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September 21, 2020
Operation steps for starting test of hydro-generator and auxiliary equipment
1. This specification does not include inspections and tests during installation, but adjustments to equipment after installation
2. Test and inspection of water diversion equipment before filling
2.1. Review all installation records and qualification certificates of the turbine and its auxiliary equipment during the installation process, and draw conclusions.
2.2. Check the installation quality and sealing of the water guiding mechanism. Check the lubrication of each mechanism of the turbine (for the links that need to be refueled). Fill with lubricant.
2.3. Check the correctness of the relationship between the guide vane opening and the stroke of the servomotor.
2.4. Check the liquid level of the oil tank under the bearing and the oil level of the oil storage tank, which must meet the design requirements.
2.5. Check the measurement results of the gap between the rotating parts, and check the measurement results of the bearing gap.
2.6. Slowly inflate the pressure tank to perform a minimum oil pressure test of the water guiding mechanism to check the flexibility of its action.
2.7. Check the working conditions of the hydraulic equipment pump and the safety valve group, determine the unloading time of the unloading valve, the starting time of the oil pump group, and the action and recovery pressure value of the safety valve.
2.8. Check the automatic operation of hydraulic equipment and record the operating pressure value of the pressure relay.
2.9. In the case of low oil pressure in the accident, record the pressure and oil level drop value in the pressure oil tank when the water guiding mechanism changes from fully open to fully closed.
2.10. Carry out a pump oil test on the oil pump of the hydraulic equipment to make the pressure oil tank reach the normal pressure and maintain the normal oil level, and check the oil and gas leakage of the pressure oil tank.
2.11. Check the operation of the oil leakage device, and conduct manual and automatic pump oil tests.
2.12. Manually and automatically operate the servomotor locking device of the water guiding mechanism to check its flexibility and reliability.
2.13. Carry out manual and automatic simulation operation test of speed control mechanism.
2.14. Carry out the simulation test of the automatic start and stop of the unit, and determine and adjust the opening and closing time of the water guiding mechanism.
2.15. The simulation unit runs in automatic quasi-synchronization mode to check the correctness of the operation of the operating system.
2.16. Operate the generator brake with air, jack up the rotating part of the unit, and check the maximum increase of the runner, which should be less than the actual axial distance between the runner and the top cover of the turbine.
2.17. Before the water turbine runner is filled with water, careful inspection should be carried out, and all construction installation and other construction remnants should be removed from the water diversion pipe, volute, and draft tube.
2.18. After the water diversion and drainage equipment are all completed, close all manholes and prepare the turbine runner to partially fill with water.
2.19. All meters should be checked and qualified.
3. Test and inspection during water diversion and filling
3.1. Check the working conditions of the drainage equipment of the power plant.
3.2. The oil pressure of the oil hydraulic equipment remains normal, the oil pump is in normal working condition, the water guiding mechanism is closed, and the lock spindle is put in.
3.3. Lift the downstream gate and fill the draft tube with water.
3.4. Open the upstream water inlet valve, slowly fill the water pipe and volute with water, and check the leakage of the volute inlet door, volute drain valve, end face seal with the top cover and bottom ring, and the vertical seal of the guide vane . And the reading of the volute pressure gauge relative to the water level of the reservoir. 4. Test and inspection when the unit is running without load.
4.1. For the first start, use the opening limit mechanism to manually open the guide vanes slowly.
4.2. According to the opening of the piston rod of the governor and the servomotor, record the opening value of the guide vane at the moment when the unit starts to rotate.
4.3. When the unit speed reaches 50% and 100% of the rated speed, measure the swing of the main shaft and the vibration of the unit, and record the opening value of the guide vane and the upstream and downstream water levels when there is no load.
4.4. Carry out the manual and automatic operation of the governor, check the working performance of each mechanism, and select the speed control parameters through the no-load test of the governor.
4.5. When the oil temperature and the action of the servomotor are stable for a period of time, according to the operating conditions of the oil pump of the hydraulic equipment, determine the amount of oil leakage of the regulating system during no-load operation.
4.6. Check the working condition of the guide bearing lubrication system and bearing seal.
4.7. If the mechanical parts of the unit are operating normally, a speed test has been carried out. During the test, the swing and the movement of the unit should be measured, and the overspeed protection setting value of the overspeed relay should be checked and adjusted.
4.8. After the overspeed test, the unit should shut down for a comprehensive inspection and record the inspection results.
5. Test and inspection when the unit is running under load
5.1. The unit is integrated into the power grid or connected to a special water resistance load method to carry out a load test. When the water head has reached the rated value and the grid load cannot meet the rated power of the unit, the water resistance load should be adopted. Method to proceed.
5.2. Determine the start-up characteristics of the unit that meets the requirements of automatic quasi-synchronization, check the start-up characteristics of the unit, and check the actions of each organization when the unit is automatically quasi-synchronized and connected to the power grid.
5.3. Check the performance of the governor when the unit is running under load, and verify and adjust the parameters through the load test.
5.4. In the process of increasing load, draw the relationship curve between unit power and guide vane opening.
5.5. When the unit measures the actual water head, use 25%, 50%, 75% and 100% of the rated power or maximum allowable power to carry out the load rejection test, and perform the measurement and record according to the specially prepared table.
5.6. In the case of the unit with rated power or maximum allowable power with water head, close the water guiding mechanism with low oil pressure
5.7. Check the uniformity of the tail water flow under various operating modes, that is, under different downstream water levels of different powers. Whether there is normal pressure pulsation and vibration caused by poor water flow, check the working condition of the air supply valve.
6. Test of automation equipment for hydraulic turbine equipment
6.1. Automatic start check
6.1.1. Check and record the time from the beginning of the pulse to the valve opening.
6.1.2. Check the entire cycle of starting the unit, and record from the beginning of the pulse to the unit reaching the rated speed or putting it on
6.2. Automatic shutdown inspection
6.2.1. Check the entire cycle of automatic shutdown from no-load and full-load operation. Record the time from when the pulse is started to when the unit is stopped.
6.2.2. Check and record the time from when the pulse is started to when the inlet valve is fully closed.
6.3. Use the protection device to shut down the unit accidentally when running under load to check the operation of the protection device.
7. Long-term continuous operation of the unit with load
7.1. Before the unit is put into normal operation, a continuous 72-hour test should be carried out with rated power in the grid, which does not include the operating time under 1/4, 1/2 and 3/4 of the rated power. It depends on the need.
7.2. In the process of continuous operation, all mechanisms should be guaranteed not to fail, and the bearing temperature should be stable within the allowable range.