Technical Guidelines for the

Development of Small Hydropower Plants

UNITS

Part 3: Hydro Turbine

Governing System

SHP/TG 003-3: 2019

DISCLAIMER
This document has been produced without formal United Nations editing. The designations and the presentation of the material in this
document do not imply the expression of any opinion whatsoever on the part of the Secretariat of the United Nations Industrial Development
Organization (UNIDO) concerning the legal status of any country, territory, city or area of its authorities, or concerning the delimitation
of its frontiers or boundaries, or its economic system or degree of development. Designations such as “developed”, “industrialized” and
“developing” are intended for statistical convenience and do not necessarily express a judgement about the stage reached by a particular
country or area in the development process. Mention of company names or commercial products does not constitute an endorsement by
UNIDO. Although great care has been taken to maintain the accuracy of information herein, neither UNIDO nor its Member States assume
any responsibility for consequences which may arise from the use of the material. This document may be freely quoted or reprinted but
acknowledgement is requested.

© 2019 UNIDO / INSHP- All rights reserved

Technical Guidelines for the
Development of Small Hydropower Plants
UNITS

Part 3: Hydro Turbine

Governing System

SHP/TG 003-3: 2019

Technical Guidelines for the Development of Small Hydropower Plants – Units

ACKNOWLEDGEMENTS
The technical guidelines (TGs) are the result of a collaborative effort between the United Nations Industrial Development
Organization (UNIDO) and the International Network on Small Hydro Power (INSHP). About 80 international experts and 40
international agencies were involved in the document’s preparation and peer review, and they provided concrete comments
and suggestions to make the TGs professional and applicable.

UNIDO and the INSHP highly appreciate the contributions provided during the development of these guidelines and in particular
those delivered by the following international organizations:

- The Common Market for Eastern and Southern Africa(COMESA)

- The Global Network of Regional Sustainable Energy Centres (GN-SEC), particularly the ECOWAS Centre for Renewable Energy
and Energy Efficiency (ECREEE), the East African Centre for Renewable Energy and Energy Efficiency (EACREEE), the Pacific
Centre for Renewable Energy and Energy Efficiency (PCREEE) and the Caribbean Centre for Renewable Energy and Energy
Efficiency (CCREEE).

The Chinese government has facilitated the finalization of these guidelines and was of great importance to its completion.

The development of these guidelines benefited greatly from the valuable inputs, review and constructive comments as well
as contributions received from Mr. Adnan Ahmed Shawky Atwa, Mr. Adoyi John Ochigbo, Mr. Arun Kumar, Mr. Atul Sarthak,
Mr. Bassey Edet Nkposong, Mr. Bernardo Calzadilla-Sarmiento, Ms. Chang Fangyuan, Mr. Chen Changju, Ms. Chen Hongying ,
Mr. Chen Xiaodong, Ms. Chen Yan, Ms. Chen Yueqing, Ms. Cheng Xialei, Ms. Chileshe Kapaya Matantilo, Ms. Chileshe Mpundu
Kapwepwe, Mr. Deogratias Kamweya, Mr. Dolwin Khan, Mr. Dong Guofeng, Mr. Ejaz Hussain Butt, Ms. Eva Kremere, Ms. Fang
Lin, Mr. Fu Liangliang, Mr. Garaio Donald Gafiye, Mr. Guei Guillaume Fulbert Kouhie, Mr. Guo Chenguang, Mr. Guo Hongyou, Mr.
Harold John Annegam, Ms. Hou Ling, Mr. Hu Jianwei, Ms. Hu Xiaobo, Mr. Hu Yunchu, Mr. Huang Haiyang, Mr. Huang Zhengmin, Ms.
Januka Gyawali, Mr. Jing Songkun, Mr. K. M. Dharesan Unnithan, Mr. Kipyego Cheluget, Mr. Kolade Esan, Mr. Lamyser Castellanos
Rigoberto, Mr. Li Zhiwu, Ms. Li Hui, Mr. Li Xiaoyong, Ms. Li Jingjing, Ms. Li Sa, Mr. Li Zhenggui, Ms. Liang Hong, Mr. Liang Yong, Mr.
Lin Xuxin, Mr. Liu Deyou, Mr. Liu Heng, Mr. Louis Philippe Jacques Tavernier, Ms. Lu Xiaoyan, Mr. Lv Jianping, Mr. Manuel Mattiat,
Mr. Martin Lugmayr, Mr. Mohamedain Seif Elnasr, Mr. Mundia Simainga, Mr. Mukayi Musarurwa, Mr. Olumide Taiwo Alade, Mr.
Ou Chuanqi, Ms. Pan Meiting, Mr. Pan Weiping, Mr. Ralf Steffen Kaeser, Mr. Rudolf Hüpfl, Mr. Rui Jun, Mr. Rao Dayi, Mr. Sandeep
Kher, Mr. Sergio Armando Trelles Jasso, Mr. Sindiso Ngwenga, Mr. Sidney Kilmete, Ms. Sitraka Zarasoa Rakotomahefa, Mr. Shang
Zhihong, Mr. Shen Cunke, Mr. Shi Rongqing, Ms. Sanja Komadina, Mr. Tareq Emtairah, Mr. Tokihiko Fujimoto, Mr. Tovoniaina
Ramanantsoa Andriampaniry, Mr. Tan Xiangqing, Mr. Tong Leyi, Mr. Wang Xinliang, Mr. Wang Fuyun, Mr. Wei Jianghui, Mr. Wu
Cong, Ms. Xie Lihua, Mr. Xiong Ji, Ms. Xu Jie, Ms. Xu Xiaoyan, Mr. Xu Wei, Mr. Yohane Mukabe, Mr. Yan Wenjiao, Mr. Yang Weijun,
Ms. Yan Li, Mr. Yao Shenghong, Mr. Zeng Jingnian, Mr. Zhao Guojun, Mr. Zhang Min, Mr. Zhang Liansheng, Mr. Zhang Zhenzhong,
Mr. Zhang Xiaowen, Ms. Zhang Yingnan, Mr. Zheng Liang, Mr. Zheng Xiongwei, Mr. Zheng Yu, Mr. Zhou Shuhua, Ms. Zhu Mingjuan.

Further recommendations and suggestions for application for the update would be highly welcome.

IV SHP/TG 003-3: 2019

 Part 3: Hydro Turbine Governing System

Table of Contents
Foreword VI
Introduction VII
1 Scope 1
2 Normative references 1
3 Terms and definitions 1
4 Service Conditions 1
4.1 Model selection of the governor and the oil pressure device 1
4.2 Operational situation of the hydro turbine generator unit 2
4.3 Water inertia time constant and turbine generator unit inertia time constant 2
4.4 Environmental conditions 2
4.5 Oil for the hydro turbine governing system 2
4.6 Others 2

5 Technical requirements 2
5.1 Servomotor capacity 2
5.2 Oil pressure grade 3
5.3 Static characteristics (speed droop) 3
5.4 Dynamic characteristics 3
5.5 Governor 4
5.6 Oil pressure installation 6

6 Supply scope and spare parts 8

7 Technical documents 8
8 Inspection and acceptance 8
9 Nameplate, packing, transportation and storage 10
9.1 Nameplate 10
9.2 Packing 10
9.3 Transportation 10
9.4 Storage 11

10 Installation, operation and maintenance 11

10.1 Installation 11
10.2 Operation and maintenance 11

11 Quality guarantee period 11

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Technical Guidelines for the Development of Small Hydropower Plants – Units

Foreword
The United Nations Industrial Development Organization (UNIDO) is a specialized agency under the United
Nations system to promote globally inclusive and sustainable industrial development (ISID). The relevance of
ISID as an integrated approach to all three pillars of sustainable development is recognized by the 2030 Agenda
for Sustainable Development and the related Sustainable Development Goals (SDGs), which will frame United
Nations and country efforts towards sustainable development in the next fifteen years. UNIDO’s mandate for
ISID covers the need to support the creation of sustainable energy systems as energy is essential to economic
and social development and to improving quality of life. International concern and debate over energy have
grown increasingly over the past two decades, with the issues of poverty alleviation, environmental risks and
climate change now taking centre stage.

INSHP (International Network on Small Hydro Power) is an international coordinating and promoting
organization for the global development of small hydropower (SHP), which is established on the basis of
voluntary participation of regional, subregional and national focal points, relevant institutions, utilities
and companies, and has social benefit as its major objective. INSHP aims at the promotion of global SHP
development through triangle technical and economic cooperation among developing countries, developed
countries and international organizations, in order to supply rural areas in developing countries with
environmentally sound, affordable and adequate energy, which will lead to the increase of employment
opportunities, improvement of ecological environments, poverty alleviation, improvement of local living and
cultural standards and economic development.
UNIDO and INSHP have been cooperating on the World Small Hydropower Development Report since year
2010. From the reports, SHP demand and development worldwide were not matched. One of the development
barriers in most countries is lack of technologies. UNIDO, in cooperation with INSHP, through global expert
cooperation, and based on successful development experiences, decided to develop the SHP TGs to meet
demand from Member States.

These TGs were drafted in accordance with the editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.
org/directives).

Attention is drawn to the possibility that some of the elements of these TGs may be subject to patent rights.
UNIDO and INSHP shall not be held responsible for identifying any such patent rights.

VI SHP/TG 003-3: 2019

 Part 3: Hydro Turbine Governing System

Introduction
Small Hydropower (SHP) is increasingly recognized as an important renewable energy solution to the
challenge of electrifying remote rural areas. However, while most countries in Europe, North and South
America, and China have high degrees of installed capacity, the potential of SHP in many developing countries
remains untapped and is hindered by a number of factors including the lack of globally agreed good practices
or standards for SHP development.

These Technical Guidelines for the Development of Small Hydropower Plants (TGs) will address the current
limitations of the regulations applied to technical guidelines for SHP Plants by applying the expertise and
best practices that exist across the globe. It is intended for countries to utilize these agreed upon Guidelines
to support their current policy, technology and ecosystems. Countries that have limited institutional and
technical capacities, will be able to enhance their knowledge base in developing SHP plants, thereby attracting
more investment in SHP projects, encouraging favourable policies and subsequently assisting in economic
development at a national level. These TGs will be valuable for all countries, but especially allow for the
sharing of experience and best practices between countries that have limited technical know-how.

The TGs can be used as the principles and basis for the planning, design, construction and management of
SHP plants up to 30MW.

• The Terms and Definitions in the TGs specify the professional technical terms and definitions commonly
used for SHP Plants.

• The Design Guidelines provide guidelines for basic requirements, methodology and procedure in terms
of site selection, hydrology, geology, project layout, configurations, energy calculations, hydraulics,
electromechanical equipment selection, construction, project cost estimates, economic appraisal,
financing, social and environmental assessments—with the ultimate goal of achieving the best design
solutions.
• Units Guidelines specify the technical requirements on SHP turbines, generators, hydro turbine governing
systems, excitation systems, main valves as well as monitoring, control, protection and DC power supply
systems.

• The Construction Guidelines can be used as the guiding technical documents for the construction of SHP
projects.

• The Management Guidelines provide technical guidance for the management, operation and maintenance,
technical renovation and project acceptance of SHP projects.

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Technical Guidelines for the Development of Small Hydropower Plants – Units

Technical Guidelines for the

Development of Small Hydropower Plants
UNITS

Part 3: Hydro Turbine

Governing System

VIII SHP/TG 003-3: 2019

 Part 3: Hydro Turbine Governing System

1 Scope
This Part of the Units Guidelines specifies the technical requirements as well as the basic requirements for the
supply scope, spare parts, technical documents, inspection and acceptance, packing, transportation, storage,
installation, operation and maintenance for the SHP hydro turbine governing system.

This document applies to the electro-hydraulic governor (hereinafter referred to as the governor) with a
working capacity of 350N•m or above as well as the oil pressure device. It is recommended to use the electric
governor or operator for the governor with a working capacity less than 350N•m.

2 Normative references
The following documents are referred to in the text in such a way that some or all of their content constitutes
requirements of this document. For dated references, only the edition cited applies. For undated references,
the latest edition of the referenced document (including any amendments) applies.
ISO 8068 Lubricants, Industrial Oils and Related Products (Class L) - Family T (Turbines) - Specification for
Lubricating Oils for Turbines

ISO 11158Lubricants, Industrial Oils and Related Products (Class L) – Family H (Hydraulic Systems) -
Specifications for Categories HH, HL, HM, HV and HG

IEC 61000-4-4Electromagnetic Compatibility (EMC) - Part 4-4: Testing and Measurement Techniques- Electrical
Fast Transient/ Burst Immunity Test

IEC 60308 Hydraulic turbines - Testing of the Control systems

IEC 61362 guide to the specifications of the hydraulic turbines control system

SHP/TG 001 Technical guidelines for the development of small hydropower plants —Terms and definitions.

3 Terms and definitions

For the purposes of this document, the terms and definitions given in IEC 60308, IEC 61362 and SHP/TG 001
apply.

4 Service Conditions

4.1 Model selection of the governor and the oil pressure device
4.1.1 The model selection of the governor and the oil pressure device shall be reasonable, the working capacity
shall be matched with the hydro turbine, and they shall be able to reliably control the turbine generator unit
under the maximum water head and at maximum flow rate and have a certain allowance.

4.1.2 The actual maximum opening of the guide vane shall at least correspond to over 80% of the maximum
stroke of the servomotor.

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Technical Guidelines for the Development of Small Hydropower Plants – Units

4.2 Operational situation of the hydro turbine generator unit

4.2.1 The turbine shall operate under the conditions specified by the manufacturer.

4.2.2 The turbine generator unit shall be able to operate stably under various manual conditions. When
operating under the manual no-load condition (the generator exciter is working in automatic mode), the
relative value of the speed oscillation of the turbine generator unit shall not exceed ±0.3%.

4.3 Water inertia time constant and turbine generator unit inertia time constant
The water inertia time constant Tw of the turbine water diversion system shall not be more than 4s; the turbine
generator unit inertia time constant Ta shall not be less than 4s for the reaction turbine nor less than 2s for
the impulse turbine. And the specific ratio of the water inertia time constant Tw to the turbine generator unit
inertia time constant Ta shall not be more than 0.4.

4.4 Environmental conditions

The altitude shall not exceed 2,500m. When the equipment is used in places with an altitude exceeding
2,500m, the reduction in the dielectric property and the decrease of the air cooling effect shall be considered,
and the user shall negotiate with the supplier.

Ambient temperature is 5°Cto 40°C.

Relative air humidity: The monthly maximum relative humidity shall not exceed 85% (without condensation)
during the wettest month, meanwhile, the monthly average minimum temperature shall not be more than
25°Cduring this month.

4.5 Oil for the hydro turbine governing system

The viscosity grade of the oil used in the hydro turbine governing system shall be consistent with the oil
used in the turbine. The oil temperature scope is 10°C to 50°C. When the oil pressure grade is not more than
12.5MPa, L-HL hydraulic oil should be selected and the oil quality shall comply with the provisions of ISO
8068; when the oil pressure grade is more than 12.5MPa, L-HM hydraulic oil should be selected and the oil
quality shall comply with the provisions of ISO 11158;

4.6 Others
If the service environment conditions do not meet the requirements, the performance indices may be
negotiated by the supplier and the user.

5 Technical requirements

5.1 Servomotor capacity

The servomotor capacity of the hydro turbine governing system shall match the design requirements for the
turbine.

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 Part 3: Hydro Turbine Governing System

5.2 Oil pressure grade

The oil pressure grade of the governor and the oil pressure device shall be (MPa): 2.5, 4.0, 6.3, 10.0, 12.5 and 16.0.

5.3 Static characteristics (speed droop)

5.3.1 The static characteristic curve shall be approximately a straight line.

5.3.2 When the permanent difference coefficient bp is 4%, see Table 1 for the speed dead band measured at
the main servomotor.

Table 1 - Speed dead band of the turbine governing system

Type of governor

Item Medium-scale Small-scale governor Ultra-small-scale

Large-scale governor
governor (18,000N·m (3,000N·m governor (350N·m
(A >75,000N·m)
≤A≤75,000N·m) ≤A<18,000N·m) ≤A<3,000N·m)

Speed dead
0.02 0.06 0.10 0.20
band ix (%)

5.3.3 For the hydro turbine governing system of the Kaplan turbine, the ia(the inaccuracy of the blade servo
system) shall not exceed 0.8% and the allowable deviation of the measured combination curve and the
theoretic combination curve shall be 1% of the full stroke of the blade servomotor.

5.3.4 For the hydro turbine governing system of the multi-nozzle impulse turbine, the position deviation
between any two needles shall not exceed 1% of the full stroke and the position deviation of each needle from
the average value of all needle positions shall not exceed 0.5% under the steady-state condition.

5.4 Dynamic characteristics

5.4.1 The governor shall ensure the stability of the turbine generator unit under various working conditions
and in various operating modes. When the governor is operating automatically under no-load condition,
apply a step-type speed command signal and observe the transition process so as to select the operation
parameters of the governor. After it becomes stable, record the relative value of speed oscillating: the relative
value shall not exceed ±0.25% for the medium and small-scale governor and shall not exceed ±0.3% of
the ultra-small-scale governor. If the relative value of the manual no-load speed oscillating of the turbine
generator unit is greater than the specified value, the relative value of its automatic no-load speed oscillating
shall not be more than the relative value of the manual no-load speed oscillating. For the turbine generator
unit whose rotational inertia could not satisfy the regulation guarantee calculation requirement, the relative
value of its automatic no-load speed oscillating shall be negotiated by the supplier and the user separately.

5.4.2 The servomotor dead time shall not be more than 0.2s.

5.4.3 The dynamic quality of the turbine generator unit after load shedding:

a) After 100% load shedding, the crest that is 3% above the rated rotation speed value in the steady state
shall not appear more than twice in the speed variation process;

b) The regulation time shall meet one of the following requirements:

1) The regulation time from the moment when the servomotor starts moving toward the opening

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Technical Guidelines for the Development of Small Hydropower Plants – Units

direction for the first time after load shedding to the moment when the relative value of the speed
oscillating is not more than ±1% shall not be more than 40s;

2) The ratio of the regulation time tE from the start of load shedding to the moment when the deviation
between the rotation speed and the rated value is less than ±1% to the time tM from the start of load
shedding to the moment when the rotation speed rises up to the maximum value shall not be more
than 8 for the reaction turbine with medium and low water head, shall not be more than 12 for the
Kaplan turbine with relatively long blade closing time and shall not be more than 15 for the reaction
turbine with high water head and the impulse turbine.

c) For the turbine generator unit supplying power to the hydropower station after disconnecting from the
power grid, the minimum relative speed of the turbine generator unit after load shedding shall not be less
than 0.85 (except for the bulb turbine units with inrush control and a relatively long blade closing time).

5.5 Governor
5.5.1 The governing parameters of the PID-based governor shall be adjustable within the design scope: The
minimum value of the proportional gain KP shall not be more than 0.5 and the maximum value shall not be
less than 20; the minimum value of the integral gain Ki shall not be more than 0.05s-1 and the maximum value
shall not be less than 10s-1; the minimum value of the differential gain KD is 0and the maximum value shall not
be less than 5s.

5.5.2 The permanent speed droop coefficient bp shall be adjustable as appropriate within the scope of 0 to
10%.

5.5.3 The adjustment scope of the speed command signal shall be ±10% of the rated speed.

5.5.4 The opening (load) limiting shall be adjustable within the scope from 0 to the maximum opening (load).
5.5.5 The closing time Tf and the opening time Tg of the servomotor shall be adjustable as appropriate within
the design scope.

5.5.6 The governor shall be able to realize the starting, stopping and emergency shutdown of the turbine
generator unit in the automatic and manual modes.

5.5.7 The governor shall be able to set the artificial dead band, its scope is ±1% of the rated speed and it could
be set as appropriate within its design scope.

5.5.8 When the input signal of the speed detector, the water head signal, the power signal or the servomotor
position signal disappears, it shall enable the turbine generator unit to maintain the current load, the allowable
deviation of the opening variation of the turbine main servomotor shall be ±1% of its full stroke; meanwhile
the orderly shutdown and the emergency shutdown of the turbine generator unit will not be influenced.

5.5.9 Basic requirements of the software design:

a) The software shall employ the structured and modular design, and satisfy the regulation and control
requirements of the turbine generator unit under various working conditions;

b) The software system shall consist of the following modules: Frequency measurement, PID regulation,
input/output processing, display, diagnosis and error detection.

5.5.10 In addition to the basic functions, the microcomputer-based governor also shall have the fault
diagnosis and fault-tolerance control functions, and shall be fitted with the communication interface and the
open communication protocol.

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 Part 3: Hydro Turbine Governing System

5.5.11 Speed detector: Within a ±10% scope of the rated speed, the static characteristic curve shall
approximate a straight line and its speed dead band shall comply with the design specification value; within a
±2% scope of the rated speed, the allowable value of the measured value of the amplification coefficient shall
be ±5% of the design value.

5.5.12 Electric-hydraulic and electric-mechanical converter.

a) Under the specified service conditions, the converter shall be able to work properly and reliably;

b) In the dead band of the electric-hydraulic converters, the oil pressure drifting, the measured deviation of
the amplification coefficient and the oil consumption shall not exceed the design value and the working
scope shall not be less than the design requirement value;

c) The operating force and stroke of the electric- mechanical converter shall not be less than the design
value;

d) The electric-hydraulic and electric- mechanical converters shall be able to return to the neutral position
after the power is shut off. In the stable state, the allowable deviation of the servomotor stroke variation
shall be ±1% of its full stroke when its power is off.

5.5.13 The flow characteristics of the main distributing valve with the specified pressure drop shall comply
with the design value.

5.5.14 The governor may be fitted with closing device in stages according to the closing rule of the guide
vane. Its initiating point shall be adjustable within the opening scope of 0 to 60%, its action shall be stable
and reliable, and the position deviation of its initiating point shall not exceed ±3% of the full-stroke of the
servomotor.

5.5.15 Requirements for the emergency distributing valve:

a) The setting of the shutdown time shall not be less than the minimum shutdown time of the servomotor
under the quick emergency shutdown condition;

b) The time delay from the action of the emergency distributing valve to the action of the main servomotor
shall not be more than 0.5s;

c) The position signal reflecting the action state of the valve core shall be set.

5.5.16 After the hydraulic components are assembled, the oil leakage shall not exceed the design value under
the specified oil temperature and the rated oil pressure.

5.5.17 The highly reliable displacement transducer near the servomotor shall be used as the servomotor
feedback device. The output signals of the displacement transducer may be -10V to 0V, 0V to 10V voltage type
or 4mA to 20mA current type. The accuracy level of the displacement sensor shall be no less than 0.5.

5.5.18 The governor should employ DC and AC power supplies at the same time which serve as standby for
each other. If either of them fails, it will be switched over automatically and the alarm signal will be triggered.
When the power supply is switched over, the allowable deviation of the servomotor stroke variation shall be
±1% of the full stroke. It can ensure the continuous and stable operation of the governor within the following
power supply and frequency range:

a) AC power supply:
Input voltage range:380/220×(85% to110%)V
Frequency allowable deviation:±10%

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Technical Guidelines for the Development of Small Hydropower Plants – Units

b) DC power supply:
Input voltage range: 220/110×(85% to 110%)V

5.5.19 Insulation resistance and the power frequency withstand voltage:

a) The insulation resistance between electrical loops and between the electric circuit and the enclosure
or the ground shall not be less than 1MΩ in the environment with a temperature of 15°C to 35°C and a
relative humidity of 45% to 75%.

b) When the tests are carried out between the separate live part and the exposed conductive part, and
between the circuit and the metal enclosure (or ground) in the environment with a temperature of 15°C
to 35°C and relative humidity of 45% to 75%, they shall be able to undertake the withstand test voltage
specified in Table 2 by 5s depending on its working voltage.

Table 2 - Withstand test voltage of the hydro turbine governing system

Unit: Volt (V)

Rated voltage Ui Power frequency test voltage (AC root-mean-square value)

Ui≤60 1000

60<Ui≤300 2000

300<Ui≤690 2500

c) The auxiliary circuit which is not suitable to be directly supplied power from the main loop shall be able
to undertake the withstand test voltage specified in Table 3 by 5s.

Table 3 - Withstand test voltage of the auxiliary circuit of the

hydro turbine governing system
Unit: Volt (V)

Rated voltage Ui Power frequency test voltage (AC root-mean-square value)

Ui≤12 250

12<Ui≤60 500

Ui>60 2 Ui+1,000, minimum value is 1,500

5.5.20 The electrical device shall be able to undertake the interference from the power supply, the signal
source and the control port, as well as the radiated electromagnetic field interference from the ambient
environment; meanwhile, the electromagnetic interference from the device itself shall be minimized, and the
electrical fast transient test shall be carried out in accordance with IEC 61000-4-4. When the interference is
applied, the function and action of the electrical device shall be correct, and the servomotor shall not have
abnormal action.

5.6 Oil pressure installation

5.6.1 The pressure tank shall comply with the design and use specifications of the pressure container.

5.7.2 When the working oil pressure exceeds 6.3Mpa, the pressure container of the oil pressure device shall
adopt the bladder type accumulator with the oil and gas separated. When the working oil pressure does not

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 Part 3: Hydro Turbine Governing System

exceed 6.3Mpa, the ordinary pressure tank with the oil and gas in contact or the bladder type accumulator
may be used.

5.6.3 At the upper limit of normal working oil pressure, the volume ratio of oil to gas in the non-isolated
pressure container should be 1/3 to 1/2.

5.6.4 The scope of the normal working oil pressure of the oil pressure device shall be ±2% to ±5% of the
nominal working pressure. The emergency shutdown pressure (minimum pressure of emergency shutdown)
shall be selected so that the pressure will not drop below the minimum operating pressure after shutting
down.

5.6.5 Volume of available oil in the pressure tank: At the lower limit of the normal working oil pressure and
when the oil pump is not started, the volume of the pressure tank shall at least be able to provide the specified
number of servomotor strokes under the condition that the pressure drop does not exceed the difference
between the lower limit of the normal working oil pressure and the minimum operating oil pressure. For the
Francis turbine, it shall provide 3 strokes of the guide vane servomotor; for the impulse turbine, (1.5 to 2)
strokes of the needle servomotor shall also be considered in addition to 3 strokes of the deflector servomotor;
for the Kaplan turbine, (1.5 to 2) strokes of the blade servomotor also shall be considered in addition to 3
strokes of the guide vane servomotor; for the governor with the pressure regulating valve, (1.5 to 2) strokes
of the pressure regulating valve servomotor also shall be considered in addition to 3 strokes of the guide vane
servomotor. With regard to the control system used for the isolated power system operation, the volume of
available oil may be appropriately increased, which is usually 1.5 to 2 times the aforesaid values.

5.6.6 Technical requirements of the oil pump:

a) The oil pressure device should be fitted with dual oil pumps, one for service and one for standby purposes;

b) The working speed of the oil pump should not exceed 1,500r/min. When the governor is under the stable
working condition, the pressure rise time from the lower limit of the normal working pressure to the
upper limit of the normal working pressure shall not be more than 100s; with regard to the governor
operating in the isolated power system, the pressure rise time from the lower limit of the normal working
pressure to the upper limit of the normal working pressure shall not be more than 40s;

c) In the static or stable state of the turbine generator unit, the starting interval for the intermittently
operated oil pump of the oil pressure device shall be more than 20 minutes.

5.6.7 Technical requirements for the safety valve:

a) When the oil pressure is 2% higher than the upper limit of the working oil pressure, the safety valve
shall start draining the oil; before the oil pressure is 10% higher than the upper limit of the working
oil pressure, the safety valve shall be fully opened so that the oil pressure in the pressure tank will not
further increase;

b) The leakage rate of the safety valve shall not be 1% more than the oil delivery amount of the oil pump;

c) The safety valve action shall be correct, reliable, and free from strong vibration and noise.

5.6.8 The allowable action error of the set value of the individual pressure annunciator for the oil pressure
device shall be ±2% of the set value.

5.6.9 The oil flow rate in the pipeline of the control system shall not exceed 5m/s.

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Technical Guidelines for the Development of Small Hydropower Plants – Units

6 Supply scope and spare parts

The supply scope and spare parts shall include the following items:

a) Supply scope: Governor, oil pressure device, position transmitters and special cables between the
governor electronic part and the hydraulic unit;

b) Spare parts: Necessary quick-wear parts to be provided;

c) Other equipment and spare parts to be negotiated by the supplier and the user and specified in the order
contract.

7 Technical documents
The supplier shall submit the necessary technical documents to the user; the contents, quantity and delivery
time shall be determined by the supplier and the user through negotiation. The attached technical documents
include the following contents:

a) System schematic diagram and operational schematic diagrams;

b) Outside view and installation drawing;

c) Arrangement plan and wiring diagram of the main components in the panel cabinet;

d) Documents attached to the outsourced equipment (including the hardware);

e) Delivery inspection report and the conformity certificate (1 set/unit);

f) Installation, use and maintenance instructions;

g) Delivery specification.

8 Inspection and acceptance

See Table 5 for the inspection and acceptance items.

Table 5 - Factory inspection and site acceptance test items of the

hydro turbine governing system

Factory Site
S/N Test items
inspection acceptance

1 Appearance inspection √ √

2 Meter inspection √ √

3 Inspection of the electric connection √ √

4 Insulation test of the electric circuit √

5 Communication function inspection √ √

6 Inspection and test of the power supply √ √

7 Pressure-tight test of the pressure tank √

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 Part 3: Hydro Turbine Governing System

Factory Site
S/N Test items
inspection acceptance

8 Test of the oil pump √

9 Leakage test of the oil pressure device √ √
Verification of the setting values of the oil pressure and oil level signals of
10 √ √
the oil pressure device
11 Simulation test of the automatic operation of the oil pressure device √ √

12 Inspection and test of the speed detector √

13 Test of the electric-hydraulic converter √
14 Adjustment of the closing time Tf and opening time Tg of the servomotor √ √
15 Measurement of the closing and opening time scope of the servomotor √
16 Action test of the operating circuit √ √

17 Switching test of the regulation modes and control modes √ √

Measurement of the practical open-loop gain and the setting test of the
18 √ √
open-loop gain
Verification of the rotation speed command signal, opening command
19 signal, power command signal and the permanent difference coefficient √
bp
Verification of the proportional gain KP, integral gain KI and differential
20 √
gain KD
Measurement and test of the static characteristics (including artificial
21 √ √
speed dead band) and the speed dead band ix of the governor
Measurement and test of the combination curve and inaccuracy ia of the
22
blade servo system
23 Synchronization test between the guide vanes (needles) √

24 Measurement and test of the servomotor dead time Tq √ √

25 Measurement of the total oil consumption of the governor √
26 Switching test of the fault simulation and the control modes √ √

27 Automatic start-up/shutdown tests √

28 No-load test √

29 Load dump test √

30 Test of the guide vane closing under the tripping lower oil pressure √

31 Continuous loaded 72hr operation test √

NOTE 1 The items marked with “√” in the table should be completed.
NOTE 2 If the tested equipment does not have the structure and function relevant to a certain test item, such item does not need to be
tested.

SHP/TG 003-3: 2019 9

Technical Guidelines for the Development of Small Hydropower Plants – Units

9 Nameplate, packing, transportation and storage

9.1 Nameplate
The product nameplate shall be fixed at an appropriately obvious position on each product. The fabrication
materials and engraving method of the nameplates shall ensure that its text is not obliterated during the
entire service period.

Its main contents shall include:

a) Name and model;

b) Rated oil pressure (MPa);

c) Service capacity (N·m);

d) Nominal size of the main distributing valve

d) Volume of pressure tank (m3);

e) Manufacturer name, delivery date and product number.

9.2 Packing
9.2.1 The packing shall be determined by the supplier and the user through negotiation. Special requirements
of the equipment, if any, shall be marked on the packing container.

9.2.2 The product shall have internal packing and external packing containers, the plug-in box shall be firmly
locked and fastened, the packing container shall be fitted with the dustproof, rainproof and anti-vibration
measures, and shall be provided with the hoisting facility and marks.

9.2.3 The inspections of the product before packing mainly include:

a) Whether the accessories, spare parts, compliance certificate and relevant technical documents of the
product are complete;

b) Whether the product appearance gets damaged;

c) Whether there is dust on the product surface.

9.2.4 The packing of the products for export shall comply with the provisions of the relevant national
inspection and quarantine regulations.

9.2.5 The packing guarantee time shall not exceed 12 months from the delivery date.

9.3 Transportation
The supplier and the user shall specify the transportation tools suitable for the equipment and the
requirements in the transportation process. The transportation and handling shall be carried out according
to the marks on the packing containers.

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 Part 3: Hydro Turbine Governing System

9.4 Storage
9.4.1 The products shall be stored in the dust-free and rainproof warehouses with an ambient temperature
of -25°C to +55°C, relative humidity of not more than 85% and without acid, alkali, salt and corrosive or
explosive gases or a strong electromagnetic field.

9.4.2 From the date of delivery by the supplier, the supplier shall guarantee that the products are free from
corrosion and accuracy reduction due to improper packing within 12 months under the storage conditions
specified in 4.4.

10 Installation, operation and maintenance

10.1 Installation
The product shall be installed by experienced and well-qualified competent professionals.

10.2 Operation and maintenance

Before going into formal operation, the relevant tests shall be carried out, and the specified requirements
shall be met.

The operation and maintenance shall comply with the provisions of the normative references, the installation,
use and maintenance instructions provided by the supplier as well as relevant operation specifications for
the hydropower station.

The supplier shall provide technical support for solving the problems occurring in the installation, use and
maintenance process for the equipment, and shall train the user’s personnel in the aspects of the equipment
installation, use and maintenance.

11 Quality guarantee period

Under the premise that the product is properly stored, installed and used, the product quality guarantee
period shall be one year after the date of the 72-hour trial operation, or two years after the delivery date
of the last batch of goods, whichever comes earlier. If the equipment gets damaged or is unable to function
properly due to the manufacturing quality during the quality guarantee period, the supplier shall repair or
replace it free of charge.

SHP/TG 003-3: 2019 11

 INTERNATIONAL NETWORK
ON SMALL HYDROPOWER
Vienna International Centre 136 Nanshan Road
P.O. Box 300 · 1400 Vienna · Austria Hangzhou · 310002 · P.R.China
Tel.: (+43-1) 26026-o Tel.: (+86-571)87132793
E-mail: [email protected] E-mail: [email protected]
www.unido.org www.inshp.org