GOMAL ZAM DAM MULTIPURPOSE PROJECT

（DAM &HYDROPOWER COMPONENT）

SUBLET CONTRACT NO. 1/492/DAM/GZD

TESTING PROCEDURES FOR

COMMISSIONING AND TRIAL OPERATION

Employer:

WATER AND POWER DEVELOPMENT

AUTHORITY

Management Consultant:

NATIONAL DEVELOPMENT CONSULTANTS LEADER

(Five National/International Firms)

Contractor:

FRONTIER WORKS ORGANIZATION

Sublet Contractor:

SINOHYDRO CORPORATION

Table of Contents

1 Introduction ................................................................................................................... 1

2 General Principles ......................................................................................................... 1

2.1. Purposes, Scope and Requirements of Commissioning and Trial Operation ..... 1

2.2 Requirements prior to Commissioning and Trial Operation of Units .................... 2

2.3. Testing Procedures of Commissioning and Trial Operation ............................... 3

3 Inspection prior to Commissioning and Trial Operation ................................................ 5

3.1. Water-diversion System Inspection .................................................................... 5

3.2 Hydraulic Turbine Inspection .............................................................................. 6

3.3 Governing System Inspection.............................................................................. 6

3.4. Generator Inspection .......................................................................................... 6

3.5. Excitation System Inspection .............................................................................. 6

3.6. Inspection for Oil, Water and Air Systems .......................................................... 7

3.7 Electrical Equipment Inspection ......................................................................... 7

4 Water Filling Test ........................................................................................................... 8

4.1 General Requirements ........................................................................................ 8

4.2 Water Filling Operation and Inspection .............................................................. 9

5 Primary Manual Commissioning Test for Generating units .......................................... 10

5.1 Preparation for Commissioning ......................................................................... 10

5.2. First Manual Commissioning Test for Generating units .................................... 11

5.3 Adjustment and Test of Governing System in No-Load Running ....................... 11

5.4 Manual Shutdown of Generating units and Followed Inspection ....................... 12

6 Over Speed Test .......................................................................................................... 12

6.1 Preparation for Test ........................................................................................... 12

6.2. Over Speed Test ............................................................................................... 12

7 Auto-Start and Auto-Stop Test without Excitation Control ............................................ 13

7.1 Pre-conditions for Test ....................................................................................... 13

7.2 Auto-Start and Auto-Stop Test ............................................................................ 13

8 Short Circuit Current and Voltage Boosting Test for Generating units ......................... 14

8.1. Pre-conditions for Short Circuit Test ................................................................. 14

8.2 Short Circuit Current boosting test for Generating units .................................... 15

8.3. Pre-conditions for Voltage Boosting Test .......................................................... 16

8.4. Voltage Boosting Test for Generating units ....................................................... 16

8.5. Adjustment and Test of Excitation Controller in No-Load Running ................... 17

9 Test of Generating units loading with Main Transformer and High Voltage Distribution

Device ............................................................................................................................ 18

9.1 Short-Circuit Current boosting test .................................................................... 18

9.2. Voltage Boosting Test of Generating units Loading with Main Transformer and

High Voltage Distribution Device ............................................................................. 20

9.3 Test with Current for Bus bar of High Voltage Distribution Device .................... 20

9.4. Switching-on Test of Power System Impact upon Main Transformer ................ 20

10 Synchronous and On-Load Test ................................................................................ 21

10.1 Pre-conditions for Synchronous Test ............................................................... 21

10.2 Synchronous Test ............................................................................................ 22

10.3. Station Transformer Test with Current and Switching-over ............................. 23

10.4 On-Load Test for Generating units................................................................... 23

11 Load rejection test ..................................................................................................... 24

11.1 Pre-Conditions for Load rejection test ............................................................. 24

11.2 Load Rejection Test ......................................................................................... 24

12 Performance Test and Reliability Operation of Generating units for Acceptance and

Handover ........................................................................................................................ 26

12.1 36-Hour Continuous Trial Operation with Load................................................ 26

12.2. Performance Test for Generating units ........................................................... 26

12.3 Submission of Generating Units Performance Test Acceptance Report .......... 27

12.4 Generating units Performance Acceptance ..................................................... 27

12.5 Reliability running inspection ........................................................................... 27

12.6 Submission of Reliability Operation Acceptance Report .................................. 27

12.7 Acceptance and Handover after Reliability Operation ..................................... 27

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1 Introduction

The Gomal Zam Multipurpose Dam Project locates on Gomal Zam River which is a

branch of India River. The total installed capacity of GZDP is 17 MW with two sets mixed

flow Hydro-Turbine generating units of 8.5 MW. The powerhouse is connected to the

Power Grid with 132KV XLPE cable, wherein one outgoing circuit is connected with

TANK substation and another one is connected with WANA substation. Main Electrical

Connection of powerhouse are: 1#, 2# hydraulic-turbine generating units are

respectively connecting with two sets of 12.5 MVA three phase transformers to form unit-

connection, the 132KV power distribution devices shall adopt the outdoor Gas Insulated

Switchgear (GIS).

Power house is constructed as ground powerhouse, wherein panels, speed governors

etc are installed on El.643.15m generator floor; the outgoing cables and neutral point

equipment are installed on El.639.95m cable floor, butterfly valve hydraulic equipment,

bottom outlet hydraulic hoist pump, leakage draining equipment and low-medium air

compression equipment, turbine oil system are installed on El.637.0(El.637.8m)hydraulic

turbine floor; service and dewatering system and butterfly valves are installed on

El.633.15m butterfly valve floor.

The Auxiliary Power House which is located at one side upstream of Powerhouse is

divided into four floors. The ground floor for power distribution device locates at

El.643.15m, wherein 11kv system and 415v system are installed. Second floor for cables

locates at El.648.25m. Third floor for central control locates at El.650.85m, which is

mainly arranged with storage battery room, relay protection and central control room.

The fourth floor for office locates at El.658.2m, which is mainly arranged with

communication room, offices etc.

GIS Switchyard locates on the roof of Powerhouse, outgoing line equipment is installed

on the roof of Auxiliary Powerhouse, and main transformers are installed at El.656.4m

the left side and adjacent to Powerhouse .

2 General Principles

This program together with trial operation procedures shall be the main basis of

commissioning and trial operation tests for Hydro-Turbine generating units.

2.1. Purposes, Scope and Requirements of Commissioning and Trial Operation

2.1.1. Purpose

Commissioning tests and trial operation tests are essential work and should be centered

on Hydro-Turbine generating units, which includes the comprehensive examination of

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the water intake structure, generating units, tailrace structures, metal structures, and

electrical & mechanical equipment, inspection of the design & manufacture & installation

of hydraulic structures, metal structures and electrical & mechanical equipment to

conform with quality assurance, adjusting and fulfillment of trial operation tests to overall

electrical & mechanical equipment to demonstrate the Works or Section can be

operated safely as specified under contract, to ensure hydropower system to be stably

and reliably run within commercial operating life.

2.1.2. Scope

(1) Metal structure and electrical & mechanical equipment at Dam and intake.

(2) Hydraulic structure and metal structure equipment in headrace tunnel.

(3) Penstock, metal structure, electrical & mechanical equipment of 1# & 2# inlet

butterfly valve and tailrace gate of 1# (2#) generating units.

(4) Seepage drainage system, service drainage system, technical water supply system,

low and medium compressed air system, turbine oil system in Powerhouse.

(5) 1#(2#) Hydro-Turbine generating units and auxiliary equipment.

(6) Excitation system for 1#(2#)units; primary & secondary electrical equipment and

relay protection devices in main circuit of 1#(2#) generator.

(7) 1#(2#) main transformers and neutral points equipment, 132kV GIS equipment,

132kV outgoing line equipment.

(8) Computer monitoring system for 1＃ (2#)units and public control & protection,

illumination and communication system.

2.1.3. Requirements

All defective matters if found during commissioning of Hydro-Turbine generating units

shall be remedied in time to ensure a long-time, safe and stable operation of Hydro-

Turbine generating units after taking over.

Apparatuses, Devices and equipment consisting in relay protection, auto control,

measure instruments etc, as well as electrical circuit, electrical and mechanical

equipment in relative to the operation of Hydro-Turbine generating units shall be tested.

2.2 Requirements prior to Commissioning and Trial Operation of Units

2.2.1 General Requirements prior to Trial Operation

(1) Communications with Dam monitoring, reservoir operation and hydrological

forecasting system are in good condition.

(2) Communications with power gird dispatching are in good condition.

(3) Clearance for all subsystem in relative to trial operation is completed.

(4) Lifting hole and temporary manhole in relative to trial operation are plugged.

(5) Illumination for all parts relative to trial operation and passages are in good condition.

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(6) Organization and personnel for trial operation are in order, communications and

contacts between the related subsystems and commanding agency are established.

2.2.2 Requirement of Water Conduit System

(1) Trash racks are installed.

(2) Emergency gate and hydraulic hoist are completely installed, tested to be qualified,

sluice gate remains on closed, hoist remains on standby.

(3) Penstock is completely installed, examined and be qualified upon inspection.

(4) Emergency Gate in Service Tunnel is completely installed and remains on closed.

(5) 1# & 2# inlet butterfly valves are completely installed, tested to be qualified, and

remain on closed.

(6) 1# & 2# outlet drainage valve are completely installed and remain on closed, spiral

case and tailrace gates remain on closed.

(7) 1# & 2# tailrace gate and hoist are completely installed, tested and accepted to be

qualified; tailrace gate remains on closed; hoist remains on standby.

2.2.3. Requirement of Powerhouse

Illumination system and all passages relative to trial operation of 1#(2#)units are

arranged, wherein handrails of main passages and holes are installed so as to meet the

safe trial operation, drainage system in Powerhouse is performing under normal

operation.

2.2.4. Requirement of Electrical Equipment

1# & 2# Hydro-Turbine generating units are completely installed; oil, air and water

system as well as auxiliary equipment relative to the trial operation of units are

completely installed, tested to be qualified and implemented commissioning tests in

steps.

Primary and secondary electric equipment relative to the trial operation of 1#(2#)units

are inspected, tested and accepted to be qualified. During the whole process all

operations are accurate and stable, the earth resistance in Powerhouse can meet the

design requirement.

Internal communication system and external communication system are completely

installed, tested as per the design and can be reliably operated.

2.3. Testing Procedures of Commissioning and Trial Operation

2.3.1. Principals

(1) Taking into account of the difficulty degree of testing or restricted conditions,

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sequences of some test items can be adjusted as per the site situation.

(2) Computerized procedure tests may carry out concomitantly in the process of each

procedure test.

(3) Within the permitted scope of regulations, after 36-hours continuous trial operation

test, part of tests may be postponed subject to confirmation by site commanding agency

after coordinating with all concerned parties, while consented by the Contractor, the

Employer, and the Management Consultants.

(4) This programme cannot be carried out until approved by the Contractor, the

Employer, and the Management Consultants. The operations relative to system

equipment shall be executed after approved by Pakistan National Electricity

Communication Center.

2.3.2. Inspection of the Hydro-Turbine Generating Units before water filling

2.3.3. Water filling test For Hydro-Turbine generating units

2.3.4. No-load Operation for Hydro-Turbine generating units

(1) the first time manually Start-up tests for units

(2) Governing system test under no-load running condition.

(3) Manually shutdown of generating units and subsequent inspection.

2.3.5. Over speed test and inspection

2.3.6. Non-excitation auto-start and auto-stop tests

2.3.7.Short circuit current boosting test

(1) Short circuit current boosting test for generating units.

(2) Short circuit current boosting test of generating units loading with main transformer

and high voltage distribution equipment.

2.3.8 Voltage boosting test

(1) Voltage boosting test for generating units.

(2) Adjustment and test of excitation controller under no-load running condition.

(3) Voltage boosting test of generating units loading with main transformer and high

voltage distribution equipment.

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2.3.9. High voltage distribution equipment’s busbar test with current.

2.3.10. Switching-on impulse test between power system and main transformer

2.3.11. Parallel loading test for Hydro-Turbine generating units

(1) Generating units parallel test .

(2) Generating units loading test.

(3) Generating units load-dropping test.

2.3.12. 36-hour continuous trial operation with load

According to upstream water level and actual reservoir inflow, perform trial operation

with loading as per characteristic curve of hydraulic turbine.

2.3.13 Generating units performance test

2.3.14 Acceptance of generating units reliability run and Taking-over

3 Inspection prior to Commissioning and Trial Operation

3.1. Water-diversion System Inspection

3.1.1 .Inspection of the intak

(1) The trash racks are installed, tested, cleaned and be qualified upon inspection.

(2) Emergency gate is cleaned up without any obstructions.

(3) Sluice gate and hydraulic hoists are installed, cleaned and tested to be qualified.

Sluice gate remains on closed.

3.1.2 Water passage inspection

(1) 1#(2#) inlet butterfly valves are installed, tested to be qualified, are under hoisting

performance condition and remains on closed.

(2) Spiral case and tail pipe.,etc water conduit system are cleaned and qualified upon

inspection.

(3) Drainage pipe of spiral case and tailrace are cleaned up; drain valves are installed

and remain on closed.

(4) Tailrace gate and its surroundings are cleaned up; tailrace gate and gate hoist are

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installed and are under hoisting performance condition, tailrace gate remains on closed.

(5) Finishing the inspection of the above mentioned items, close access gates o tailrace

and spiral case.

3.2 Hydraulic Turbine Inspection

(1) Rotating wheel of turbine and all auxiliary components are installed and tested to be

qualified upon inspection.

(2) Top cover self-flow drainage holes are cleaned up.

(3) Operation seal and overhauling sealing of main shaft are installed.

(4) Water-guide bearing lubrication system is inspected and tested to be qualified upon

inspection.

(5) Gate operating mechanism are installed, tested and are kept closed.

3.3 Governing System Inspection

(1) Governing system is installed and tested to be qualified.

(2) Oil pressure devices are installed and qualified upon inspection; air-pressure filling

devices of oil tank are installed accurately, stably, and are in a regular state of operation.

3.4. Generator Inspection

(1) Generators are completely installed and qualified upon inspection.

(2) Internal parts of generators are cleaned up, and no debris is allowed inside turbine

pit.

(3) Guide bearing and thrust bearing are installed; oil sink level are regular; oil cooling

system is in a regular performance.

(4) Collecting ring, carbon brush, brush holder together with auxiliary wiring are installed,

cleaned up and be qualified upon inspection.

(5) Mechanical braking system is installed, can be regularly operated, and is in a

braking state before water filling.

(6) The circuits of temperature measurement system and single-point temperature

controller etc are installed, tested and put into operation.

(7) Shimmy damper equipment is installed and tested; the monitored parameters are

accurate and stable.

3.5. Excitation System Inspection

(1) Excitation system is installed, tested to be qualified.

(2) Excitation transformer is installed, tested and accepted upon inspection.

(3) Excitation equipment tests in steady state are qualified upon inspection.

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3.6. Inspection for Oil, Water and Air Systems

(1)Technical water supply system is installed, tested and accepted upon inspection.

(2)Seepage drainage system and service drainage system in powerhouse are installed,

tested, accepted upon inspection, and are put into operation with regular performance.

(3)Turbine Oil system of Powerhouse is put into operation partially, can satisfy the

requirements of oil supply, using and discharging for 1#(2#)generating units.

(4)Medium and low air compression systems are installed, tested and accepted upon

inspection and entirely are put into operation.

(5)Hydraulic measurement system of 1#(2#)generating units is installed and put into

operation.

3.7 Electrical Equipment Inspection

3.7.1. Primary electrical equipment

(1) Main outgoing line and Generator are well connected and installed, tested to be

qualified; Neutral point equipment is installed, tested to be qualified and provided with

electrified test conditions.

(2) Breaker, insulation switch at Generator outgoing terminal, Station transformers and

voltage transformers, current transformers etc are installed, tested and provided with

electrified test conditions.

(3) The cables and equipment between generator outgoing terminal and main

transformers are connected, installed, tested and provided with electrified test conditions.

(4) Main transformers are installed, tested to be qualified, neutral point is connected

with grounding; the main transformers are connected with 132kV GIS equipment and

11KV cable separately; the tapping switch remains on running grade as per the

requirements of system.

(5) GIS bays, 132KV outgoing line equipment, 132KV high voltage cables etc as well as

overhead lines are installed, tested to be qualified.

(6) Earthed network and earth resistance at Powerhouse are tested to conform to

design requirements; all equipment earthings in Powerhouse are in good condition.

3.7.2 Power Supply for Station and D.C systems

(1)Power supply system relative to the generating units is installed, tested, electrified

and put into normal operation.

(2)D.C 220V system is put in operation; D.C power is launched.

(3)UPS equipment is installed and tested; A.C control power is launched.

(4)Central Control room, field G-set control and motive power screen are put into

operation; all AC and DC control load are launched.

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3.7.3. Secondary electric equipment

(1) Computerized monitoring system is installed, tested to be qualified.

(2) Oil, water, and air system, local control panel for auxiliary system in powerhouse,

local control panel for dam and intake control system are installed and tested;

communications between PLC and computerized system are set up; simulation /

switching value input and output are regulated.

(3) The micro-computerized protective devices contained in generators, main

transformers, 11KV transformer for station service, excitation transformers, breakers

and 132kV GIS boosting station are installed, tested to be qualified.

(4) Computer monitoring system’s simulation test is completed.

(5) Auto control simulation test for generating units is completed accurately.

(6) High frequency channels connecting TANK station and WANA station are modulated.

(7) System communication devices are installed and tested that conforms to unimpeded

requirements, working data in Powerhouse can be transmitted to communication

network in power dispatching center.

(8) Communication equipment for coordination and management in Powerhouse is

installed and tested, which is capable to match the communication demands of

commissioning for 1#(2#)generating units.

4 Water Filling Test

4.1 General Requirements

Filling water does mean the beginning of commissioning test and trail operation for

generating units, when it shall be confirmed that all inspection are completed. Dam

Water level shall have reached the lowest level for generating, and current water level

shall be accordingly recorded.

Confirm the following items before filling water:

(1) Confirm that the intake gantry crane, tailrace hydraulic hoist are working regularly

and are in a condition to perform hoisting.

(2) Intake emergency gate is kept closed.

(3) The butterfly valve is closed and locked.

(4) Tailrace drainage valve is closed.

(5) Technical water supply valve, butterfly drainage valve, spiral case drainage valve

and access doors of spiral case, tailrace all are closed.

(6) Make sure that: speed governor and turbine operating mechanism are kept closed;

servomotor locking devices are locked; main oil supply valve is closed.

(7) The low-pressure air compressor is under working condition; intake valve connecting

to overhauling sealing of main shaft is kept open; drainage air valve is kept closed;

overhauling sealing of main shaft is kept in operation.

(8) Braking air supply circuit within braking air-compensation control cabinet is kept

open; reverting and air-out return ducting are kept closed; airbrake is kept in braking

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status.

(9) Tailrace gate is kept closed.

(10) Leak drainage system in Powerhouse, service drainage system of generating units

are being kept in regular operation.

4.2 Water Filling Operation and Inspection

4.2.1 Water filling for tailrace pip

(1) Record tailrace water level.

(2) Adopt narrow opening of tailrace hydraulic hoist in lifting tailrace gate, and fill water

from the bottom of tailrace gate to tailrace pipe.

(3) In the process of water filling, the leakage situation of each part shall be inspected at

all times. Immediately stop water filling once find abnormal situation such as massive

water leakage etc. Do not resume water filling until the related problems are solved.

(4) After confirming the filling level is equal to tailrace water level, open tailrace gate

completely.

(5) Tailrace equalizing filling is completed.

4.2.2 Water filling for headrace structures

(1) Water filling procedures for headrace structures strictly complying with the design

requirements.

(2) Fill water to headrace tunnel by opening the filling valve of intake emergency gate,

and then inspect the leakage situation of each part. After the filling level is equal to

reservoir water level the filling valve of emergency gate shall be closed for 3 hours to

observe the leakage situation of all hydraulic structures and butterfly valve during closed

state.

(3) In the process of water filling, immediately stop water filling once find massive water

leakage. Do not resume water filling for headrace structures until the related problems

are solved.

(4) Lift intake emergency gate to orifice and lock up; water filling procedures for

headrace structures are completed.

4.2.3 Water filling for spiral case

(1) Open bypass pipe manual valve of butterfly valve of 1#(2#)generating units and

bypass pipe electric valve, fill water to spiral case of 1#(2#)generating units, and then

monitor water pressure in spiral case. Stop water filling when water pressure in spiral

case reaches up to design pressure.

(2) In the process of water filling, inspect the leakage situation of each part and top

cover drainage, and closely monitor pressure changes in spiral case. Immediately close

bypass pipe valve and stop water filling once find massive water leakage. Do not

resume water filling for spiral case until the related problems are solved.

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(3) Implement water filling until water pressure in spiral case is equal to inlet water

pressure.

(4) Close down bypass pipe electric valve as soon as pressure equalizing in spiral case.

4.2.4. Inspection and test after pressure equalizing

(1) When spiral case is fully filled with water, operation test with water filling in inlet

butterfly valve shall be implemented. After the test, butterfly valve shall be fully opened.

(2) Inspect the leakage situation of each part in Powerhouse as well as drainage

capacity and performance reliability of leak drainage pump.

(3) Inspect performance of the overhauling sealing of main shaft.

(4) After spiral case is filled with water, pipeline equipment of water supply system for

1#(2#)generating units shall be inspected, and adjust water pressure to operating

pressure(or enable the water flow to meet the requirements), while inspect the

performances of all pipelines, valves and joints.

5 Primary Manual Commissioning Test for Generating units

5.1 Preparation for Commissioning

(1) Conduct complete inspection for the rotor and stator, and make sure that there are

no sundries left inside.

(2) Make sure that both intake gate and inlet butterfly valve are fully opened.

(3) Inspect to make sure that cooling water for each part of generating units is applied

and water pressure therein is normal.

(4) Inspect to make sure that the performance of lubrication system and oil operation

system is regular, and oil level of each bearing oil sink is normal.

(5) Inspect to make sure drainage system is under automatically operating state and

there is no obvious alteration of water level in service drainage sump.

(6) Records initial temperatures (bearing bushing temperature, oil temperature, cooling

water temperature and stator temperature of each bearing part).

(7) Jack up the rotor of generator by high pressure oil jacking devices within 24 hours

prior to commissioning, inspect and make sure that all braking switches are off.

(8) Governor is kept in preparing state.

(9) Equipment relative to generating units shall accord with the following conditions:

1) Generator outlet breaker shall be on disconnecting position.

2) Make sure that excitation system de-excitation switch, build-up excitation switch,

alternative & direct-current switches within excitation power panel shall be off-switch

state.

3) Hydro-mechanical protective and temperature measurement devices are put in

operation.

4) All short wiring and earthing cables for test are removed.

(10) Local control units of generating units are under working state and communications

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are regular.

5.2. First Manual Commissioning Test for Generating units

(1) Unlock servomotor locking device and open guide blade manually. Then close the

guide blade while generating units are running. Afterwards, inspect and make sure there

is no attrition or collision between the running and the static components.

(2) After confirming the regular performances of all parts, open the guide blade manually

again to start-up the generating units and prompt speed.

(3) When the speed approximates 50% of rated speed, suspend speed promotion,

observe the performance of each part, and enlarge the opening of guide blade if there is

no abnormal performance being observed.

(4) In the process of speed boosting, strengthen the monitoring of bearing temperatures

for each part. Significant temperature variation is not allowed. Inspect the changes of

bearing oil level and the condition of oil splash.

(5) After reaching to the rated speed, record the opening under idling motion and

servomotor stroke, stabilize the performance of generating units, and implement the

close monitoring of temperature of thrust bearing shoe valve, guide bearing temperature,

oil temperature until all the temperatures of each bearing liner are stable.

(6) Record the amplitude degree of all bearings. The degree shall be not beyond 75% of

total bearing gap.

(7) Measure the residual voltage and phase sequence of generating units.

(8) The subsequent tests can be implemented when generating units are in no-load

running with the stable temperature of each bearing liner.

5.3 Adjustment and Test of Governing System in No-Load Running

(1) Inspect and make sure that each component of governor is performing regularly.

(2) Disturbance degree of ±8％ shall be used for governor no-load running disturbing

test so as to select PID parameter as per the following requirements:

Under idling operating mode Generating units is motion automatically, impose ±8％of

rated speed as stepped disturbance signal, record transient process of generating units

speed, and servomotor stroke, the maximum percent overshoot of speed shall not be

over than 30% of disturbance amount. Overshoot action cannot be over twice. Adjusting

duration from disturbing motion until it reached within the specified rotating swing degree

shall meet with design standards. Select one set of parameters to be the adjustment

reference for no-load running. As per the selected reference and in no-load running, the

rotating relative amplitude degree cannot be over 0.15％ of the rated speed.

(3) Mimic guide blade signal loss with the servomotor variation of △Y＜5%.

(4) Implement the test of mimicking power loss with the servomotor variation of △Y＜5%.

(5) Implement oil filter changing-over test and the test shall have no influence on

governor operation.

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5.4 Manual Shutdown of Generating units and Followed Inspection

(1) After the adjustment of governing system, manual shutdown of generating units can

be applied.

(2) When the speed decreases to 15—20％ of the rated speed, apply manual closure to

stop generating units, confirm air-brake jacked up from signal of monitoring system;

Release braking and put into reverting air pressure and then relieve the air reverted

pressure once the air-brake signal of monitoring system falls down.

(3) During shutdown of generating units, inspect and adjust movement state when signal

indicating operated speed at 95%、20%、5% contact points.

(4) Apply servomotor locking and overhauling sealing of main shaft after generating units

are closing down.

(5) Inspection and adjustment after generating units are closing down.

1) Inspect whether bolts, dowel pins, lock blades of each part are loose or drop off.

2) Inspect whether the welding seam of rotating parts split.

3) Regulate the setting values of oil sink level annunciators.

6 Over Speed Test

After all the parameters of governor are regulated and accepted, implement over speed

test for generating units as per setted values of over speed protective devices by the

design provisions, so as to test the strength and installation quality of rotating parts of

generating units.

6.1 Preparation for Test

(1) Disconnect the 115%、140% electric speed contact points of speed monitoring

control devices from the turbine protective return circuit, in addition, use new signal to

monitor the on-off actions of all contacts.

(2) Correctly install the measurement gauges for all sections.

(3) Surveyor and operation personnel shall be in place, ensuring good communications

among all the related parts.

6.2. Over Speed Test

(1) Apply manual starting-up of generating units to increase the speed to the rated speed.

(2) Enlarge the guide blade opening after generating units are performing regularly and

stalely for a while, thereafter increase the speed to 115% of the rated speed while

inspect the speed contract signal of speed monitoring control devices.

(3) If there is no abnormal performance of generating units being observed, continuously

increase the speed to 140% of the rated speed while inspect the speed contract signal.

(4) In the process of over speed test, monitor that amplitude degree, vibration value, any

oil sink splash and any abnormal sound of each part.

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(5) When perform the over speed protection motion, monitor and record the increased

water pressure value of spiral case and increased speed value.

(6) Speed increase operation shall be stable and steady, neither too fast nor too slow.

Once the shutdown operation of generating units fails, the instructor shall immediately

instruct to push emergency button to compel generating units to closing down.

(7) Implement the following inspections after over speed test:

1) Completely inspect the rotating parts of generator.

2) Inspect the stator foundation and upper bracket of generator.

3) Inspect whether the bolts, dowel pins and lock blades of each part are loose or drop

off.

7 Auto-Start and Auto-Stop Test without Excitation Control

The main purpose of auto-start and auto-stop test is to inspect whether motion on return

circuit or computerized monitor system under the auto–start and auto-stop state is

correct.

7.1 Pre-conditions for Test

(1) Speed governor shall be switched at “Auto” position, Capacity factor presetting shall

be on “No-load” position, the frequency presetting shall also be set to the rated

frequency, and governor parameter is set to no-load running optimum position.

(2) Inspect and confirm that the de-excitation is switched off.

(3) Inspect and confirm that generator outlet breaker is switched off.

(4) Confirm the following preconditions before starting:

1) All the auxiliary equipment of generating units shall be under automatic operation.

a. Shift the braking system to automatic operation mode.

b. Shift the overhauling sealing to automatic operation mode.

c. Confirm that oil pressure device and pumps of speed governor and technical water

supply system are under automatic operation.

2) Hydraulic machinery protective return circuits are applied and are in a condition to

operate automatically.

3) The breaker is reset.

4) Break pin is intact.

7.2 Auto-Start and Auto-Stop Test

(1) Implement auto-start test with no-load running procedures by situ control or remote

control, and inspect the following items:

1) Whether the operation procedures from start to no-load running are correct.

2) According to automatic start shift no-load running procedures, inspect the

performance of technical water supply equipment, and whether the performance of auto

elements is correct.

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3) Inspect the motion of speed governor.

4) Inspect whether the contact points motion of rotation rate indicating in velocity

measurement devices is correct.

(2)Auto-stop test for generating units

1) Implement automatic stop of generating units by situ control or remote control, and

inspect whether the auto stop procedures are correct.

2) Inspect the contactor’s motion of rotation rate indicating in velocity measurement

devices to be correctly worked, and the motions of speed governor and automatic

elements to be correctly worked.

3) Inspect whether the automatic operations of breaking devices and overhauling strip

are correct.

4) Inspect the braking and self-reset conditions.

(3) Perform the automatic start test, inspect and record on LCU panel at site.

(4) Perform the automatic stop test, inspect and record on LCU panel at site.

(5) Perform and check the emergency button reliability on LCU panel at site.

8 Short Circuit Current and Voltage Boosting Test for Generating units

8.1. Pre-conditions for Short Circuit Test

(1) Confirm that the tests of such equipment as 1G(2G) & 1B(2B) & 1G(2G) voltage

distributing devices, 1B(2B) high voltage distributing device, GIS equipment and 132kV

outlet circuits, are completed and can meet the requirements of specifications as well as

the conditions of operation with power.

(2) Confirm that the 3B branch bus bar is not connected with 132KV bus bar and bus bar

joints are completely sealed.

(3) Confirm that the related current circuits are inspected and tested, no open circuit

exists and all the circuits can meet the conditions of operation with power.

(4) Confirm that the related voltage circuits are inspected and tested, no short circuit

exists and all the circuits can meet the conditions of operation with power.

(5) The adjustment test of governing system in no-load running is completed.

(6) The inspections and tests of monitoring system procedures for 11KV, 132KV breaker,

isolating switch and earthing switch are completed and the performance and signals are

correct and accurate. Switch off generator main outlet circuit earthing switch and

isolating switch; disconnect the branch bus bar of Station transformer 41T(42T); switch

off generator outlet breaker; cut off the operation power of generator outlet breaker.

(7) The protective tests and settings of generator and transformer are completed.

(8) The protective tests and settings of GIS sets are completed.

(9) Inspect and confirm that 1B(2B)voltage branching joints is correctly placed on the

system-required gear.

(10) The inspection and test of excitation system are completed before commissioning,

and control, operating electrical source is applied.

(11) Over speed test for generating units is completed.

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(12) Auto-start and auto-stop tests for generating units are completed.

(13) Confirmation of the short circuit point

One of the short circuit points: the short circuit point of generator is set at K1 point at the

inner side of outlet breaker.

(14) separate excitation power supply configuration:

Separate excitation power supply configuration programme adopts: lay 11kv high

voltage cable to connect 11kv external power with the low voltage side of transformer for

local service as well as the connection side of 11KV breaker, then switch off the breaker

of transformer for local service and from the outlet side thereof connect 11kv high

voltage cable with excitation transformer.

(15) The external power shall meet the requirements of short circuit current and voltage

boosting tests for generating units.

(16) The hydraulic turbine protection, rotor earthing protection and excitation transformer

protection are all applied.

8.2 Short Circuit Current boosting test for Generating units

(1) Switch status: switched off generator outlet breaker; pull out the isolating switch and

earthing switch of the generator main outlet; switch off de-excitation on brake state.

(2) Design a short-circuit point K1for the generator outlet; make a short circuit at 1G

outlet line by cable or copper plate.

(3) Switch on the breaker of transformer for local service; Inspect whether the A.C.

voltage and phase sequence comply with the requirement at the inlet side of capacity

factor panel A.C. excitation power switch, and make sure that The phase measuring

results of three capacity factor panels shall be the same, afterwards switched on A.C.

excitation power.

(4) Manual applying of the cooling water (except cooling air) for each part is regular;

overhauling sealing is manually moved out; manual start of generator is implemented

after servomotor lock is moved out; whether each part of generating units is performing

regularly or not shall be inspect.

(5) Switch on the de-excitation switch manually and boost the current manually by

excitation regulators. The stator current shall be increased from zero by 10%Ie step-size

change.

(6) Manually boost the current until it reaches at 25% of stator rated current. Inspect the

correctness and symmetry of each current circuit; inspect the protection state of neutral

point current transformer of the generating units and generator outlet current transformer;

measure current circuits and confirm that no open circuit exists and triple phases current

is fairly balanced. All meter readings and monitored current (rotor and stator) shall be

correct. The polarity and phase sequence of current circuit protection shall also be

inspected.

(7) Once the above mentioned items are normal, continuously increase the current to

stator rated current, inspect the aforementioned circuits, make sure that the tripled

phase current shall be balanced and all meter readings are correct, and measure

generator shaft voltage.

(8) Once the aforementioned items are normal, the stator current shall be decreased

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from the rated current by 10%Ie. At the meantime, record the stator current, excitation

current and excitation voltage.

(9) After completing the parameter record of the aforementioned current decrease

process, manually re-increase the stator current from zero by 10%Ie step-size change

while record the stator current, excitation current and excitation voltage.

(10) According to the above parameters, make the characteristic curve of generator

triple-phase short circuit.

(11) After the current boosting test is accepted, switch off the de-excitation in the rated

current, and inspect whether the performance of de-excitation is normal.

(12) Manually stop the generating units.

(13) Manually switch off the breaker of transformer for local service.

(14) Measure the stator wilding earthing resistance and absorptance ratio, and the rotor

wilding earthing resistance of the generating units.The measuring results shall meet the

requirements of manufacture and specifications.

(15) Dismantle the outlet testing short circuit line of generating units, and reset the

normal operation wiring for generator bus bar.

(16) Reset the normal operation wiring of the generator outlet and neutral point CT

circuit.

8.3. Pre-conditions for Voltage Boosting Test

(1) Voltage return circuit of voltage transformer of generator’s voltage distribution

protective device is inspected and there is no short circuit being observed.

(2) Speed governor is set in auto-operation mode.

(3) Excitation regulator is set to manual operation mode, super-excitation device is

moved out.

(4) Power supply for voltage boosting adopts excitation source which is temporarily used

for short circuit current boosting.

(5) Put the hydraulic turbine and generator into protective state, and withdraw the

excitation transformer from protective state. Put the auxiliary equipment and signal

circuit electrical source into operative state.

(6) The generator overvoltage protection value is adjusted to be more than 1.3 times of

operating value of stator rated voltage.

(7) Measure the stator wilding earthing resistance and absorption ratio which shall meet

the requirements of voltage boosting test.

(8) The cooling water of generator and air-cooled machine is put in operation.

8.4. Voltage Boosting Test for Generating units

(1)Disconnect the generator outlet breaker; pull out the insulation switch and earthing

switch of the generator voltage distribution device.

(2)Put the generator outlet PT in operation.

(3)Operate auto-start of generating units by remote-control (process from start to on-load

running). Following the normal operation of each part, measure generator outlet PT

secondary voltage and inspect the symmetry thereof which shall be not irregular.

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(4)Put excitation control and operation power in operation.

(5)Switch on the breaker of transformer for local service.

(6)Switch on the de-excitation switch; manually increase the voltage to 25% of stator Ue;

inspect the following items:

1) The generator and outlet bus bar, transformer etc shall perform normally; there is no

short circuit being observed in generator outlet PT secondary circuit; all meter readings

and monitoring readings are correct.

2) Inspect and confirm that the secondary phase sequences and voltage of the

aforementioned voltage circuit shall be correct, the generator phase sequence is positive.

(7) After the aforementioned items are inspected and are in a normal condition,

continuously increase the voltage to 50% of the rated voltage, switch off the de-

excitation and inspect the extinction of arc.

(8) When the is ok, close the de-excitation switch and continue increase the voltage to

100% of G-set rated voltage, check the shaft voltage at G-set rated voltage situation.

(9) After the aforementioned items are inspected and are in a normal condition, at 100%

of stator Ue, Switch off the de-excitation and inspect the extinction of arc.

(10) Build up excitation and gradually increase the excitation current from zero to the

rated excitation current. In the process of the current increasing, read the rated stator

voltage corresponding to the excitation current and the stator highest voltage

corresponding to the rated excitation current at 0, 20%, 40%, 60%, 80%, 100% , 110%,

130% points respectively and record the characteristic increasing curve of generator in

no-load running. Under the stator highest voltage (no more than 1.3 times of stator rated

voltage) corresponding to the rated excitation current, pressure stator inter-turn for five

minutes.

(11) After the stator inter-turn is pressured and the stator voltage decreases to the rated

voltage, continuously decrease the rated voltage by 10% progressively while record

stator voltage, rotor current and make no-load running characteristic decrease curve.

Attention: during the measurement of decrease and increase curve, the adjustment of

excitation current shall only be regulated toward one direction, and reverse operation in

the process is prohibited.

(12) Manually decrease the stator voltage to zero and switch off the de-excitation

manually.

(13) Switch off the breaker of transformer for local service.

(14) Implement auto-start of the generating units and make preparation for the next test.

8.5. Adjustment and Test of Excitation Controller in No-Load Running

8.5.1. Manual voltage boosting characteristic test

At the rated speed of generator, the excitation is in the manual position. After confirming

that the setting value of manual channel is set to zero, implement the increase and

decrease, build up excitation and inspect regulating scope of manual control unit as well

as whether the voltage boosting and decreasing works normally and the characteristic of

regulator is stable. The lower limit of regulating scope shall not be over 20% of generator

excitation voltage in no-load running while the upper limit shall not be below 110% of

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generator rated excitation voltage.

8.5.2. Automatic voltage boosting characteristic measurement

Implement the voltage boosting to generator by automatic channel, and operate the

Plus/Minus button for the measurement of voltage boosting characteristic. Then inspect

the voltage adjusted scope of excitation regulation system. The auto excitation regulator

can smoothly and stably adjust in the range of 70%-110% of generator rated voltage in

no-load running.

8.5.3 Measure the open-loop amplification factor of excitation regulator, and

observe the characteristic of each part of excitation regulator.

Under the rated no-load running exciting current, inspect the voltage-sharing and

current-sharing factors of Rectifier Bridge. The voltage-sharing factor shall not be below

0.9 while the current-sharing factor shall not be below 0.85.

8.5.4. Low frequency protection test

Under the no-load running rated voltage, the generator speed shall be slowly decreased

so that the low frequency protection shall be performed as the frequency is below setting

values.

8.5.5 During the regulation and simulation tests of low-excitation, over-excitation,

PT brokage, over voltage and current-sharing etc, all shall be performed correctly.

9 Test of Generating units loading with Main Transformer and High

Voltage Distribution Device

9.1 Short-Circuit Current boosting test

9.1.1Short circuit point setting:

short circuit point to WANA GRID STATION (TO TANK GRID STATION) shall be

arranged at the inner side of the isolating switch of outgoing bay by using the inside

earthing switch to connect the outlet wire through triple-phase short circuit.

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9.1.2 The generator’s relay protection, excitation protection, hydraulic machinery

protective devices and main transformer’s non-electricity quantity protection as

well as its control signal circuit shall be put in operation

9.1.3 Short circuit current boosting test for 132KV high voltage distribution device

(1) Close the earthing switch at the short circuit point of the outgoing line equipment

along the line to WANA GRID STATION(to TANK GRID STATION line), and then connect

the outlet circuit with the triple-phase short circuit. Disconnect all the earthing switches

on return circuit from 1G(2G) generator to short-circuit point, close isolating switch of

return circuit, disconnect connection of outlet bay on anther return circuit, and manually

switch on all breakers on return circuit from generator to short-circuit point.

(2) Disconnect the operation power for the isolating switch and breakers of return circuits.

(3) Put into the main transformer cooler and its control signal circuit.

(4) Manually start Generator, the temperatures of all parts and running should be normal.

(5) Manually switch on the breaker of transformer for local service.

(6) Manually close the de-excitation switch, and progressively boost the stator current by

10%Ie through of excitation regulator by manual channel.

(7) During the current boosting, inspect the 11kV bus bar, main transformer, 132KV bus

bar protection, as well as that there is no open circuit being observed, triple-phase

current is balance and all meter indications are correct. Inspect the current polarity and

phase sequence of main transformer, bus bar and wire protection. After the

aforementioned items are confirmed to be correct, put the main transformer, the high

voltage outlet (or high voltage cable) and bus bar protective devices into operation.

(8) Continuously boost the current to 50%, 75%, 100% of the rated current, observe the

performance of main transformer and high voltage distribution device. Inspect the

aforementioned current circuits, and confirm that the triple-phase current is balance and

all meter indications are correct.

(9) When the current amplitude and phase angle are completely inspected and recorded,

manually decrease the current to zero and switch off the de-excitation.

(10) Operate the generator in no-load running.

(11) Manually switch off the breaker of transformer for local service.

(12) Switch off the breaker of test circuits, disconnect the isolating switch of test circuit,

and then close the earthing switch of 132KV distribution device.

(13) In addition to temporary excitation cable and excitation transformer, dismantle the

other temporary test circuits and reset working wiring of current return circuit of GIS bay.

(14) After the short-circuits are tested and inspected to be correct, put 1G(2G), 1B(2B)

and 132kV bus bar protection in operation.

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9.2. Voltage Boosting Test of Generating units Loading with Main Transformer and

High Voltage Distribution Device

9.2.1 Put the relay protective devices of generator, main transformer and bus bar

differential motion., etc in operation

9.2.2 The equipment to be boosting voltage shall cover all the high voltage

primary equipment at the current stage

9.2.3 Manually increase the voltage to 25%, 50%, 75%, 100% of the rated voltage

while inspect the performance of primary equipment

9.2.4 Inspect and confirm that the voltage phase sequences and positions of the

secondary voltage circuit and synchronous circuit are correct

9.3 Test with Current for Bus bar of High Voltage Distribution Device

9.3.1 After the outlet is supplied with electricity by the system power, charge high

voltage distribution device bus bar by the system power. When there is no

abnormity following inspection, high voltage bus bar then can be electrified

9.3.2 Inspect and confirm that the phase sequence of the system voltage shall be

the same with that of the power station bus bar

9.4. Switching-on Test of Power System Impact upon Main Transformer

9.4.1 Switching-on test of power system charging main transformer shall start

from the high voltage side, before which the main transformer shall be safely

disconnected with generator

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9.4.2 Put the relay protective device of main transformer and cooling system

control, protection and signal devices into operation

9.4.3 Put the earthing switch of main transformer’s neutral point into operation

9.4.4 Switch on the breaker at the high voltage side of main transformer, and use

system power to electrify main transformer by switching-on for 5 times with

about 10-min interval for each time. Inspect the main transformer and any

abnormal performance

9.4.5 Inspect the performances of main transformer differential voltage protection

and gas protection

10 Synchronous and On-Load Test

10.1 Pre-conditions for Synchronous Test

10.1.1Complete the current boosting tests while generator matching with main

transformer and high voltage distribution devices, inspect each breaker

synchronous voltage in main wiring circuit without any problem, and then

examination of synchronous devices is up to standard

10.1.2 The bus bar test with current of high voltage distribution device is

completed. The phase sequence of system is the same with that of 132kv bus bar

voltage. 132kv system in Powerhouse is in a condition to operate with electricity

10.1.3 Switching-on test while power system charging main transformer is

completed, and the neutral point of the main transformer is earthed

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10.1.4 The adjustment and test of excitation regulator under generator no-load

running state are completed

10.1.5 The short circuit wiring and earthing wire used for tests have been removed

10.1.6 All the protective devices and automatics are put in operation

10.1.7 Speed governor is set in auto-operation mode

10.1.8 Inspect and confirm that each breaker operating pressure on main wiring

circuit and SF6 air pressure can meet the requirements of operation

10.2 Synchronous Test

10.2.1 Select synchronous breaker and synchronous points, the following

breakers can be selected to be synchronous points for the test: generator’s outlet

breaker, main transformer bay breaker, and outgoing line bay breaker. Meanwhile

the correctness of synchronous circuit shall be inspected

10.2.2 Connect synchronous breaker’s isolating switch with the LCU coupling

auxiliary contact by short-circuit, and implement simulation and parallel test for

each synchronous point by manual and automatic penecontemporaneous modes

separately. Inspect the working conditions of synchronous devices and

meanwhile record the generator voltage, system voltage and impulse oscillogram

of breaker while switching-on. Then analyze the oscillogram and inspect the

switching-on voltage discrepancy, frequency discrepancy and leading time etc, all

the parameters in the synchronous switching-on condition shall meet designed

requirements

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10.2.3 Cancel the isolating switch and connect it with the short wiring of LCU

coupling auxiliary contact. Switch on the isolating switch to implement the manual

and automatic penecontemporaneous parallel tests for synchronous contacts of

generating units, and accordingly record oscillogram

10.3. Station Transformer Test with Current and Switching-over

Operate upper monitor to carry out synchronous switching-on procedures of breaker.

After breaker of station service connected with power grid by Quasi-synchronizing

parallel mode, switch over power supply by delivery of current to station transformer and

415 KV system.

Implement switching-on impact test thrice for station transformer at generator side by

manually switching on 1G (2G) breaker at the intervals of 10 min per time, observe and

confirm that the impacting test and electrification of station transformer are regular. The

measured PT secondary voltage amplitude and phase sequence shall be correctly.

After the third switch-on impulsion tests of Station transformer 41T (42T) performs

regularly, use the systematic power to electrify 415V I section (Ⅱ section) of station

service to measure and make sure that the amplitude and phase sequence of the 415V

secondary voltage are correct.

(3)After completing the aforementioned procedures and the following inspection without

any problem, implement the Station Service supply’s switchover test.

10.4 On-Load Test for Generating units

To adjust generating units’ active loading and inactive loading respectively on the situ

governor and excitation device initially, thereafter implement control and adjustment by

computerized monitoring system.

10.4.1 On-load test for generating units

Gradually increase the active loading, observe and record each meter reading and the

working condition of each part, and make sure that the generating units shall be under

normal operating. Afterwards the peak load value shall be recorded at the instant water

head.

10.4.2 Speed governor system test while generating units under on-load running

In the automatic running condition, implement the switchover tests by different control

modes.

Under the speed and capacity control, inspect the regulating stability and mutual

switching stability of generating units.

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When inspecting the different regulating parameters under lower load,

increase/decrease the speed of generator by 10% of the rated load, record the transient

process of operating parameters, and select the regulated parameters for loading state.

In the process of this test, the vibration region of generating units should be avoided.

10.4.3. Adjustment test for excitation regulator under on-load running state

When the active power of generator separately reaches at 0%, 50% and 100% of the

rated values, the inactive power shall be adjusted from zero to the rated value as per the

design requirements, and wherein the adjustment shall be steady without any bounce.

While stator reaches the rated current under on-load running state, the current-sharing

and voltage-sharing factors of Rectification Bridge shall be inspected.

Proceed with adjustment and inspection of protection of low excitation, over excitation

and current-sharing, and wherein all the actions shall be correct.

11 Load rejection test

The purpose of load rejection test is to examine the dynamic characteristics of speed

governor and the sensitivity of the relay protection of generating units, as well as inspect

whether the water pressure increase in value and speed increase in value of spiral case

are within the permissible range while the load is rejecting.

11.1 Pre-Conditions for Load rejection test

(1) Prior to load rejection test, all related sections shall be keep in good communications.

(2) All the protections and automatic devices are put in operation.

(3) The parameters of excitation regulator are set to the optimum value.

(4) Personnel for observation and recording within each part are in right position.

(5) Select outlet breaker of the generator to be rejecting load switch.

11.2 Load Rejection Test

11.2.1 Procedures of load rejection test for generating units.

Execute the generating process by upper monitor and combined to the grid.

Apply for load rejection test to the system as per the 25%, 50%, 75% and 100% of the

rated load in four times separately.

Complete the aforementioned load rejection tests at four stages by manually

disconnecting the generator outlet breaker 1QF.

Record relative values of before, during and after load rejection tests.

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11.2.2. Requirements of load rejection test for generating units

(1) During the load rejection test for generating units, inspect that the stability and

excessive adjustment value of excitation regulator shall comply with the stipulated value

of specifications.

Implement the load rejection tests (by 50% and 100% of the rated power separately) for

generator with active power and inactive power state, and record the generator voltage,

rotor voltage and stator current.

Requirements: the excessive adjustment value of generator voltage shall be no more

than 15—20% of the rated value, oscillation shall not be more than 3—5 times, and

regulated time shall be less than 5 seconds.

During the load rejection test, to inspect whether the performances of over voltage

protection and de-excitation circuit of generator are regular and measure the de-

excitation and stators’ over voltage multiples while the generator stator is under open-

circuit state.

(2) During the load rejection test, inspect the dynamic adjustment performance of

governing system, as well as the conditions of the increased rate of water pressure in

spiral case and the speed increase in rate of generating units.

(3) The dynamic character of the governor after the load rejection test shall meet the

following requirements.

1) While rejecting the load by 25% of rated load, record the transitive process of

automatic regulation. Inspect that the immobility time of servomotor shall be no more

than 0.2S.

2) While rejecting the load by 100% of the rated load, the wave crests exceeding 3% of

the rated speed shall not be more than twice in the process of speed varying.

3) While dumping the load by 100% of the rated load, since when the governor is firstly

moved toward the opening direction until the swing value of generating units does not

exceed the tolerance of ±0.5%, the duration time for this process shall be less than 40s.

4) The speed or control signal shall vary as stipulated format. The immobility time of

servomotor shall be less than 0.2S.

(4) If water head for station operation and grid system are restricted, and when the

generating units are unable to reject or be on the rated load as the above required, the

frequency and numbers of the load rejection test can be appropriately adjusted

according to the instant conditions, moreover the final load rejection test shall be

implemented under the allowable maximum load capacity.

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12 Performance Test and Reliability Operation of Generating units for

Acceptance and Handover

12.1 36-Hour Continuous Trial Operation with Load

(1) After all the items of commissioning test for generating units are completed,

inspected and accepted, the generating units are qualified for proceeding grid-connected

36-hours trial operation with the rated load.

(2) If there are restrictions on the water head for power plant operation or power supply

system, due to which generating units is unable to reach the rated output, the maximum

load for generating units wherein can be determined according to particular conditions at

that time and under this load wherein shall remain on satisfactory running for 36 hours

(including the satisfactory full-load running no less than 24 hours continuously)

(3) Comprehensively record all the parameters relative to operation in accordance with

duty regulation.

(4) After the continuous 36-hour trial operation, the generating units shall be shut down

to process comprehensive inspection for the electrical and mechanical equipment.

(5) Any defects if found during the 36-hour trail operation shall be eliminated and

remedied.

12.2. Performance Test for Generating units

(1) Once generating units complete the satisfactory running continuously for no less than

36 hours (including satisfied full-load running for no less than 24 hours) as well as all

equipment and systems linked with the generating units can safely perform as per the

requirements of industrial practice, operation and maintenance guides, the performance

test for generating units can be implemented after being approved and consented by the

Contractor/the Employer’s Representative.

(2) Reference values of generating units’ performance are the performance parameters

provided in the design and manufacturer’s technological data.

(3)The contents and acceptable conditions of the units’ performance test:

1) During the test, a complete performance test shall be fulfilled (the independent output

of the generating units, the average weighted efficient of the turbine as well as the

losses of generator and generator transformer therein are recorded).

2) All the service for the performance of the generating units and the other working tests

have been completed except punch list items; the generating units can satisfy the

applicable requirements; the project can function its intended purposes.

3) All equipment and facilities which ensure the generating units to approach

comprehensive, safe and reliable operations are properly set up, installed, insulated and

protected (at all requisite place) as well as correctly tested.

4) The generating units shall comprehensively and correctly connect and synchronize

with the main power grid, all the natures and plants pertinent to units thereof meet the

27

requirements of the Contractor/the Employer’s Representative, moreover the generating

units remain on being capable to transmit electricity to the power grid constantly and

being safely approach commercial operation, achieved the purposes desired.

12.3 Submission of Generating Units Performance Test Acceptance Report

While the tests meet the requirements of the generator-units performance acceptance,

the “Generating units Performance Acceptance Notice” thereafter can be submitted to

the Contractor/Employer. Such Notice is deemed to be the latest test results report

which is drawn up as per an acceptable format by the Contractor/the Employer’s

Representative.

12.4 Generating units Performance Acceptance

The Employer and the Contractor shall inspect the generating units together with the

other related equipment within 30 days after receiving the Generating units Performance

Acceptance Notice, and afterwards give a formal reply in writing: the contents and

acceptable conditions of the generating units performance test can meet the

requirements, and pass the generating units performance acceptance.

Rearrangement after generator-units performance acceptance

Once having passed the performance test, the generating units and the related

equipment shall be reset to the operating control collocations and configured states

which are used for determining the generator-units performance acceptance during the

performance test.

12.5 Reliability running inspection

When the generating units have passed the performance test, thereafter implement a

successful reliability operation for each unit prior to the completion date.

12.6 Submission of Reliability Operation Acceptance Report

When the generating units can meet the requirement of single generator reliability

operation guarantee, the “Reliability Operation Guarantee Notice” shall be submitted to

the Contractor/Employer. The Reliability Operation Guarantee Notice is deemed to be

the reliability operation results report which is drawn up in as per acceptable format by

the Contractor/the Employer’s Representative.

12.7 Acceptance and Handover after Reliability Operation

The Employer and the Contractor shall inspect the reliability operation result within15

days after receiving the reliability operation guarantee report, and afterwards give the

Sublet Contractor a formal reply in writing that the report can meet the requirements of

guarantee plan, and the generating units pass the reliability operation test can be

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accepted.