turbine does not include the inlet or outlet valves nor the associated generator or governor.
[SOURCE: IEC TR 61364:1999, 4.1, modified – Addition of Note 1 to entry.]
3.1.4
pump
machine for transforming mechanical energy into hydraulic energy in order to store water that
will be used later on to produce electric energy
Note 1 to entry: The term pump includes a storage pump and a pump-turbine functioning as a pump.
Note 2 to entry: The term pump does not include the inlet or outlet valves nor the associated motor.
[SOURCE: IEC TR 61364:1999, 4.1, modified – Replacement of "storage pump" with "pump" in
the main term, and addition of Note 1 to entry.]
3.1.5
starting device
starting equipment for a motor-generator or motor
EXAMPLE 1 pony motor
EXAMPLE 2 starting turbine
EXAMPLE 3 frequency converter
EXAMPLE 4 hydraulic torque converter
EXAMPLE 5 back to back
Note 1 to entry: Each example is representing a different method to start the hydraulic machine functioning as a
pump.
3.1.6
opening device
guide vanes or the turbine needle of impulse turbines and its driving components (governing
systems)
3.1.7
electrical machine
generators and motor-generators of synchronous type including the excitation equipment as
well as of the asynchronous type
3.1.8
associated equipment
all additional machinery which is necessary to allow operation of the hydraulic machine (if
applicable)
EXAMPLE 1 inlet and outlet gates or valves, draft tube gates, cylindrical valves (ring gates)
EXAMPLE 2 pressure relief valves
EXAMPLE 3 couplings
EXAMPLE 4 gear drives
EXAMPLE 5 brake system
EXAMPLE 6 water depression system
EXAMPLE 7 air supply system
EXAMPLE 8 cooling-water systems
EXAMPLE 9 drainage systems
EXAMPLE 10 dewatering systems
EXAMPLE 11 oil supply systems
3.2 Tests, periods, operating modes
3.2.1
commissioning
testing of new or rehabilitated equipment to check its conformity with contractual specifications,
as well as operation of the equipment until formally accepted by the purchaser
3.2.2
operation
utilization of the equipment to convert energy, or a state of readiness for such production
3.2.3
maintenance
activity performed on equipment in order to keep it in a state of optimum operating condition
3.2.4
pre-start test
test between completion of erection of the equipment and initial run
3.2.5
initial run
first movement of rotating parts after erection
3.2.6
test run
operation to obtain one set of data for a specific test
3.2.7
test operation
utilization of the equipment for testing purposes
– 10 – IEC 60545:2021 © IEC 2021
3.2.8
test operation period
test period following initial run and followed by test service
Note 1 to entry: It includes no-load runs for checking power plant equipment, as well as load runs in turbine and
pumping operation, load rejections and energy supply interruption pump-turbine tests.
3.2.9
no-load test
operation of the machine without connection to the electrical grid
3.2.10
no-discharge test
operation of the machine in pump-mode with the high pressure side valve closed
3.2.11
test service period
operation of the equipment for an agreed period
Note 1 to entry: During this test, the supplier is generally responsible.
3.2.12
commercial service
operation of the equipment, under the operator’s responsibility
3.2.13
commercial service period
period starting after acceptance and including service periods, as well as periods when the
equipment can be out of operation for maintenance, inspection, repairs, etc.
3.2.14
guarantee period
time, extending through an agreed part of the commercial service period, during which the
supplier has commercial obligations to correct defects in his equipment in order to bring it into
conformity with the contract
Note 1 to entry: For this purpose, tests in accordance with the appropriate parts of 6.3.1.5 are performed.
3.2.15
inspection
check on the condition of equipment
3.2.16
repair
restoration after wear or damage
3.2.17
modification
change intended to improve performance
3.2.18
rehabilitation
restoration of equipment capacity and/or equipment efficiency to near to “as-new” levels;
extension of equipment life by re-establishing mechanical integrity
[SOURCE: IEC 62256:2017, Clause 3]
3.2.19
supplier
entity (for example manufacturer, contractor, installer, integrator) who provides equipment or
services associated with the machine
Note 1 to entry: The user organization can also act in the capacity of a supplier to itself.
[SOURCE: IEC 60204-1:2016, 3.1.62, modified – Addition of Note 1 to entry.]
3.2.20
operator
entity (for example owner of the equipment or entity contracted by him) who is responsible for
operation of the equipment
4 Information on operating conditions
4.1 General
This clause describes the information which should be given by the supplier(s) to the operator.
A fundamental requirement for proper operation and maintenance is a satisfactory knowledge
of the machine and its accessories by the operator.
The supplier shall deliver to the operator all necessary documents, instructions and information.
They shall include as a minimum:
– general drawings (e.g. general arrangement of the hydraulic machine, power house, …);
– material lists, descriptions and test certificates for main parts;
– function diagrams;
– instructions for operation (especially the range of operation), inspection and maintenance
of the supplied equipment;
– assembly and dismantling instructions;
– safety instructions;
– list of spare parts, as stated in the contract;
– constraints.
These documents, even not final (but updated and finalised after test period), shall be given to
the operator as soon as required and, in any case, before the initial run to be reviewed by the
operator.
The operator shall define additional constraints (e.g. regarding shipping on rivers, slope
stability, public safety, …).
4.2 Documents, data and instructions
The documents submitted by the supplier shall include the following data, some of which can
be amended according to experience gathered during commissioning:
1) The characteristic diagrams relating to heads, flow, power, opening (e.g. guide vane or
needle), speed, tailwater elevations, and operating limits; also, where applicable, runner
blade or deflector position. Examples of such diagrams are the pump characteristic and the
turbine hill chart.
2) Statement of similitude of model and prototype, depending on the contract.
3) Operation and safety instructions on inlet and outlet gates or valves of the machine and
pressure relief valves. The interlocking between the valves and gates shall be considered.
– 12 – IEC 60545:2021 © IEC 2021
4) Detailed sequential diagrams, illustrating ordinary changes from one mode of operation to
another (generating, pumping, synchronous condenser operation, standby) as well as
actions due to various electrical or mechanical faults.
5) Guide vane opening (or needle opening of impulse turbines) for no-load, starting and
cavitation limits, as functions of head and tailwater levels also, where appropriate, runner
blade or deflector position.
6) Transient calculations (model presentation, input data, design criteria/admissible value,
load cases and descriptions of maximum and minimum values for pressure, speed, flow,
safety margin, references), depending on the contract.
NOTE 1 Closing and opening times of main valve sealings are considered.
7) Governor and servomotor characteristics (e.g. relationship between guide vane angle and
servomotor stroke, cam relationship if applicable).
8) If applicable, description of the water-depression-system or de-watering and refilling
system of the runner, data for compressed air tanks (including capacity of air tanks, control
pressure, etc.), compressors, valves, automatic control devices (both for de-watering
system and air leakage supplement system), maximum and minimum water level in the
draft tube, etc.
9) Adjustment of overspeed protection device, information of set value (shutdown value).
10) If applicable, description of the coupling type between the hydraulic machine shaft and
motor-generator shaft and of the synchronizing arrangement.
11) Characteristics of the fluids for the governing system. Filter specifications and information
on purification frequency and method.
12) Control and servo systems. Description of type and control system of the main valve, the
distributor and the movable blade of the runner (as applicable) as well as closing and
opening laws for the main valve, the guide vanes and runner blades.
13) Maximum steady state runaway speed and maximum transient speed and pressure
variations at some specific operating heads (maximum/minimum/rated water head).
NOTE 2 The speed value is below the maximum speed for machine safety.
14) Minimum continuous operating speed (depending on design of thrust bearing and other
bearings).
15) Minimum operating water head for initial run.
16) Description of lubrication systems, stating amount and characteristics of lubricants and
frequency of replacement.
17) If applicable, data on high pressure lifting oil injection system for rotating parts.
18) Speed or time limits below which operation of the thrust bearing high pressure lifting oil
injection system is necessary.
19) If applicable, maximum and minimum speeds for mechanical and electrical brake operation.
20) Intermediate oil levels and pressures at which pumps and compressors should be started
or alarms given; also data for automatic signalling and emergency devices.
21) Maximum and minimum temperatures in bearings, seals and in the oil or fluid pressure
circuits (alarm and shutdown values).
22) Maximum and minimum pressures, flows and levels in oil or fluid pressure systems and
bearings (alarm and shutdown values).
23) If applicable, maximum and minimum temperatures and pressures in oil head (alarm and
shutdown values).
24) Maximum acceptable load of thrust bearing, if required.
25) Design values and tolerances for machine erection (bearings and seals clearances,
inclination, circularities, concentricities).
26) Maximum and minimum pressures and flows in coolers (alarm and shutdown values).
27) Maximum water levels in drainage pits (alarm and shutdown values).
28) Data on electric motors, pumps and other accessories.
29) Safety instructions for test and operating staff.
30) Other data of importance which are considered necessary by either operator or supplier for
safe operation of the equipment or for instruction of personnel (e.g. axial hydraulic thrust,
weight force of the rotating parts of the turbine/pump-turbine and the generator/motor-
generator.
4.3 Final stage of erection, before commissioning
During the final stage of erection, the supplier shall give appropriate instructions to the operator
and provide the information stated in 4.2 on operating the equipment.
During the final stage of erection, the start, the test runs and test service period, the operator
shall make his staff available to the supplier for instruction and training in order for them to be
properly capable of operating the machine and associated equipment.
After first filling of bearing and governor oil tanks, it is recommended to take oil samples that
should be kept as reference of the oil at the beginning of commissioning.
After first filling of “water-filled” Kaplan runners, it is recommended to take samples of the filling
(water plus some additives) that should be kept as reference at the beginning of commissioning.
It is recommended that critical spare parts are available (e.g. parts with long delivery time).
5 Commissioning
5.1 General
5.1.1 Overview
This clause deals with the commissioning of hydraulic machinery. It describes and gives advice
and recommendations about (pre-) conditions, measurements, health and safety, organization.
Tests during commissioning and final documents are suggested.
In the lifetime of the hydraulic machine, the commissioning period is the time in which the
supplier shall demonstrate to the operator (owner) that the equipment fulfils the requested
characteristics and is ready to run in commercial operation. As the equipment is exposed to the
actual loads for the first time, the commissioning procedure shall be carried out with the
necessary care and coordination between the parties.
The process chart in Figure 1 shows different steps for a typical commissioning procedure.
– 14 – IEC 60545:2021 © IEC 2021
Figure 1 – Commissioning procedure
5.1.2 Commissioning period
The commissioning period starts after finishing of erection of a new unit and ends with the
beginning of the test service period. Similar procedures can also be utilized with or without
formal acceptance after repair or rehabilitation.
5.1.3 Operating conditions during commissioning
The operating requirements given in Clause 4 shall be complied with during commissioning. If
the operating conditions of the power station prevent commissioning within these requirements,
the operator and supplier shall define acceptable conditions and agree on the commissioning
procedure.
5.1.4 Measurements during commissioning
For correct interpretation and determination of the causes of any unexpected phenomena, it is
advantageous to make simultaneous recordings of significant parameters (such as the pressure
in the spiral casing and draft tube, openings of control mechanisms, speed, displacement of
shaft and vibration of bearings, guide vanes and covers, and possibly power, loads and
temperatures on bearings, pressures in servomotors, etc.) on recording instruments. These
should be in operation during the initial run and thereafter. Each recording shall have an
identification of the test, unit number and a time and date registration.
5.1.5 Grid and hydraulic conditions
It is the operator’s responsibility to obtain from all the authorities concerned agreements on the
specified conditions (grid, head, flow, etc.) for test operation.
5.1.6 Pre-conditions for commissioning
5.1.6.1 General
Before starting the commissioning, all activities which belong to the erection and which are
necessary to carry out the commissioning safely shall be finalized and recorded. The start of
commissioning shall be agreed between the operator and the supplier and certified in a protocol
“ready for commissioning”.
5.1.6.2 Administrative and organizational
– The commissioning co-ordinator shall be defined.
– The commissioning committee with members of all parties (commissioning engineers of the
different suppliers) clarifies the roles of all participants in the commissioning organization
and their respective obligations.
– The commissioning committee establishes a work permit system to ensure safe working
(locking and tagging system).
– A time schedule for the planned activities shall be worked out and agreed between the
parties.
– The commissioning programme (e.g. see Table C.1).
5.1.6.3 Available documents
– All relevant final erection protocols (e.g. records of gaps between stationary and rotating
parts).
– All relevant protocols “Ready for commissioning” from the different suppliers.
– All relevant commissioning instructions and commissioning protocols.
5.1.6.4 Available equipment
In the case of any unforeseen events during commissioning, the water ingress into the
powerhouse shall be stopped (as well as the water flow in the waterways and the hydraulic
machine). The following equipment if applicable shall be ready for emergency closure:
– intake gates;
– outlet gates;
– inlet and outlet valves;
– stop logs designed to close under discharge.
5.1.6.5 Available systems
– Main power supply and emergency power supply
– Station AC and DC supply
– Auxiliary power supply
– Common auxiliaries such as pumps, coolers, heaters
– Drainage
– Dewatering
– Cooling
– Compressed air
– Monitoring turbine
– Monitoring generator
– 16 – IEC 60545:2021 © IEC 2021
– Excitation
– All protection systems for the unit
– Electrical protection for gas insulated switchgear (GIS), bus bars and feeders
– Main transformer including protection and monitoring devices
– Transformer auxiliaries, such as fans and water pumps
– Synchronizing system
– Communication
– Automation
– Lighting
– Fire detection and fire fighting
– Heating, ventilation, air conditioning (HVAC)
– Earthing
and other applicable systems of the power plant.
5.1.7 Health and safety during the commissioning
As a part of test and commissioning, the facilities are put into live conditions (pressurised,
energized, equipment in the vicinity are in normal operation, etc.) and risk awareness shall be
emphasized. All personnel involved in the commissioning activities should be informed and
trained in the valid health and safety regulations. It is recommended to practice procedures for
fire protection, evacuation, first aid service, etc. Extra pushbuttons for fire protection and
emergency shutdown might be installed temporarily during commissioning. The area around the
facilities which are being commissioned should be marked with some kind of barrier and should
be cleaned before commissioning. In order to restrict the number of persons in the area, only
authorised personnel taking part of the commissioning should have access.
5.2 Commissioning co-ordinator and organisation
A commissioning co-ordinator shall be appointed by agreement between the operator, the main
contractors and the suppliers. The commissioning co-ordinator shall be in charge of the
commissioning activities and prepare a program which describes the commissioning activities,
including relevant activities from the contractors/suppliers detailed programmes. The program
can be designed as a step by step program that can be signed off. This program shall be
checked and approved by the operator, the main suppliers and contractors before and during
the tests if changes appear to be n
...
IEC 60545:2021 표준은 수압 기계 및 관련 장비의 커미셔닝 및 운영을 위한 적합한 절차를 수립하고, 이러한 기계 및 장비가 어떻게 커미셔닝되고 운영되어야 하는지를 간략히 안내하는 것을 목적으로 합니다. 이 표준은 최대 약 15 MW의 기계 및 약 3 m의 기준 직경을 일반적으로 포함하며, 계약 당사자 간에 동의한 경우에만 구속력이 있음을 명시하고 있습니다. 표준의 강점 중 하나는 커미셔닝과 운영 절차에 대한 체계적인 접근 방식입니다. 특히, 수압 기계의 커미셔닝 및 운영에 중점을 두고 있으며, 전기 기계와의 인터페이스에 대한 언급은 이해를 돕기 위한 것입니다. 또한, 커미셔닝 및 가변 속도 테스트의 정의가 최신 기술 수준으로 업데이트되어 있어, 업계의 변화에 적시 대응하고 있습니다. 이 문서의 범위는 주요 상업적 관심을 배제하며, 수압 기계 및 장비와 불가분의 관계가 있는 경우를 제외한 수로, 게이트, 배수 펌프, 냉각수 장비, 발전기, 모터-발전기 및 전기 장비와는 관련이 없습니다. 이는 표준이 특정 기술적 요구사항에 더욱 집중될 수 있도록 하여, 사용자가 필요한 정보를 받을 수 있도록 하고 있습니다. IEC 60545:2021의 두 번째 판은 1976년에 발표된 첫 번째 판과 1985년에 발표된 IEC 60805 첫 번째 판을 취소하고 대체하는 기술 개정판으로, 검사 및 유지보수와 같은 측면들이 제외되어 있어, 사용자가 직접적으로 필요한 정보에 집중할 수 있는 구조를 제공합니다. 이러한 점에서, 표준은 수압 기계의 커미셔닝과 운영에 있어 매우 중요한 지침을 제공하며, 업계에서의 활용도가 높다고 할 수 있습니다.
IEC 60545:2021は、水力タービン、ポンプタービン、貯蔵ポンプの導入および運転に関するガイドラインを定めた重要な文書です。この標準は、これらの水力機械と関連設備の導入および運転のための適切な手順を一般的に確立することを目的としています。特に、最大約15 MW、直径約3 mの機械がIEC 62006によって一般的にカバーされることを考慮すると、この文書は水力機械の導入プロセスの構造を理解するための強固な基盤を提供します。 この標準の強みは、導入と運転の手順について、商業的な関心事からの影響を最小限に抑えつつ、あくまで水力機械に直接関連する内容に焦点を当てている点です。導入プロセスの各ステップを独立して扱っているため、設備の運用に際しての透明性が高まります。 IEC 60545:2021は、前版からの重要な技術的変更を含んでおり、特に水力機械の導入および運転に対する焦点が強調されています。これにより、最新の技術的進展に基づいた定義が更新され、実際的な導入手続きが明確に示されています。また、供給業者が提供すべき情報に関するガイドラインも含まれており、各供給業者が自らの設備に対する適切な情報を提供することが求められます。 この文書は、1976年に発行された初版および1985年に発行されたIEC 60805の初版を取り消し、技術的な見直しとして位置づけられているため、非常に重要な意味を持っています。水力機械の導入と運転に関する実務において、IEC 60545:2021は、業界の標準としての役割を果たし、関連するすべての関係者にとって不可欠なリソースとなるでしょう。特に、この標準は現代の技術に適応する形で進化しており、今後の水力機械の運用において重要な指針を提供します。
IEC 60545:2021 provides essential guidelines for the commissioning and operation of hydraulic turbines, pump-turbines, and storage pumps. Its scope is clearly delineated, focusing specifically on establishing suitable procedural frameworks that ensure effective commissioning and operational practices for hydraulic machinery and associated equipment. One of the significant strengths of this standard is its clear demarcation of responsibilities and procedures. By recognizing that commissioning and operation must be treated as distinct phases, IEC 60545:2021 facilitates a streamlined approach, which is particularly beneficial for engineering teams tasked with implementing these processes. This clarity is further enhanced by the exclusions outlined in the document, which specifies that matters of a purely commercial nature are not addressed unless they directly impact commissioning and operation. Moreover, this second edition of IEC 60545 brings several updates that align with contemporary technological standards. The revisions to the definitions of tests for commissioning and adjustable speed signify a vital alignment with current best practices in the industry, ensuring that operators have access to the most relevant and effective methodologies. In omitting outdated sections, such as the measurements during erection, the standard ensures that only pertinent, actionable information is included, thereby improving usability for practitioners in the field. The emphasis on compressing guidelines relevant to the hydraulic machines while providing just enough context regarding interfaces to electric machines further strengthens the document’s utility. It creates a focused resource that allows professionals to hone in on hydraulic aspects without becoming sidetracked by broader electrical or environmental concerns. Overall, IEC 60545:2021 stands out as a pivotal standard that encapsulates modern practices in the commissioning and operation of hydraulic turbines, pump-turbines, and storage pumps, making it a relevant and essential resource for engineers and technicians in the field.








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