Commissioning Procedure of Turbine and Generator (Rev.0)

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3x15MW WAMPU HEPP PROJECT 1000-0183-EM-462-001(1/2)
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Commissioning Procedure of
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Turbine and Generator Page. No : Cover
Turbine and Generator
DISCIPLINE : TURBINE GENERATOR TEST

PROJECT NAME : 315MW WAMPU HEPP PROJECT
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Turbine and Generator Page. No : 1 / 36
Turbine and Generator
DISCIPLINE : TURBINE GENERATOR TEST

PROJECT NAME : 315MW WAMPU HEPP PROJECT
For Construction
REV.
DATE DESCRIPTION PREP'N CHECK REVIEW APPROVAL
NO.
REV.
CNEEC PREPARATION CHECK REVIEW APPROVAL
NO.
WANG XUAN MA MING N/A WANG XUAN

0
31/11/14 31/11/14 - 31/11/14
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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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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

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1. Establishment of the organization for unit trial run

1.1 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 directors 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 Directors Office: The Unit Trial Run Directors 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. Inspection before start-up and trial run of the turbine generator unit
2.1 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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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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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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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
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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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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,
dThe circuits of automatic unit operation and hydraulic machinery protection,
e) The generator excitation operating circuit,
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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
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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. Water filling test of the turbine generator unit

3.1 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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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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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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1There should be no leakage at each pipeline, valve and joint of the entire technical water supply
system,
2Each 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.
3The water pressure of each branch line should be in conformity with the requirements of the
manufacturers and the design.
4. No-load trial run of the turbine generator unit

4.1 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:
aThe 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,
bThe 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 24.
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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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
Allowable Vibration Value

No. Description
mm
1 Horizontal vibration of head cover 0.07

Turbine
2 Vertical vibration of head cover 0.04
3 Vertical vibration of upper bracket 0.07
Generator Unit
4 Horizontal vibration of upper bracket 0.07

Turbine
5 Vertical vibration of lower bracket 0.08

6 Horizontal vibration of lower bracket 0.08
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:
1Manually operate the governor, shut the guide vane to the position of full close step by step,
2Manually put in the brake when the unit speed lowers down to 20%nN-25%nN,
3Record the time of the unit speed lowers from the close time of the servomotor down to 25%nr,
4Put in servomotor blocking devices, and
5When 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:
1During 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,
2Record the time from the brake putting in to fully stopping the unit,
3After shutdown, monitor oil level changes of the bearing at each part,
4Test the AC impedance of the rotor after shutdown,
5Inspect bolts, pins, locking plates and keys at each part of the unit if there any loosening and
declutching,
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6Inspect the welded joints rotating part of the unit if there are any cracks,
7Inspect the wind shield, bustle pipe and air deflector of the generator if there are any looseness and
breaks
8Inspect wear extent of the pneumatic brake plate,
9Inspect leakage quantity of the unit guide vane,
10Adjust oil level contact of liquid level switch of each bearing oil bath if necessary, and
11Set 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:
1In accordance with the mass of the rotor and horizontal vibration value 0 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,
3Temporarily 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
1,
4The 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 2,
5The 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 3, and
6Draw a vector diagram in accordance with 0, 1, 2, 3 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
1Manually start the unit to rated speed until bearing liner temperature is stable when the unit
operates under the rated speed.
2Conduct 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.
3Record the values of vibration and throw of the unit when overspeed 115% nN, and compare with
the tested values before overspeed.
4Conduct 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.
1Record the values of unit vibration and throw before overspeed,
2When 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,
3Record the values of vibration and throw of the unit when overspeed 140% nN, and compare with
the tested values before overspeed, and
4Repeat 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:
1In the process of manual startup and speed rise, monitor the speed signal device of the unit and
check up its setting values,
2Record water levels up and down stream and the guide vane opening when overspeed 115% nN
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and 140% nN,

3Record the unit flowrate when overspeed 115% nN and 140% nN,
4Record the values of the unit vibration and throw before and after overspeed as well as when
speedover,
5Monitor the bearing liner temperature and oil level changes of the each part before and after
overspeed, and
6Fill 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 ___=7.24 M
1000 S (1000+ 450
100 1
In the formula:
RInsulation resistanceM
URated voltage of the statorV
SRated capacity of the generatorkVA
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
1Inspect the operation of each live equipment,
2Inspect 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.
3Test the voltage of each terminal in the secondary circuit of PT and the correctness of the voltmeter
indication, and
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4When 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
1Manually operate the excitation regulator to decrease the generator voltage down to the lowest
value.
2Manually 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.
3Step 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:
1After 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),
2Take 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,
3One compensation ammeter A2 is series-connected between the arc-extinguishing coil grounding
wires,
4Operate the governor to make the unit steadily operates under the rated speed,
5Disconnect the isolating switch of the generator neutral point arc-extinguishing coil before the
de-excitation switch (FMK) is put in,
6Manually 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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7Convert 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,
8After 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
9In 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%,
10During stepping up, inspect the motion of single grounding of the generator (protection outlet is
released in advance, only signal given), and
11Recover 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. Test of the turbine generator unit with the main transformer and HV distribution equipment
5.1 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. Parallel and load tests of the turbine generator unit

7.1 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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2The 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.
2Switch on the isolating switch that was disconnected when the analogue parallel test has been
conducting.
3After 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:
1Record the vibration and throw values at every load of the unit,
2When the unit load rising up step by step, inspect the load vibration zone of the unit under the
water head then,
3Inspect the noise from relating part of the unit,
4Record 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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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:
1Select operation parameters of the governor under the loading condition of the generator by means
of adjusting test method,
2Inspect the responsiveness and operation stability of the governor power setting under the loading
condition of the generator, and
3Under 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:
1Under the loading condition of the generator, inspect the polarity of the setting-up difference
coefficient of the excitation regulator,
2When the active power is 0%, 50% and 100% of the rated value respectively, adjust the reactive
load of the generator to the rated value,
3Inspect the responsiveness of the reactive setting of the excitation system,
4Inspect the setting values of maximum and minimum excitation current limits of the excitation
system,
5Inspect the operation capability of the power system stabilizer (PSS), and
6Under 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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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
1Select the PID parameters of the governor to the optimal value defined by no-load disturbance,
2Adjust the coulomb or non-coulomb monitoring instruments to monitor the unit vibration, throw,
spiral case pressure, unit speed (frequency), the servomotor travel and etc.,
3All relay protection and automation devices have been put in, and
4The parameters of the automatic excitation regulator have been selected at the optimal values.
7.3.2 Load rejection test of the unit
1The 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,
2Record 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,
4When 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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of oscillating movement not more than 3-5 and regulating time not more than 5s.
5After the unit suddenly rejects load, dynamic performance of the governor should reach the
following requirements:
1When rejecting 25% of the rated load, inspect the time of immovability of the servomotor should
not exceed 0.2s,
2When 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,
3When 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%.
4When 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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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. Unit operation test of stability and reliability

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

9.1 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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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.
4When 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.
5After the unit suddenly rejects load, dynamic performance of the governor should reach the
following requirements:
1When rejecting 25% of the rated load, inspect the time of immovability of the servomotor should
not exceed 0.2s,
2When 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,
3When 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%.
4When 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.

Commissioning Procedure of Turbine and Generator (Rev.0)

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Commissioning Procedure of Turbine and Generator (Rev.0)

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DOCU. NO.

DISCIPLINE : TURBINE GENERATOR TEST

DISCIPLINE : TURBINE GENERATOR TEST

WANG XUAN MA MING N/A WANG XUAN

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

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

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

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

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

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

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

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

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

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

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

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

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

1. Establishment of the organization for unit trial run

3. Water filling test of the turbine generator unit

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

Allowable Vibration Value

1 Horizontal vibration of head cover 0.07

4 Horizontal vibration of upper bracket 0.07

5 Vertical vibration of lower bracket 0.08

of PID parameters to do a disturbance test which disturbance degree is 8% (viz. 4HZ).

and 140% nN,

temperature can be adjusted with cooling water.

7. Parallel and load tests of the turbine generator unit

and the pressure pulse.

4. Observe if the brake putting in and releasing is normal,

8. Unit operation test of stability and reliability

8.2 72 hours on-load trial run test

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

9.2 Simultaneous load rejection test of the 3 units

Preparatory works refer to clause 7.3.1.

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