Commissioning Procedure Of Turbine And Generator(rev.0)

3x15MW WAMPU HEPP PROJECT

DOCU. NO. : 1000-0183-EM-462-001(1/2)

Rev. No. : 0

Commissioning Procedure of Turbine and Generator

TITLE

Commissioning Procedure of Turbine and Generator DISCIPLINE

:

TURBINE GENERATOR TEST

PROJECT NAME

:

3×15MW WAMPU HEPP PROJECT

Page. No : Cover

3x15MW WAMPU HEPP PROJECT

Rev. No. : 0

Commissioning Procedure of Turbine and Generator

TITLE

DOCU. NO. : 1000-0183-EM-462-001(1/2)

Page. No : 1 / 36

Commissioning Procedure of Turbine and Generator

DISCIPLINE

:

TURBINE GENERATOR TEST

PROJECT NAME

:

3×15MW WAMPU HEPP PROJECT

For Construction

REV. NO. REV. NO.

DATE

CNEEC

DESCRIPTION

PREP'N

CHECK

REVIEW

APPROVAL

PREPARATION

CHECK

REVIEW

APPROVAL

WANG XUAN

MA MING

N/A

WANG XUAN

31/11/14

31/11/14

-

31/11/14

0

3x15MW WAMPU HEPP PROJECT

TITLE

Commissioning Procedure of Turbine and Generator

DOCU. NO. : 1000-0183-EM-462-001(1/2)

Rev. No. : 0 Page. No : 2 / 36

Content 1.

Establishment of the organization for unit trial run ............................................................................................ 4

1.1

Establishment of the Unit Start-up and Acceptance Commission .................................................................................... 4

1.2

The functions of the organizations under the Unit Start-up and Acceptance Commission ........................................ 4

2.

Inspection before start-up and trial run of the turbine generator unit ............................................................ 4

2.1

Inspection of the diversion system ......................................................................................................................................... 4

2.2

Inspection of the turbines ........................................................................................................................................................ 5

2.3

Inspection of the governing system ........................................................................................................................................ 6

2.4

Inspection of the turbine generator unit............................................................................................................................... 6

2.5

Inspection of the excitation system ........................................................................................................................................ 7

2.6

Inspection of the oil, air and water supply systems .......................................................................................................... 7

2.7

Inspection of the primary circuit equipment ....................................................................................................................... 8

2.8

Inspection of the secondary circuit system ........................................................................................................................... 9

2.9

Inspection of the fire protection system and fire fighting equipment .......................................................................... 10

3.

Water filling test of the turbine generator unit .................................................................................................. 11

3.1

Water filling conditions ........................................................................................................................................................... 11

3.2

Water filling in the draft tube of the turbine .................................................................................................................. 11

3.3

Water filling in the spiral case of the turbine .................................................................................................................. 12

3.4

Observation, inspection and test after water is filled and pressure equalized ............................................................ 13

3.5

Water filling and test of the technical water supply system of the unit ..................................................................... 13

4.

No-load trial run of the turbine generator unit .................................................................................................. 14

4.1

Preparation before startup ..................................................................................................................................................... 14

4.2

Initial startup test .................................................................................................................................................................... 15

4.3

Test of the governing system in no-load operation of the unit ..................................................................................... 16

4.4

Manual shut down of the unit ............................................................................................................................................. 17

4.5

Dynamic balance test of the unit ......................................................................................................................................... 18

4.6

Overspeed test of the turbine generator unit .................................................................................................................... 19

4.7

Tests of non-excited automatic startup and automatic shutdown of the unit ............................................................. 20

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Commissioning Procedure of Turbine and Generator

DOCU. NO. : 1000-0183-EM-462-001(1/2)

Rev. No. : 0 Page. No : 3 / 36

4.8

Short circuit test and the stator short circuit aridity of the turbine generator ........................................................ 21

4.9

Step-up test of the turbine generator unit and adjusting test of the excitation equipment .................................... 24

4.10

Recording of the no-load characteristics curve of the generator................................................................................... 25

4.11

Single-phase grounding test of the generator and arc-extinguishing coil position setting: ....................................... 25

5.

Test of the turbine generator unit with the main transformer and HV distribution equipment ................ 27

5.1

Short-circuit current rise test ................................................................................................................................................ 27

5.2

Single-phase grounding test of the main transformer and HV distribution equipment ............................................ 28

5.3

Step-up test of the turbine generator unit to the main transformer and the HV distribution equipment .......... 28

6. Impact switching in test of the electric power system to the busbar of the HV distribution equipment and the main transformer................................................................................................................................................ 29 6.1

Preparation and inspection before the test ......................................................................................................................... 29

6.2

Test method ............................................................................................................................................................................... 29

7.

Parallel and load tests of the turbine generator unit ....................................................................................... 29

7.1

Parallel test of the turbine generator unit ......................................................................................................................... 29

7.2

On-load test of the turbine generator unit ........................................................................................................................ 30

7.3

Load rejection test of the turbine generator unit ............................................................................................................. 32

7.4

The unit efficiency test ........................................................................................................................................................... 33

7.5

The maximum output test of the turbine generator unit ............................................................................................... 34

8.

Unit operation test of stability and reliability ..................................................................................................... 34

8.1

Stable and reliable operation for 24 hours ........................................................................................................................ 34

8.2

72 hours on-load trial run test ............................................................................................................................................. 35

9.

Joint operation test of multiple units (3 units) .................................................................................................. 35

9.1

Load test of joint operation of 3 units ............................................................................................................................... 35

9.2

Simultaneous load rejection test of the 3 units ................................................................................................................. 35

3x15MW WAMPU HEPP PROJECT

TITLE

1. 1.1

Commissioning Procedure of Turbine and Generator

DOCU. NO. : 1000-0183-EM-462-001(1/2)

Rev. No. : 0 Page. No : 4 / 36

Establishment of the organization for unit trial run Establishment of the Unit Start-up and Acceptance Commission

The Unit Start-up and Acceptance Commission should be organized by the main contractor, t he Engineer, the designer and the sub-contractors of manufacture and installation. The chief o f the Unit Start-up and Acceptance Commission should be headed by the main contractor. Th e Unit Start-up and Acceptance Commission should consist of a unit trial run director’s offic e, an acceptance group, a general office and a technology group. The Unit Start-up and Acce ptance Commission should be the top organization of the unit trial run operation which is th e responsibility of the owner to organize. 1.2

The functions of the organizations under the Unit Start-up and Acceptance Commission

1.2.1 The Unit Trial Run Director’s Office: The Unit Trial Run Director’s Office operates un der the leadership of the Unit Start-up and Acceptance Commission, in charge of the unit tri al run implement. The chief director is held by the person from the installation contractor. M ajor working procedures during the unit trial run should be approved by the Unit Start-up an d Acceptance Commission. 1.2.2 The Acceptance Group: The Acceptance Group is responsible for the acceptance works during the overall unit trial run operation. The head of the Acceptance Group is held by the Engineer. 1.2.3 The Technology Group: The Technology Group is responsible for the document control and technology support of the unit trial run operation. The Technology Group is mainly com posed of the persons from the designers and the manufacturers. 1.2.4 The General Office: The General Office is composed of the persons from the main con tractor and the installation subcontractors, in charge of works as safeguard, materials supply a nd logistics supports for the unit trial run operation.

2. 2.1

Inspection before start-up and trial run of the turbine generator unit Inspection of the diversion system

2.1.1 Adjustment and test of the inlet trash rack of penstock have been completed, cleaned and checked up to standard. 2.1.2 The penstock emergency gate slots have been cleaned and checked up to standard, installations of emergency gates, filling valves and hoisting devices completed, manual and automatic operations under the condition of no-water regulated up to standard, hoisting operation proves good, hoisting

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Commissioning Procedure of Turbine and Generator

DOCU. NO. : 1000-0183-EM-462-001(1/2)

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time complies with the requirement of the design. Be sure the emergency gates are under the condition of close. 2.1.3 The water-carrying system as penstocks, air vents, spiral cases, draft-tube has been cleaned and checked up to standard, all cover plates of manholes tightly closed. 2.1.4 Installation of the butterfly valves and their by-pass valves have been completed, regulated and tested up to standard, hoisting operation proves good and under the condition of close. Installation of the hydraulic control station and its operation system has been completed and checked up to standard, the oil pumps operate normally. 2.1.7 The draft tube gate slots and all around have been cleaned up, installation of the draft tube gates and their hoisting devices completed and checked up to standard, hoisting operation proves good. The draft tube gates are under the condition of close, the draft tube gate hoisting devices can be put into operation whenever necessary. 2.1.8 Installation of the water level gauging system up and down stream of the power station has been regulated and tested up to standard. Remote transmission of the water level signals proves correct. 2.2

Inspection of the turbines

2.2.1 Installation of the runner and all parts of the turbine has been completed and checked up to standard with full construction records, clearances of the upper and lower sealing rings inspected, there are no sundries left over. The spiral cases, runner chambers and draft tubes have been cleaned up, the wedges to fix the runners removed. 2.2.2 Opening/closure operations of the emptying valves of the spiral cases and the draft tube drainage valves prove good and on the position of closure. Installation of vacuum breaking valves have been completed and proved good via tight percolation test and action test under the design pressure. 2.2.3 Installation of the head cover drainage pipes have been completed and checked up to standard, the gravity drain holes unblocked. 2.2.4 Installation of the working seals and service seals of the main shaft has been completed and proved there are no seepages on the service seals after inspection. 2.2.5 Lubricating and cooling system of the main guide bearing has been checked up to standard, oil level and temperature sensors and cooling water pressure regulated and tested. Each of the setting values complies with the requirements of the design. 2.2.6 Installation of the guide apparatus has been completed and checked up to standard and on the condition of close with the servomotor locking devices put in. The maximum opening of the guide

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Commissioning Procedure of Turbine and Generator

DOCU. NO. : 1000-0183-EM-462-001(1/2)

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blade, tightness and compression stroke after close have been inspected and in conformity with the requirements of the design, shear signals of the shear pins and other guide blade protection devices checked and tested up to standard. 2.2.8 Installation of each of pressure gauges, flow indicators, flowmeters, throw and vibration sensors and transmitters has been completed, pipelines connect sound and unblocked, sundries in the pipelines cleared off. 2.3

Inspection of the governing system

2.3.1 Installation of the governing system and its equipment have been completed and tested up to standard. Oil pressure and level of the oil pressure unit prove normal, all gauges and meters, valves, automation elements of each part set in conformity with the requirements. 2.3.2 The oil pumps of the oil pressure unit operate normally under the working pressure without abnormal vibration and heating. Operating oil pumps and standby pumps switch over normally. On/off times of the governor are set on the design values. 2.3.3 Manually operate the pressure oil in the oil pressure unit to the governing system, inspect that there is no seepage on oil each oil pressure pipeline, valve and joint. 2.3.4 Installation of the governor cabinet has been completed and tested up to standard, electric-mechanical-hydraulic switches over normally. 2.3.5 Manually operate the coordinated debugging of the governing system and inspect flexibility and reliability of coordinated operation of the governor, servomotor and guide apparatus and motion smoothness within the entire travel. 2.3.6 Analogue operating test is carried out for the automatic operating system of the governor to inspect motions’ accuracy and reliability of each part in case of automatic start-up, shut-down and emergency shut-down. The servomotor pin is put in after above operations have been completed. 2.3.7 Installation of the speed detector has been completed and checked up to standard, the relay contacts set preliminarily in accordance with the requirements. 2.4

Inspection of the turbine generator unit

2.4.1 Installation of the generator body has been completed, tested and inspected up to standard with complete records. The interior of the generator has been thoroughly cleaned up without any sundries left inside the stator, rotor and air space. 2.4.2 The oil level and temperature sensors and cooling water pressure (or rate of flow ) of the guide bearings and thrust bearings have been regulated and tested, which setting values are in conformity with the requirements of the design.

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Commissioning Procedure of Turbine and Generator

DOCU. NO. : 1000-0183-EM-462-001(1/2)

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2.4.3 All valves, pipelines, joints, sensors and transmitters in the air shield of the generator have been inspected up to standard and in condition of normal operation. 2.4.4 The collecting rings, carbon brushes and carbon brush brackets of the generator rotor have been inspected, the carbon brushes are properly contacted with the collecting rings, regulated and tested up to standard. 2.4.5 All cables, wires, auxiliary wires and terminal boxes in the air shield of the generator have been inspected and proved correct without any errors. They are reliably fixed. 2.4.6 Manual and automatic operation of the mechanical braking system of the generator have been inspected, regulated and tested up to standard with normal motion. The braking system is in condition of manual braking before filling water. 2.4.7 The air cooler of the generator has been inspected up to standard, the air and water conduits are unblocked. There are no seepages in the valves and pipelines. 2.4.8 Installation of all gauges and meters, vibration and throw sensors to test operation condition of the generator has been completed, regulated, tested and set up to standard. 2.4.9 Jack up the generator rotor approx 5mm with a rotor jacking device. 2.5

Inspection of the excitation system

2.5.1 Installation of excitation power source transformer has been completed and tested up to standard, connecting wires and cables of HV and LV terminals inspected up to standard. 2.5.2 Installation of the cabinets of the excitation system have been completed and inspected up to standard, the main circuit connects reliably, insulation proves good. 2.5.3 Installation of the ventilation system of the excitation power cabinet has been completed and inspected up to standard. 2.5.4 The main contacts of AC/DC de-excitation switch contact properly, the spacing is in conformity with the requirements, the motion smooth and reliable. 2.5.5 The open-loop characteristics of the excitation regulator are in conformity with the requirements of the design, passages switch over reliably. 2.5.6 Operation, protection and signal circuits of excitation connect correctly and act reliably, the meters and gauges are inspected up to standard. 2.6

Inspection of the oil, air and water supply systems

2.6.1 The pumps, strainers, valves and fittings of the technical water supply system of the unit are individually regulated and tested up to standard and in normal operation. 2.6.2 The circular pipe for the unit cooling water supply, the valves and joints of the cooling water

3x15MW WAMPU HEPP PROJECT

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Commissioning Procedure of Turbine and Generator

DOCU. NO. : 1000-0183-EM-462-001(1/2)

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inlet and outlet pipelines into the unit cooler, automatic elements such as pressure annunciators and flow indicators have all been inspected up to standard. The inlet valves of each cooler of the unit are in position of close, the drainage valves in position of open. 2.6.3 The seepage drainage and service drainage systems in the power station have been overall inspected up to standard. Manual and automatic operations of each drainage pump are normal, output signals and setting values of the water level annunciators are in conformity with the requirements of the design after regulation and test. The seepage drainage system and the service drainage system are in normal state to put into operation. 2.6.4 The part that has been put into operation of the turbine oil system is able to meet the requirements of oil supply, consuming and drainage of this turbine. 2.6.5 Low pressure air compressors have been regulated and tested up to standard, there is no air leakage in the air vessel and pipeline system which is unblocked. Each pressure gauge, safety valve and relief valve operates normally, the setting values are in conformity with the requirements of the design. The low pressure air supply system has been put into operation and in the state of automatic operation. 2.6.6 The main shaft service seal of the turbine has been put in. 2.6.7 Each pipeline and auxiliary equipment has been painted and flow direction indicated. 2.7

Inspection of the primary circuit equipment

2.7.1 Installation of the equipment as the main outlet wires of the generator and the current transformer at the outlet has been completed and inspected up to standard, the outlet wires of the neutral point and the current transformer installed and inspected up to standard. 2.7.2 The high voltage equipment as the circuit breaker, isolating switch, potential transformer at the outlet and excitation transformer of the generator has been installed and inspected up to standard. 2.7.3 The generator bus PT cabinet and station-service transformer switch cubicle have been tested up to standard and provided with condition of live line test. 2.7.4 The busbars in the bus box at the outlets of the unit and HV cubicle have been installed and completed, HV test proves up to standard. 2.7.5 Installation of the main transformer has been completed and test up to standard, the tapping switch placed at the appointed position required by the system, the insulating oil tested up to standard, the oil cooling system regulated and tested up to standard and provided with condition of live line test. 2.7.6 Installation f all equipment of the station-service power has been completed, inspected and

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Commissioning Procedure of Turbine and Generator

DOCU. NO. : 1000-0183-EM-462-001(1/2)

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tested up to standard and already put into normal operation by dual power supply. The automatic put-in apparatus of the standby power source has been inspected up to standard and in normal operation. 2.7.7 150kV switch, current transformer, isolating switch, potential transformer, lightning arrester, communication wave damper, wave filter, neutral point equipment and electrical control box of the main transformer, busbar control box in the step-up substation have been installed, regulated and tested up to standard. 2.7.8 The earth screen and equipment of the entire station have been inspected and provided with satisfactory earthing connection, the earth resistance meets the value required by the design. 2.7.9 The lightings of the power house have been installed, the lightings and evacuation indicating lamps at the major workplaces, accesses and staircases inspected up to standard. 2.8

Inspection of the secondary circuit system

2.8.1 Installation of the cubicles of the computer monitoring system, protection cubicles, unit temperature pick-up and brake cabinets and instrument panels has been completed and inspected up to standard, the cables connection proves correct with distinct numbering and reliable connection. 2.8.2 Installation of the common system cubicles, monitoring network cubicles, high frequency switchover cubicles in the oil, air and water supply system of the power station and the step-up substation has been completed and inspected up to standard, the cables connection proves correct with distinct numbering and reliable connection. 2.8.3 Installation of the main transformer protection, 220kV busbar protection, 220kV line protection, fault oscillograph and fire alarming panel in the central control room has been completed and inspected up to standard, with correct and reliable connection and distinct numbering. 2.8.4 The direct current power source system has been installed, inspected up to standard and put into normal operation. The inversion apparatus and its circuit have been inspected up to standard. 2.8.5 The following electric operating circuits have been inspected and analogue tests carried out to prove the correctness, reliability and accuracy of the motions. a) The automatic operating circuit of the intake valve, b) The automatic operating circuit of the butterfly valve, c) The automatic hydraulic operating circuit of the governor and the operating circuit of electro-hydraulic operation, d）The circuits of automatic unit operation and hydraulic machinery protection, e) The generator excitation operating circuit,

3x15MW WAMPU HEPP PROJECT

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Commissioning Procedure of Turbine and Generator

DOCU. NO. : 1000-0183-EM-462-001(1/2)

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f) The operating circuits of the generator breaker and station-service substation breaker, g) The circuits of DC and switching value signal and analogue value signal, h) The circuit of the low pressure air supply system, technical water supply, service and seepage drainage system commonly used in the entire power station, i) The synchronous operating circuit, j) The automatic put-in circuit of the standby power source, k) The automatic operation and safety lock-up circuit of the 150kV switch and isolating switch, and l) The operating circuit of the station service power equipment. 2.8.6 Analogue tests of the following relay protection circuits should be carried out to verify the accuracy of the motions after energizing inspection of current circuit and potential circuit of the secondary circuit has been completed: a) The generator protection by the microcomputer, b) The main transformer protection by the microcomputer, 150kV busbar protection and fault oscillograph circuits, c) 150kV transmission line protection by the microcomputer and fault oscillograph circuit, d) The station service power protection circuit by the microcomputer, e) Other relay protection circuits, and f) The instrumentation circuits. 2.8.7 Installation and test of the devices of in-station communication, system communication and outgoing communication have all been completed and inspected up to standard with unblocked, accurate and reliable circuit which is able to meet the requirements of the power grid control, remote control, microcomputer protection, in-station production and dispatching and administrative management. 2.8.8 Installation and test of the on-line monitoring system of the unit have been completed and able to be put into normal operation. 2.9

Inspection of the fire protection system and fire fighting equipment

2.9.1 The fire pumps and pipeline system, pressure regulating and filtering apparatus have been installed in place, the pipeline flushing test proved to be up to standard, the local control and remote control of the fire pumps start and stop normally. 2.9.2 Installation of the fire fighting equipment relating to the unit to be tested for start-up at the positions of the main and auxiliary power houses have been completed and in conformity with the

3x15MW WAMPU HEPP PROJECT

TITLE

Commissioning Procedure of Turbine and Generator

DOCU. NO. : 1000-0183-EM-462-001(1/2)

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fire protection design and the requirements of the specifications and accepted by the fire department. 2.9.3 Installation and test of the CO2 fire fighting system of the generator have been completed and able to put into operation. 2.9.4 The oil sump and emergency oil drain system of the main transformer are in conformity with the requirements of the design and oil drainage unblocked. 2.9.5 The fire alarming and coordinated control system of the entire station are installed and tested up to standard, the fire probe and coordinated control act accurately and accepted by the fire department. 2.9.6 The water source for fire fighting of the entire station is reliable, the pipeline unblocked, the pressure meets the requirements of the design. 2.9.7 Installation of fire stopping material, painting, and fire segregation barrier of the cable have been completed, holes the cables go through the floor slabs, walls, shafts and cubicles and cable conduit orifices reliably blocked off, the fire fighting equipment in the station arranged in place in accordance with the requirements of the design. 2.9.8 Allocation of the temporary fire fighting facilities required by the unit trial run has been completed.

3. 3.1

Water filling test of the turbine generator unit Water filling conditions

3.1.1 The reservoir has impounded above the design water level and provided with the condition of water filling to rotate the unit. 3.1.2 Confirm that the intake valve of the forebay is in state of close before filling water, the butterfly valve in state of full close, the pins put in, the spiral case drainage valve and draft tube drainage valve in state of close, the governor in state of the close, the turbine servomotor locking device put in, the main shaft service seal of the turbine in state of put-in and the draft tube service gate in state of close. 3.1.3 Confirm the seepage drainage system of the power house is in normal operation and the drainage pump in position of automatic operation before filling water. 3.1.4 Enough lighting should be provided for each passage and staircase of each floor relating to water filling, standby power source for lighting reliable, communication and liaison facilities complete, the emergency passageway unblocked and clear direction marks established. 3.2

Water filling in the draft tube of the turbine

3.2.1 Slowly lift up the equalizing valve at the top of the draft tube and fill water into the turbine draft tube.

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Commissioning Procedure of Turbine and Generator

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3.2.2 During water filling process, observe there should be no seepage on each connecting flange of the turbine under the tail water level and no seepage on the manhole and emergency drainage valve of the draft tube. 3.2.3 During water filling process, inspect if there are leakages from the head cover of the turbine, guide apparatus, main shaft seal, pipeline of pressure test system, spiral case manhole and draft tube manhole, there should be no seepage on expansion joint of butterfly valve, spiral case manhole and head cover of the turbine. 3.2.4 Inspect leakage on the upper shaft sleeve of the turbine guide vane, leakage quantity should be within a normal range. 3.2.5 During water filling process, it must be paid close attention to seepage and leakage of each part of the power house and the turbine, if abnormal leakage is found, water filling must be immediately stopped and treated. 3.2.6 After water is filled and pressure equalized to normal, lift and lock up the tail gate on the opening gate slot 3.3

Water filling in the spiral case of the turbine

3.3.1 Water filling in the penstock: Slowly open the water filling valve of the forebay gate and fill water into the penstock, monitor the pressure gauge at the inlet of the butterfly, know well the filling condition of the penstock and lift up the emergency gate after pressure is equalized. Observe leakage of the working gate at the side downstream. 3.3.2 During water filling process, pay close attention to leakage of the penstock expansion joint and the flange at the side upstream the inlet butterfly of the unit, when leakage reaches an abnormal level, the filling valve at the forebay gate should be immediately closed. 3.3.3 If all normal, fill the penstock to full and lift up the forebay gate and lock it on the full open position. The above-stated operations are completed by the subcontractor of penstock installation. 3.3.4 When the penstock is fully filled, inspect that leakage quantity under the condition of close of the butterfly valve should meet the requirements of the design. 3.3.5 Manually open the bypass valve of the butterfly valve to fill water into the spiral case of the turbine and inspect the condition of pressure rise in the spiral case. 3.3.6 Inspect leakage of the butterfly expansion joint, spiral case manhole and air relief valve. 3.3.7 Inspect leakage of the head cover of the turbine, guide apparatus and main shaft seal and observe that leakage of the guide blade should be within allowed range.

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Commissioning Procedure of Turbine and Generator

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3.3.8 Inspect drainage of the elastic cushion layer of the spiral case. 3.3.9 Observe leakage of each pressure test instrument and joints, monitor the readings of each pressure gauge in the hydraulic measuring system. 3.3.10 During water filling process, inspect if the air relief valve of the spiral case is unblocked, meanwhile pay attention to discharge accumulated air from the spiral case, afterwards, the air relief valve should be able to fully close. 3.4

Observation, inspection and test after water is filled and pressure equalized

3.4.1 When the spiral case is fully filled with water, manually operate the butterfly valve, inspect the motion of the valve body and record the opening and closing times. 3.4.2 After manual operation is tested up to standard, carry out open-close motions test in static water under automatic operation. Local and remote operations are carried out respectively. Opening and closing operation of the butterfly valve in static water should be normal. 3.4.3 After the spiral case is fully filled with water, the pressure test pipelines, turbine head cover, butterfly valve expansion joint, spiral case manhole and each of connecting flanges should be inspected, and the seepage and distortion should be observed. 3.4.4 Observe leakage in the power house and drainage capability of seepage pump and reliability of its operation. 3.5

Water filling and test of the technical water supply system of the unit

3.5.1 Open the head-gate valve of the technical water supply and the feed valve of the generator air cooler, manually start up the water supply pump to fill water into the main pipe of the technical water supply system, during water filling process, pay attention to monitor water pressure at the pump outlet. 3.5.2 When the main pipe of the technical water supply of the unit operates stably, fill water to the following branch lines successively: 1). The cooling water supply and drainage system of the air cooler of the generator, 2). The water supply and drainage system of the lubricating oil cooler of each bearing of the unit, and 3). The water supply system of the main shaft seal of the turbine. 3.5.3 Put in the turbine shaft seal, cut off the main shaft service seal and observe leakage quantity at the main shaft. 3.5.4 Adjust the pressure values of water supply and drainage at each branch line to the values required by the manufacturer. 3.5.5 During water filling process, the following items should be inspected:

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Commissioning Procedure of Turbine and Generator

DOCU. NO. : 1000-0183-EM-462-001(1/2)

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1）There should be no leakage at each pipeline, valve and joint of the entire technical water supply system, 2）Each pressure gauge, thermometer and flow indicator in the entire technical water supply system indicate correctly, operation of the automation elements as pressure switch, differential pressure transmitter, electromagnetic valve, electromagnetic flow meter operate normally. 3）The water pressure of each branch line should be in conformity with the requirements of the manufacturers and the design.

4. 4.1

No-load trial run of the turbine generator unit Preparation before startup

4.1.1 Confirm the troubles found in the water filling test have been treated up to standard. 4.1.2 The command and communication system for the unit startup has been deployed in place, operators and supervisors of each part in place. 4.1.3 Confirm cooling water has been put in each par with normal water pressure, the lubricating oil system and operating oil system operate normally, oil level of each oil bath is normal, temporarily close cooling water of the air cooler of the generator. 4.1.4 Water levels up and down streams and original temperature of each part have been recorded, the bearing bush temperature protection put in. 4.1.5 Lower down the generator rotor, manually loosen the brake and confirm the brake shoe has totally separated from the brake ring. 4.1.6 The governor is in state of preparatory operation and in conformity with the following requirements: a）The main oil valve from the oil pressure unit the governor control panel has been opened up with normal oil pressure indication, the oil pressure unit is in state of automatic operation, b）The oil filter of the governor is on the position of operation, c) The governor is on the position of mechanic “manual” or electric “manual”, d) The guide blade limit of the governor is on the position of full open, e) The speed adjusting mechanism of the governor is on the position of rated speed, and f)

The permanent slip ratio bp is temporarily adjusted to between 2％～4％.

4.1.7 The equipment relating to the unit should be in accordance with the following requirements: a) The generator outlet breaker is disconnected,

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Commissioning Procedure of Turbine and Generator

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b) The carbon brushes of the collecting ring of the generator rotor have been polished and installed up, the carbon brushes pulled out, c) The hydraulic machinery protection and temperature detecting device have been put in, d) Remove all shorting stubs and grounding wires for test, e) Stick up the measuring slips on the main shaft to test the unit rotating speed, f) The de-excitation switch of the generator disconnects, and g) The local control unit has been put in state of operation, external testing terminal connected in and the functions as safety monitoring, recording, printing and alarming of major operation parameters of each part provided with. 4.2

Initial startup test

4.2.1 Temporary instruments and sensors necessary for the initial unit startup test are connected in relating parts. 4.2.2 Manually pull out the servomotor dogging device and open the gate limiting device of the governor, when the unit starts to rotate, immediately close back the guide vane, the observers at each part inspect and confirm there are no occurrences of friction or collision between rotating and stationary parts of the unit. 4.2.3 When normal operation of each part is confirmed, manually open the guide vane to start the unit (record the governor start opening), monitor rotation speed of the unit with hand tachometer after the unit starts, when speed of the unit reaches 50% of the rated value, pause speed increase operation for 10 minutes and observe the operation of each part. Continue to increase the guide vane opening if no abnormalities after inspection to raise speed up to the rated value. The unit operates with no-load. 4.2.4 During the unit is in process of start-up, operation condition of each part should be closely monitored. If abnormal occurrences as metal collision or friction, water spurt, sudden rise up of the bearing liner, oil bath throwing, over-leakage of the main shaft seal and over-vibration of the unit and other circumstances that endanger the unit are found, the unit should be immediately stopped and inspected. 4.2.5 When rated speed is reached, check out that the electric tachometer should indicate correctly, record the no-load opening of the governor at the water head then. 4.2.6 During unit speed rising up, the bearing temperature at each part should be closely monitored, there should be no occurrences of steep rising and dropping, when the unit starts and reaches rated speed, within half an hour, the temperatures of the thrust bearing liner and guide bearing liner should be recorded at an interval of every 10 minutes, afterwards, the interval of recording time can be

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properly extended, temperature rising curve of the thrust bearing liner and guide bearing liner plotted, observe the change of the bearing oil level which should be at normal position. After the temperature is stable, mark the operating oil level line of each oil bath and record stable oil level value which should not exceed the value specified by the design. 4.2.7 During operation period of the unit, water temperature, pressure of the main shaft seal and each part of the turbine should be monitored, and the water pressure of the main shaft seal adjusted to obtain the optimal effect of the seal. 4.2.8 During operation period of the unit, instrument readings of the hydraulic measuring system of each part and the unit monitoring device (spiral case differential pressure, unit flow-rate and etc.) should be also recorded except for recording bearing temperature in accordance with the clause 4.2.6. 4.2.9 Measure and record the unit operation throw (double amplitude value) which should be less than the bearing clearance. 4.2.10 Measure and record vibration at each part of the unit, the value should not exceed the requirements in the Table 1. Table 1 Allowable Vibration Value (double amplitude value) of Each Part of the Turbine Generator Unit

No.

Description

1 2

Turbine

6

Generator Unit

5

mm

Horizontal vibration of head cover

0.07

Vertical vibration of head cover

0.04

Vertical vibration of upper bracket

0.07

Horizontal vibration of upper bracket

0.07

Vertical vibration of lower bracket

0.08

Horizontal vibration of lower bracket

0.08

Turbine

3 4

Allowable Vibration Value

4.2.11 Test residual voltage and phase sequence of the generator and observe its wave shape, the phase sequence should be correct and wave shape perfect. 4.2.12 Test and record water consumption of the technical water supply system of the unit. 4.2.13 Test and record noises of relating parts when the unit operates. 4.3

Test of the governing system in no-load operation of the unit When each assessed index of the unit operation meet the requirements, the governing system is

adjusted and tested in no-load operation of the unit after the liner temperature is stable. 4.3.1 Switch over the governor to the state of automatic operation, respectively choose some groups

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of PID parameters to do a disturbance test which disturbance degree is ±8% (viz. ±4HZ). 4.3.2 During no-load disturbance test, record the disturbance adjusting wave shape to adjust maximum overshoot, the swing times and adjustment time to meet the requirements of the governor operation specifications and select the optimal PID parameters therefrom. 4.3.3 Under the selected PID parameters, relative speed change rate of the unit in no-load operation should not exceed ±0.15% (large governor) or ±0.25% (medium and small governors) of the rated speed. 4.3.4 Under the rated speed of the unit, carry out manual and automatic switchover tests of the governor, the servomotor should not be swinging sharply. 4.3.5 The governor frequency regulation range test: Under the selected PID parameters, artificially change the governor frequency setting to verify that the governor frequency regulation range should be in conformity with requirements 4.3.6 During automatic operation of the oil pressure unit, record oil delivery time from the oil pump of the oil pressure unit to the pressure oil vessel and operation cycle of the oil pump. 4.4

Manual shut down of the unit

4.4.1 Manual shut down the unit after the governor regulation test finishes. The procedures of manual shutdown of the unit are as the following: 1）Manually operate the governor, shut the guide vane to the position of full close step by step, 2）Manually put in the brake when the unit speed lowers down to 20%nN-25%nN, 3）Record the time of the unit speed lowers from the close time of the servomotor down to 25%nr, 4）Put in servomotor blocking devices, and 5）When the unit fully stops, manually operate to release pneumatic brake to drop the braking board, monitor that the unit should not creep. 4.4.2 Inspection and regulation during and after the process of initial shutdown of the unit: 1）During speed dropping process when the unit shuts down, check up the correctness of the each setting value of the speed devices, if necessary, reset them, 2）Record the time from the brake putting in to fully stopping the unit, 3）After shutdown, monitor oil level changes of the bearing at each part, 4）Test the AC impedance of the rotor after shutdown, 5）Inspect bolts, pins, locking plates and keys at each part of the unit if there any loosening and declutching,

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6）Inspect the welded joints rotating part of the unit if there are any cracks, 7）Inspect the wind shield, bustle pipe and air deflector of the generator if there are any looseness and breaks 8）Inspect wear extent of the pneumatic brake plate, 9）Inspect leakage quantity of the unit guide vane, 10）Adjust oil level contact of liquid level switch of each bearing oil bath if necessary, and 11）Set up the contacts of the gate limiting device and relating no-load opening. 4.5

Dynamic balance test of the unit

4.5.1 Conditions of dynamic balance test During no-load operation of the unit, when vibration of the upper and lower brackets of the generator exceed the allowable values listed in Table I, a dynamic balance test should be conducted, if vibration of the upper and lower brackets of the generator is less than the allowable values listed in Table I, no dynamic balance test is necessary. 4.5.2 Dynamic balance test of the unit Dynamic balance test of the unit is that a load with certain weight is added at a proper position of the generator rotor in order to decrease vibration, the method of the dynamic balance test of the unit is as the following: 1）In accordance with the mass of the rotor and horizontal vibration value μ0 of the upper bracket, preliminarily estimate added weight W for dynamic balance test of the rotor, 2) Confirm temporarily fixed radius R of the added weight (steel plate) on the rotor according to the shape of the rotor, 3）Temporarily welded steel plate which weighs W on the plane position 1 on the rotor which radius is R, start the unit to make speed reach to the rated and test horizontal vibration of the upper bracket as μ1, 4）The unit shutdown, take down the steel plate at the position 1 and temporarily weld it on the plane position 2 (the position 2 is that the position 1 rotates 120 degree clockwise) on the rotor which radius is R, start the unit to make speed reach to the rated and test horizontal vibration of the upper bracket as μ2, 5）The unit shutdown, take down the steel plate at the position 2 and temporarily weld it on the plane position 3 (the position 3 is that the position 2 rotates 120 degree clockwise) on the rotor which radius is R, start the unit to make speed reach to the rated and test horizontal vibration of the upper bracket

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as μ3, and 6）Draw a vector diagram in accordance with μ0, μ1, μ2, μ3 and R and decide the final position of the steel plate and added weight. 4.6

Overspeed test of the turbine generator unit

4.6.1 Preparatory works prior to the test 1. The unit overspeed test should be conducted after vibration and throw have met the requirements designed by the manufacturer, otherwise, a dynamic balance test should be conducted in advance. 2. Disconnect the contacts at 115% and 140% (or as the design value) of the speed relay from the turbine protection circuit, only act on signal. 3. Specially assign persons to monitor the motions of the mechanical and electric overspeed devices. 4.6.2 Procedures of overspeed test 1．Manually start the unit to rated speed until bearing liner temperature is stable when the unit operates under the rated speed. 2．Conduct 115% of the rated speed test: Operate the governor in manual mode to rise the unit speed up to 115% nN, then swiftly drop to the rated speed and operate. 3．Record the values of vibration and throw of the unit when overspeed 115% nN, and compare with the tested values before overspeed. 4．Conduct 140% of the rated speed test: Operate the governor in manual mode to raise the unit speed up to 140% nN, then swiftly drop to the rated speed and operate. 1）Record the values of unit vibration and throw before overspeed, 2）When the unit speed reaches 140% nN, inspect the motions of the mechanical and electric overspeed devices. If overspeed devices did not act as the setting values, one more overspeed test should be conducted, 3）Record the values of vibration and throw of the unit when overspeed 140% nN, and compare with the tested values before overspeed, and 4）Repeat 140% nN overspeed test: If overspeed devices did not act as the setting values, the overspeed device should be readjusted after shutdown and then repeat this test. 5． Monitoring and recording during the unit overspeed test: 1）In the process of manual startup and speed rise, monitor the speed signal device of the unit and check up its setting values, 2）Record water levels up and down stream and the guide vane opening when overspeed 115% nN

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and 140% nN, 3）Record the unit flowrate when overspeed 115% nN and 140% nN, 4）Record the values of the unit vibration and throw before and after overspeed as well as when speedover, 5）Monitor the bearing liner temperature and oil level changes of the each part before and after overspeed, and 6）Fill all records above-mentioned in the recording chart of the unit overspeed. 4.6.3 Inspection after shutdown of the unit overspeed test After completion and shutdown of the unit overspeed test, the following inspection works should be carried out: a. Inspect if there are changes of the state of the generator base plate and upper bracket jack, b. Inspect in stress and overall if there are abnormalities on the magnetic pole keys, yoke keys, damping rings, pole lead and pole holding bolts of the rotating part of the generator, c. Overall inspect the unit in accordance with the inspection item 4.4.2 after initial startup and shutdown of the unit, and d. Test the AC impedance of the rotor. 4.7

Tests of non-excited automatic start-up and automatic shut-down of the unit

4.7.1 Inspection and preparation before automatic startup 1. The governor is at the position of “automatic”, the power preset at “no-load”, the frequency preset at the rated frequency, the parameters of the governor at the optimal position of no-load, all auxiliary equipment of the unit in state of automation, 2. Confirm that all hydraulic machinery protection circuits have been put in and provided with condition of automatic startup. 3. Confirm if the actual positions of the sevomotor locking device and the brake is in conformity with the signals of the automatic circuit, 4. Switch over each of the auxiliary equipment onto the automatic positions, and 5. Disconnect the breakers and disconnecting links at the generator outlet. 4.7.2 Test procedures 1. Automatically start the unit respectively in LCU of the unit and the central control room, the following items should be recorded and inspected: a)

Inspect if the automatic start sequence of the unit is correct and the startup process of completion,

inspect putting in operation of the auxiliary equipment of the technical water supply,

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b)

Inspect the correctness of the motions of each automation elements and adjust if necessary,

c)

Inspect the motions of the microcomputer-controlled hydraulic governor,

d) Record the time needed from delivering startup pulse to the unit starts to rotate, e) Record the time needed from delivering startup pulse to the rated speed reaches, f)

Inspect if the motion of the speed contact of the tachometer is correct,

2. Automatically stop the unit respectively in LCU of the unit and the central control room, the following items should be recorded and inspected: a)

Inspect if the automatic shutdown sequence of the unit is correct and the motion of each

automation elements is correct and reliable, b) Record the time needed from delivering shutdown pulse to the unit speed drops to the braking speed, c)

Inspect if automatic put in of the braking device is correct, record the time needed from braking

to the unit fully stops d)

Inspect if the motion of the speed contact of the tachometer is correct, if the motion of the

governor and automation elements, and e) When the unit speed drops to the rated speed of design, the braking device should be able to automatically put in, when the unit stops, the brake should be able to release automatically. 3. Automatically start the unit, simulate mechanical and electric accidents, inspect correctness and reliability of emergency shutdown circuit and process. 4. Inspect correctness of the motion of emergency shutdown buttons at the parts beside the unit and in the central control room. 5. The non-excited automatic startup and shutdown tests of the unit should be conducted beside the unit and in the central control room, the devices provided with the control modes as step operation, conventional control, PLC control, SCADA and etc. tested respectively. 6. This test should be also conducted with other tests afterwards alternately including the generator boosting and interconnected test. 4.8

Short circuit test and the stator short circuit aridity of the turbine generator

4.8.1 The conditions provided with the generator short circuit test 1. Disconnect the excitation transformer and the main bus of the generator, choose proper power source point according to the site condition of power supply, lead the power to the HV side of the excitation transformer with HV cable as the separated-excited power source and connect the button at the remote trip power source of the excitation panel.

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2. Set up a three-phase short circuit point at the enclosed busbar short circuit test and disconnect the breaker and disconnecting links at the generator outlet. 3. Disconnect the isolating disconnecting links of the arc-extinguishing coil at the neutral point of the unit. 4. Add a three phase stator ammeter, rotor ammeter and voltmeter beside the excitation panel for the use of monitoring short-circuit current rise of the generator. 5. The secondary side of CT which is not used temporarily within the short circuit range of the generator is reliably short circuited and grounded. 6. Put in unit cooling water system before the unit startup, supply cooling water slightly to the generator air cooler and put in hydraulic machinery protection devices. 7. All generator protections exit, and 8. Test the unit speed with gear disk or tachometer. 4.8.2 Testing procedures 1. Manually start up the unit, to operate the unit until bearing liner temperature of each part is stable. 2. Switch over the excitation device to the manual regulation mode, manually set on the lowest position, put in the separated-excited power source, inspect that there should be current at the secondary side of CT within short circuit range. 3. After the de-excitation switch (FMK) is closed, operate the manual setting to slowly increase the stator current up to 20%, test the current at the secondary side of CT, inspect mutual phase position of the secondary circuit connection and the three phase current balance, check the polarity of each CT and inspect there should be no current at the neutral point of each group of connections. 4. Check the polarity of CT of the excitation transformer and the correctness of its differential protection connection. 5. Gradually increase the stator current up ((approx 75%), recheck the correctness of inspection (4.8.2.3), inspect the setting values of complete and incomplete differential motions of the generator, the mutual phase at the secondary side of the protection CT as loss of excitation, negative sequence overcurrent, overload and etc. and the correctness of connection, inspect the setting values of differential motions of the transformer, inspect the correctness of the current circuits of each measuring and indicating instrument. 6. After completion of the current rise test, reduce magnet and decrease current and trip the de-excitation switch (FMK). 7. Recording of the generator short-circuit characteristics:

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After the de-excitation switch (FMK) is closed, gradually increase the stator current up to the rated values. During the process of gradual increase of current, read out the three phase stator current and the rotor current at the same time, the classification of current decrease should be above 10 points, draw out the curve of the generator short-circuit characteristics. 8. During the process of test, closely monitor the operation conditions of the rotor collecting rings and the carbon brushes. 9. When the current of the generator stator reaches the rated value, inspect the output current value at the secondary side of the shaft current protection device. 10. After completion of above-mentioned inspections and tests, trip the de-excitation switch (FMK) under the rated current of the generator and record the de-excitation characteristics of the generator under the rated current. 11. Test that the insulation resistance of the stator windings to the ground, absorption ratio and polarization index should meet the following requirements, if not, measures should be taken to execute arefaction: Insulation resistance (when converted to 100℃) R≥____

_U_____= ___10500

（1000＋ S ） 100

___=7.24 MΩ

(1000+ 450 1

In the formula: R——Insulation resistance（MΩ）； U——Rated voltage of the stator（V）； S——Rated capacity of the generator（kVA）。 b) Absorption ratio (when below 40℃) not less than 1.6, polarization index not less than 2.0. 4.8.3 Short-circuit arefaction of the generator 1. Start the units to no-load manually, when the unit operates steadily, put in the separated excitation power source, and close the de-excitation switch of the generator, increase the generator current gradually (at the beginning, the current is controlled below 50% IN.), and the temperature rise is controlled at the scope of 5-80C per hour. During the course of temperature rise, the air temperature through the air cooler of the generator is not higher than 400C and the temperature of stator windings should be controlled between 600C and 650C, but not exceed 800C. 2. During the process of arefaction, when the stator winding current increases to the control value, retaining stage can be entered, the heat preservation lasts approx 8 hours. During this process, the

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temperature can be adjusted with cooling water. 3. After 8 hours heat preservation, current and temperature can be decreased, the temperature dropping rate should be controlled within 10℃/h. When the stator winding temperature lowers below 40℃, trip the de-excitation switch to stop the unit. 4. During the process of short circuit arefaction, supply cooling water slightly to the generator air cooler and adjust cold air temperature with cooling water if necessary. 5. After short circuit arefaction, simulate emergency shutdown of the hydraulic machinery and remove the short circuit wire at the short circuit point of the generator. 4.9

Step-up test of the turbine generator unit and adjusting test of the excitation equipment

4.9.1 Conditions provided with the step-up test of the generator 1. Disconnect the breaker and disconnecting links at the generator outlet, close the neutral point isolating switch of the generator. 2. Put in the generator protection and hydraulic machinery protection, temporarily change the overvoltage protection of the generator into 1.3UN, 0.5s. 3. Put in the unit vibration and throw test devices. 4. Switch over the governor and other auxiliary machine control devices to the automatic control mode. 5. The separated-excited mode is still adopted for the unit step-up. Switch over the excitation device to the manual position, the excitation regulator is set on the lowest position. 4.9.2 The generator step-up test 1. Automatically start up with LCU beside the unit the unit, to operate the unit until bearing liner temperature of each part is stable. 2. Put in the separated-excited power source, close the generator de-excitation switch, manually operate the voltage setting to slowly step up as classified as 25%, 50%, 75% and 100%Un which is inspected accordingly. 3. Detection during the unit step-up test 1）Inspect the operation of each live equipment, 2）Inspect that the three phase voltage in the secondary circuit of each potential transformer at the end of the unit should be balanced and the phase sequence correct. Test the voltage output value of PT open-delta, phasing between each PT. 3）Test the voltage of each terminal in the secondary circuit of PT and the correctness of the voltmeter indication, and

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4）When 100%UN, test the generator shaft potential and vibration and throw values of the unit. 4.10 Recording of the

no-load characteristics curve of the generator

1）Manually operate the excitation regulator to decrease the generator voltage down to the lowest value. 2）Manually operate the excitation setting to slowly boost the generator voltage and meanwhile read out the values of three phase voltage and the rotor excitation current and the unit frequency. 3）Step by step boost up as of every 10%UN between the range of 10%-60%UN, step by step boost up as of every 5%UN between the range of 60%-100%UN, at least read out two points (UF and IL values) are read out within the range of 100%-120%UN. Boosting is limited in 1.3UN and rated excitation current. Whichever is reached, boosting stops. During the process of boosting, read out the values of stator voltage, rotor current and unit frequency at each point at the same time. 4） When boosting to the maximum voltage, quickly return back to the rated value after promptly reading out 5） Manually operate the excitation setting to slowly decrease the generator voltage, meanwhile read out the values of three phase voltage of the stator and the rotor excitation current and the unit frequency at each point. 6） Draw out the no-load characteristics curve of the generator 4.11 Single-phase

grounding test of the generator and arc-extinguishing coil position setting:

1）After completion of the generator voltage boosting, reduce magnet and decrease current and trip the de-excitation switch (FMK) to operate the unit in state of no-load (the governor is automatic), 2）Take off the HV fuse of any one phase in the PT cabinet at the end of the unit, one single-phase grounding wire at the lower end in which one grounding ammeter A1 is series-connected and recover the fuse, 3）One compensation ammeter A2 is series-connected between the arc-extinguishing coil grounding wires, 4）Operate the governor to make the unit steadily operates under the rated speed, 5）Disconnect the isolating switch of the generator neutral point arc-extinguishing coil before the de-excitation switch (FMK) is put in, 6）Manually operate the excitation regulator, gradually increase the unit terminal voltage up to 50%UN, read out the single-phase grounding capacitive current (I1) of the generator,

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7）Convert the capacitive current (I1) to the corresponding value (Ic) of the rated voltage, select the gear position of the arc-extinguishing coil and set up according to the principle of under-compensation, 8）After the isolating switch of the arc-extinguishing coil is put in, operate the excitation regulator to increase the unit terminal voltage up to 50% of the rated value, recording grounding current

(I1)

compensated by the arc-extinguishing coil and the current (I2) flowing from the arc-extinguishing coil, start to step down and be de-excited, and 9）In accordance with he setting gear position current (IL) of the arc-extinguishing coil and converted single-phase grounding current (IC) under the rated voltage, calculate the out-of-resonance degree of the arc-extinguishing coil which value should not exceed 20%, 10）During stepping up, inspect the motion of single grounding of the generator (protection outlet is released in advance, only signal given), and 11）Recover normal connections at the unit end and the neutral point after the test is completed. 4.9.3 Regulation and test of the excitation device under no-load of the turbine generator 1. Disconnect the breaker and the isolating disconnecting link at the generator outlet, 2. Put in the hydraulic machinery protection of the unit, 3.Put in the generator protection, and temporarily set the overvoltage protection at 1.3UN and 0.5s. Put in excitation system protection. 4. Erect test oscillograph and relevant connecting wires beside the excitation device. 5. Recover the excitation device of the generator to permanent self-excitation system. 6. Start up the unit, close the de-excitation switch of the generator and put in excitation device. 7. Manual excitation test Set the voltage setting point in advance, manually start excitation, record excitation wave shape of each passage, overshoot of excitation, swinging times and excitation time respectively. 8. Manually conduct inversion de-excitation test Start excitation to rated voltage, put in inversion de-excitation and record waves, record and read out inversion de-excitation time. 9. Test the voltage regulation range by manual operation: Operate the voltage setting, the terminal voltage of the generator should be able to adjust within the range between 20-110%UN. 10. Inspect that the voltage regulation range of the excitation regulation system should be in conformity with the design requirements, the automatic excitation device should be able to adjust steadily and smoothly within the range between 70-110% of the rated voltage of the generator

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no-load. 11. Manual-automatic passage switchover test of the excitation device: Manual and automatic, two groups of regulator A and B mutually switch over, the unit terminal voltage fluctuation should be ≤5% UN. 12. No-load disturbance test of the excitation: Switch over the excitation device to the automatic mode, add a disturbance (step value) of 10% of the rated excitation voltage onto the regulator voltage setting, inspect the overshoot, swinging times and regulation time during the process of regulation. The disturbance test should be conducted for the regulators A and B respectively. 13. Excitation device frequency characteristics test: Switch over the excitation device to the automatic mode, manually operated the governor to make the unit speed change within the range of ±3HZ, inspect the value of the generator terminal voltage change and record voltage-frequency characteristics curve of the generator. 14. No-load de-excitation test of the excitation system: Trip the de-excitation switch under 50% and 100% of the rated voltage, inspect the condition of de-excitation, record oscillograph diagram and read out the constant of de-excitation time. 15. Operate the unit to automatically stop with the help of LCU after the test is completed.

5. 5.1

Test of the turbine generator unit with the main transformer and HV distribution equipment Short-circuit current rise test

5.1.1 Conditions provided with the short-circuit current rise test: 1. The breaker of the generator, isolating switch, voltage equipment of the generator and relevant HV equipment have all been tested up to standard and provided with the conditions of putting into operation. 2. The main transformer has been tested up to standard and accepted. The oil level and tap switch prove normal. 3. The HV distribution equipment has been tested up to standard and accepted. 4. Decide the current rise path according to the ways of main connection and protection arrangement. 5. The grounding knife of the HV distribution equipment isolating switch at the HV side of the main transformer is used as the three phase short circuit point and practical measures taken to ensure the circuit will not open during current rising process. 6. Set up trip-prevented measures for the breaker and isolating switch in the current rising circuit according to the requirement of current rising.

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7. Put in relay protection and automatic equipment of the generator, the main transformer cooler and the circuit of control signal. 8. The mode of separated excitation is still adopted for excitation. 5.1.2 Testing procedures 1. After automatic startup of the unit is normal, close the de-excitation switch. 2. Manually raise the current to 10% successively, inspect the current at the secondary current circuit of each CT, correctness of the connection and indication of the instrument within the short-circuit range, inspect the current polarity and phase position of the main transformer, busbar and line protection, draw out current vector diagram if necessary. 3. Continue to rise the current up to 50%, 70% and 100% of the generator rated current respectively, inspect and verify the each protection setting value and the correctness of motion, and draw out the current vector diagram of the main transformer, busbar differential protection and line protection. 4. After inspection is completed, reduce magnet and decrease current and trip the de-excitation switch. 5. Operate the unit to automatically stop in the central control room after the test is completed. 5.2

Single-phase grounding test of the main transformer and HV distribution equipment

5.2.1 Set up single-phase grounding point beside the HV side of the main transformer according to the single-phase grounding protection mode. 5.2.2 The neutral point of the main transformer is directly connected to the ground. Successively raise the single-phase grounding current up to the protection motion after the unit starts up, inspect if the motion of the protection circuit is correct and reliable, check up if the motion value is consistent with the setting value. 5.2.3 Remove the single-phase grounding wire after the test is completed and put in single-phase grounding protection. 5.3

Step-up test of the turbine generator unit to the main transformer and the HV distribution equipment

5.3.1 Put in relay protection device of the generator, main transformer, busbar differential and etc. 5.3.2 The step-up range should include all primary circuit equipment of HV in this stage. 5.3.3 Operate the unit to automatically start in the central control room to make the unit reach to the rated speed. 5.3.4 Manually raise the voltage successively and inspect the operation of the primary circuit equipment under the generator rated voltage value 25%, 50%, 75% and 100%

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5.3.5 Inspect that the secondary voltage circuit, voltage, phase sequence and phase position of the synchronous circuit should be correct.

6.

Impact switching in test of the electric power system to the busbar of the HV distribution equipment and the main transformer

6.1

Preparation and inspection before the test

6.1.1 Bothe the breaker and the isolating switch at the side of the generator have been disconnected. 6.1.2 Decide impact path and breaker at the HV side of the main transformer according to the main connecting mode. 6.1.3 Put in the relay protection of the main transformer and the control, protection and signal of the cooling system. 6.1.4 Put in the neutral point grounding switch of the main transformer. 6.1.5 Putting in, exiting or temporary setting of the line protection are carried out as the system dispatching requirement. 6.1.6 Put in the fault oscillograph equipment. 6.2

Test method

6.2.1 Close the breaker at the HV side of the main transformer, impact switching in is conducted for 5 times totally by utilizing the impact of the system power source to the main transformer 6.2.2 Inspect the operation of the main transformer differential protection and gas protection and record exciting surge oscillogram when the main transformer impacts. 6.2.3 Conduct the impact switching in test of the generator terminal auxiliary transformer for three times and test the secondary voltage frequency sequence at the LV side of the auxiliary transformer 6.2.4 Conduct the service power switchover test by utilizing the system power source to supply the service power. 6.2.5 For the transformers that the rated voltage is 110kV and above, the capacity 15MVA and above, the chromatography test should be conducted for transformer oil before and after impact test.

7. 7.1

Parallel and load tests of the turbine generator unit Parallel test of the turbine generator unit

7.1.1 Inspect the correctness of the simultaneous circuit. 7.1.2 Analogue parallel test: 1． Disconnect the breaker at the simultaneous point and relevant isolating switch,

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Commissioning Procedure of Turbine and Generator

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2．The system delivers voltage to the line side of the breaker at the simultaneous point, 3． The unit automatically starts to the state of no-load and deliver voltage to the unit side of the breaker at the simultaneous point, 4． Manual and automatic parallel tests are conducted at the simultaneous devices of the LCU of the unit and the LCU of the switch station. 5． Inspect under the automatic mode that the leading time of the switch in signal of the breaker should meet the requirements, inspect the correctness of the simultaneous indicator and meantime record the oscillograms of the generator voltage, system voltage and the breaker switching in pulse. 7.1.3 Formal parallel test 1． After the analogue parallel test is completed, disconnect the breaker at the simultaneous point, decrease voltage of the unit and de-excite. 2．Switch on the isolating switch that was disconnected when the analogue parallel test has been conducting. 3．After the unit voltage steps up again, conduct manual and automatic parallel tests at the simultaneous devices of the LCU of the unit and the LCU of the switch station. 7.2

On-load test of the turbine generator unit

This test can be conducted after the parallel in test of the unit is completed. Put in the relay protection and the automatic equipment for generator, transformer, HV distribution equipment and line. The operation mode of the switch station is executed in accordance with the dispatching requirement. 7.2.1 Put in automatic subsynchronous device and realize the unit parallel in the grid with the help of the unit outlet breaker. 7.2.2 Manually operate the unit gradually to be loaded as 25%, 50%, 75% and 100%PN, in which operate for one hour at each step. 7.2.3 Inspection and recording during the on-load test of the unit: 1．Record the vibration and throw values at every load of the unit, 2．When the unit load rising up step by step, inspect the load vibration zone of the unit under the water head then, 3．Inspect the noise from relating part of the unit, 4．Record water consuming flow rate under each of the unit load, 5. Record the governor opening and travel of the servomotor, and 6. Record the pressures at the spiral case outlet, the head cover, the inlet and outlet of the draft tube

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Commissioning Procedure of Turbine and Generator

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and the pressure pulse. 7.2.4 Conduct swift adding and reducing load test of the unit. The unit is made of swift adding and reducing load by means of the power setting of the governor, the variation should not be more than 25% of the rated load. Inspect and record each item under the clause 7.2.3 and observe transition process the unit load variation. During load adding and reducing process, attention should be paid to monitor the variation of the unit vibration and throw. 7.2.5 The governor test under the loading condition of the generator: 1．Select operation parameters of the governor under the loading condition of the generator by means of adjusting test method, 2．Inspect the responsiveness and operation stability of the governor power setting under the loading condition of the generator, and 3．Under the loading condition of the generator, inspect the correctness of the AGC function realized by combination of the local control unit (LCU) and the governor. 7.2.6 Excitation test under the loading condition of the generator: 1．Under the loading condition of the generator, inspect the polarity of the setting-up difference coefficient of the excitation regulator, 2．When the active power is 0%, 50% and 100% of the rated value respectively, adjust the reactive load of the generator to the rated value, 3．Inspect the responsiveness of the reactive setting of the excitation system, 4．Inspect the setting values of maximum and minimum excitation current limits of the excitation system, 5．Inspect the operation capability of the power system stabilizer (PSS), and 6．Under the loading condition of the generator, inspect the correctness of the AVC function realized by combination of the local control unit (LCU) and the excitation equipment. 7.2.7 Quick shutdown test When the unit is 100% loaded, give out the generation-shutdown instruction from the host computer in the central control room to stop the unit quickly. Observe and record each of the following: 1. Record the time needed from the shutdown instruction is given out to the unit fully stops, 2. Observe if the closing process of the governor is normal, 3. Observe if the regulating process and de-excitation of the excitation equipment is normal,

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Commissioning Procedure of Turbine and Generator

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4. Observe if the brake putting in and releasing is normal, 5. Observe if the generator outlet breaker acts promptly, 6. Observe other electric equipment operate normally, and 7. Observe other parameters as the unit vibration, throw and etc. 7.2.8 Quick startup test After the unit is at fully standstill, give out the shutdown-generation instruction from the host computer in the central control room to start the unit quickly. Observe and record each of the following: 1. Record the time needed from the startup instruction is given out to the unit starts to generate power, 2. Observe if the governor acts normally in the startup process, 3. Observe if the automatic putting in and regulation of the excitation equipment is normal, 4. Observe if the generator outlet breaker switches in normally, 5. Observe if other electric equipment put in and act normally, and 6. Observe other parameters as the unit vibration, throw and etc. 7.3

Load rejection test of the turbine generator unit

7.3.1 Preparatory works before test 1．Select the PID parameters of the governor to the optimal value defined by no-load disturbance, 2．Adjust the coulomb or non-coulomb monitoring instruments to monitor the unit vibration, throw, spiral case pressure, unit speed (frequency), the servomotor travel and etc., 3．All relay protection and automation devices have been put in, and 4．The parameters of the automatic excitation regulator have been selected at the optimal values. 7.3.2 Load rejection test of the unit 1．The load rejection test of the unit is conducted as four times gradually rejected from 25%, 50%, 75% to 100% (or the maximum load at the water head then) of the rated active power load, 2．Record relevant values as per the chart of load rejection test (as the form in Annex A), 3. Startup of the load rejection test and switching operation to trip the generator outlet breaker are completed at the LCU, 4．When the turbine generator unit suddenly rejects load, inspect stability and overshoot of the automatic excitation regulator. When the turbine generator unit suddenly reject rated active load, the voltage overshoot of the generator should not be more than 15%-20% of the rated voltage, the times

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Commissioning Procedure of Turbine and Generator

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of oscillating movement not more than 3-5 and regulating time not more than 5s. 5．After the unit suddenly rejects load, dynamic performance of the governor should reach the following requirements: 1）When rejecting 25% of the rated load, inspect the time of immovability of the servomotor should not exceed 0.2s, 2）When rejecting 100% of the rated active load, the wave peak which exceeds 3% of the steady-state speed should not be more than 2 during speed variation, 3）When rejecting 100% of the rated active load, the total time needed should not be more than 40s from that the servomotor moves to the close direction for the first time until the swinging value of the unit speed not more than ±0.5%. 4）When the turbine generator unit rejects load, inspect the dynamic regulating performance of the turbine governing system, check that the emergency closing time of the guide vane servomotor, rates of rise of the water pressure in the spiral case and rate of rise of the unit speed and etc. should be in conformity with the design provisions. If there are any discrepancies, the guide vane closing time or the dual closing inflection point should be readjusted. 7.3.3 Emergency shutdown test After the unit load rejection test completed up to standard, emergency shutdown test can be conducted. In order to lessen damage to the excitation equipment, the emergency shutdown test should be conducted on the condition that the unit is loaded as less as possible. 1. Put in all hydraulic machinery protection and electric accident protection, 2. Operate the unit to automatically start up at the LCU of the unit, and 3. Press down the emergency stop button at the unit LCU and observe each of the following items: 1）

Actions of the governor, excitation equipment, generator outlet breaker and intake valve of the turbine,

2）

Vibration, throw and noise of the unit, and

3）

Water pressure rise in the penstock.

4. Reset the emergency stop button and release accident of the emergency stop. 7.4

The unit efficiency test The unit efficiency test is conducted by selecting that the generator operates under the rated load

of 25%, 50%, 75% and 100%

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Commissioning Procedure of Turbine and Generator

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7.4.1 The turbine flow rate is tested with the differential pressure flowmeter provided by the manufacturer. 7.4.2 The working water head of the turbine is tested with differential meter, the turbine working water head is calculated by means of the pressure difference tested between the spiral case inlet and the draft tube outlet 7.4.3 The generator power is tested with the wattmeter provided by the manufacturer. 7.4.4 Via the tested turbine flow rate, the turbine working head and the generator power, 7.5

The maximum output test of the turbine generator unit

7.5.1 In accordance with the procurement and manufacturing contract of the unit, if the condition is provided at the site, the maximum output test of the unit is conducted. 7.5.2 The maximum output test of the unit is conducted at the power factor specified by the contract and the maximum power of the unit, the operating time under the maximum output should lasts not less than 4 hours. Automatically record the temperature rise, vibration, throw, active power and reactive power values, record the servomotor travel and the guide vane opening, check the turbine running characteristic curve and the guaranteed values of the manufacturer.

8. 8.1

Unit operation test of stability and reliability Stable and reliable operation for 24 hours

8.1.1 Operation time of stability and reliability is an uninterrupted operation for 24 hours parallel in the power grid. 8.1.2 During the operation, put in all hydraulic machinery protection and electric protection, all the oil, air and water supply system of the unit automatically operate. Record the relevant operation parameters in overall. 8.1.3 The unit operates within 12 load zones from no-load to the maximum load respectively, operate in each load zone for 2 hours, monitor that all equipment operation conditions should meet the requirements of relevant specifications. 8.1.4 During the operation of stability and reliability, there should be no operation interruption caused by faults of the unit, auxiliary equipment of hydraulic machinery and electric equipment. If interruption occurs, the operation of stability and reliability should be conducted again. 8.1.5 In case of interruption which is caused by the fault of the power system or the responsibility of other subcontractors, it can be continued to conduct after the interruption.

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8.2

Commissioning Procedure of Turbine and Generator

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72 hours on-load trial run test

8.2.1 The unit is parallel in the power system, 72 hours on-load operation is conducted in accordance with the dispatching instruct of the system. 8.2.2 During 72 hours operation, 10 times of manipulation are conducted from the load appointed by the dispatcher to shutdown and from shutdown to the appointed load. 8.2.3 If the unit can not reach the rated output due to not enough working head of the power station or limit of the power system condition, the maximum load on the unit can be confirmed according to the specific conditions of the time, the 72 hours uninterrupted operation is conducted under this load. 8.2.4 Put in all hydraulic machinery protection and electric protection, record the relevant operation parameters in overall as per the operation on duty system. 8.2.5 During 72 hours operation, the operation interruption caused by manufacturing and installation quality of the unit and relevant electromechanical equipment should be inspected and treated up to standard before 72 hours uninterrupted operation starts again. However, the operation time before and after the interruption should not be cumulatively calculated. 8.2.6 After 72 hours uninterrupted test operation, it should stop the unit to overall inspect the electromechanical equipment. Except inspection to the unit, auxiliary equipment and electric equipment, water in the spiral case and the draft tube should be drained out if necessary and the conditions after operation of the water-carrying section o the unit and the hydraulic structure.

9. 9.1

Joint operation test of multiple units (3 units) Load test of joint operation of 3 units

9.1.1 Conduct this test after all test items of the three units have been completed up to standard respectively. 9.1.2 The 3 units successively start up parallel in the power grid. 9.1.3 Inspect and record the items under the clause 7.2.3. 9.1.4 The 3 units are made to operate on different active load and reactive load respectively 9.1.5 Conduct a 48 hours operation of stability and reliability and one cycle of start and stop operation 9.1.6 Conduct 4 hours uninterrupted and reliable operation between maximum possible load and no-load, the operation process should not interrupt. 9.2

Simultaneous load rejection test of the 3 units

9.2.1 Preparatory works before test

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Commissioning Procedure of Turbine and Generator

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Preparatory works refer to clause 7.3.1. 9.2.2 Load rejection test of the 3 units 1． The unit load rejection test is completed as four times gradually rejected from 25%, 50%, 75% to 100% of the rated active load (or the maximum load at the water head then). 2． Record relevant values as per the chart of load rejection test (as the form in Annex A), 3. Trip the breaker at the side of 150kV line of the GIS switch station and reject load of the 3 units simultaneously. 4．When the turbine generator unit suddenly rejects load, inspect stability and overshoot of the automatic excitation regulator. When the generator suddenly reject rated active load, the voltage overshoot of the generator should not be more than 15%-20% of the rated voltage, the times of oscillating movement not more than 3-5 and regulating time not more than 5s. 5．After the unit suddenly rejects load, dynamic performance of the governor should reach the following requirements: 1）When rejecting 25% of the rated load, inspect the time of immovability of the servomotor should not exceed 0.2s, 2）When rejecting 100% of the rated active load, the wave peak which exceeds 3% of the steady-state speed should not be more than 2 during speed variation, 3）When rejecting 100% of the rated active load, the total time needed should not be more than 40s from that the servomotor moves to the close direction for the first time until the swinging value of the unit speed not more than ±0.5%. 4）When the turbine generator unit rejects load, closely monitor the value of pressure rise in the penstock, check that the emergency closing time of the guide vane servomotor, rates of rise of the water pressure in the spiral case and rate of rise of the unit speed and etc. should be in conformity with the design provisions. If there are any discrepancies, the guide vane closing time or the dual closing inflection point should be readjusted.