Wampu HPP Installation For The EM

Wampu 3x15MW Hydropower Project Installation for E&M
INSTALLATION PROCEDURE
For
WAMPU HEPP PROJECT
Prepared by
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Table of Content
1.Powerhouse Crane Installation............................................................... 4

1.1 Installation Flow Chart ........................................................................................ 4
1.2 Crane Rail Installation ......................................................................................... 5
1.2.1 During civil construction of rail beam, mount the rail embedded bolts. ...... 5
1.3 Crane Installation ................................................................................................. 5
1.4 On-site inspection & test ..................................................................................... 5
1.4.1 Commissioning inspection .................................................................................................................. 5
1.4.2 Load test .............................................................................................................................................. 6
1.4.3 Test Items and Requirements .............................................................................................................. 6
1.4.4 Test procedure and inspection ............................................................................................................. 6
1.4.5 Idle load test ........................................................................................................................................ 6
1.4.6 Rated load test ..................................................................................................................................... 7
1.4.7 Static load test ..................................................................................................................................... 8
1.4.8 Dynamic test ........................................................................................................................................ 9
2. Turbine-Generator Unit and its Auxiliary Equipments Installation ......10

2.1 Turbine Installation ............................................................................................ 10
2.1.1 Turbine Installation Flow Chart ........................................................................................................ 10
2.1.2 Draft Tube Elbow Installation ........................................................................................................... 24
2.1.3 Draft Tube Cone Installation ............................................................................................................. 24
2.1.4 Stay Ring and Spiral Case Installation .............................................................................................. 24
2.1.5 Distributor Installation ...................................................................................................................... 25
2.1.6 Runner Installation ............................................................................................................................ 25
2.1.7 Turbine Main Shaft Installation......................................................................................................... 25
2.1.8 Servomotor Installation ..................................................................................................................... 26
2.2 Generator Installation Scheme ......................................................................... 26
2.2.1 Generator Installation Flow Chart ..................................................................................................... 26
2.2.2 Generator Installation Flow Sketch ................................................................................................... 26
2.2.3 Stator Installation .............................................................................................................................. 35
2.2.4 Rotor Installation ............................................................................................................................... 35
2.2.5 Lower Bracket and Thrust Bearing Installation................................................................................. 36
2.2.6 Upper Bracket Installation and Guide Bearing Installation ............................................................... 37
2.2.7 Generator Axis Adjusting and Centering .......................................................................................... 37
2.3 Installation of turbine inlet butterfly valve ....................................................... 37
2.3.1 General .............................................................................................................................................. 37
2.3.2 Installation scheme ............................................................................................................................ 38
2.4 Governor System Installation ........................................................................... 39
2.4.1 Installation Flow Chart ...................................................................................................................... 39
2.4.2 Governor System Installation ............................................................................................................ 40
2.4.3 Governor System Oil Filling ............................................................................................................. 40
2.4.4 Governor System Regulation ............................................................................................................ 41
2.5 System Pipeline and Auxiliary Equipment Installation ................................... 42
2.5.2 Installation Sequence ......................................................................................................................... 42
3. Electrical Parts Installation ..................................................................45
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3.1 Transformer Installation Scheme ..................................................................... 45

3.1.1 Transformer Installation Flow Chart ................................................................................................. 45
3.1.2 Installation Scheme ........................................................................................................................... 45
3.2 Non-Seperated Phase Bus Installation ............................................................ 47
3.3 132KV Switchyard Equipment Installation....................................................... 48
3.3.1 Installation flow chart ........................................................................................................................ 48
3.4. Computer Monitor and Control System Installation ...................................... 49
3.4.2 Installation scheme ............................................................................................................................ 50
3.5 11KV switch equipment installation ................................................................. 51
3.5.2 Installation description ...................................................................................................................... 51
3.6 Cable tray and cable installation ...................................................................... 51
3.7 Low voltage power supply system installation ............................................... 52
3.8 Control and protection system installation ..................................................... 52
3.9 Lighting and grounding installation ................................................................. 53
4. Commissioning and Trial Operation .................................................................. 55
4.1 Set up a committee for unit start-up check and accept .................................. 55
4.2 Inspection and test before unit start-up trial run ............................................ 55
4.3 Unit Start Wet Test ............................................................................................. 57
4.4 Multiple unit test ................................................................................................ 71
4.5 Stable and reliable operation test..................................................................... 71
4.6 Performance Tests............................................................................................. 71
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1.Powerhouse Crane Installation

1.1 Installation Flow Chart
The Powerhouse Crane Installation Flow Chart is shown in Figure 1
Track foundation bolt

embedment
Track installation preparation
（6.3.2）
Track bottom plate installation
Track positioning
Track correction and installation
Track beam two-stage concrete

refilling
Bridge crane installation construction preparation
(6.4.3)
Cart running mechanism installation
Metal structure main beam hoisting
End beam hoisting and connect main beam
Bridge crane trolley hoisting
Trolley equipment installation

Railing and ladder installation Cab and electric hoist installation
Electric cabinet and board wiring, power cable laying and loop
test
Gearbox
Hook and rope installation oiling
Other accessories installation
Bridge crane test (no load, static load, dynamic load)
Figure1-1 Powerhouse Crane Installation Flow Chart
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1.2 Crane Rail Installation

1.2.1 During civil construction of rail beam, mount the rail embedded bolts.
1.2.3 Clean the foundation of rail, and lay out the survey points.
1.2.4 The rails shall be lifted onto erection position one by 25t mobile crane.
1.2.5 The rails elevation, center, linearity, joint gap, stagger, and the parallelism, span and
height difference in both sides of rails shall be adjusted in order to meet design requirements,
then the spacers, clamp plates and coupling bolts can be installed and fixed firmly.
1.2.6 After inspection and acceptance by supervisor, the second stage concrete can be placed.
1.3 Crane Installation

1.3.1During installation of crane at erection bay, the main girder shall be lifted and installed
by 50 t mobile crane. The other parts shall be lifted by 25t mobile crane.
1.3.2 The survey points for crane traversing mechanism shall be laid-out on the rail, the
deviation of diagonal line must meet design requirements.
1.3.3 The connecting surface of main girder, end girder and leg, and the connecting plate shall
be clean in free of burrs and height points.
1.3.4 The crane traversing mechanism shall be lifted and installed onto the rail, the
perpendicularity, span of wheels and synchronization deviation shall be aligned in order to
meet design requirements；
1.3.5 The leg shall be lifted by 50t mobile crane and connected with crane traversing
mechanism, and adjusted, fixed firmly.
1.3.6 The main girder shall be lifted by 50t mobile crane and connected with leg by mobile
crane 70t.
1.3.7 The trolley traveling mechanism and the trolley bracket shall be assembled integrally at
erection bay.
1.3.8 The trolley bracket shall be lifted onto rail using 70t mobile crane.
1.3.9 Install electrical panels and sliding wires, lay out and connect cables.
1.3.10 Hang up steel rope, and install lifting devices.
1.4 On-site inspection & test

1.4.1 Commissioning inspection
1.4.1.1We will inspect the structure part on time after completing all the installing
components of crane (including retest ), mainly included: installation dimension of rail and
buffer block, levelness and parallelism inspection, crane bridge (including trolley rail), trolley
dimension check and bolt connection check. Lubricate drive bearing, gearbox according to
manufacturer drawing.
1.4.1.2 Adjust the fit clearance of machine operating part, axial direction of transmission parts
and brake clearance should be adjusted according to drawing or specification. Check the
operation of fixed and free pulley block as well as the operation of crane, trolley, main and
auxiliary hoisting mechanism.
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1.4.1.3 Check if the wire winding of main and auxiliary hoisting mechanism meets the
drawing requirements, if the fixed and free pulley block operational, whether the wire end is
connected and fixed on winding drum according to technical specification.
1.4.1.4 Conduct commissioning and inspection for slide wire, electrical brake, variable
frequency equipment, remote control device, instrument, apparatus, acoustic and optical and
telecommunication system and operation system, single crane operation and synchronous
operation of two cranes, the action should be correct, ensure the reliability and safety of crane.
Check the wire and cable layout and connection according to drawing and specification make
sure the well grounded, insulating resistance value of electrical equipment and circuit as well
as grounding resistance value should meet the requirement.
1.4.1.5 Conduct idling test of each mechanism under guidance of supervisor and equipment
supplier, mechanical and electrical part of each mechanism should operate reliably, action
should be correct, electric motor operate stably, three phase current should be balanced,
wheels mesh well, limiting actions are reliable, brake device moves quickly, accurately and
reliably. Brake shoe drum and brake lining drum are evenly separated, crane and trolley travel
mechanism operate in balance, and power supply system works well.
1.4.2 Load test
Crane load test should be conducted under the guidance of owner, installation unit,
supervisor, design unit and equipment supplier. We will be responsible for on-site technical
guidance, the client will responsible for transportation of test block for load test and hanging
basket and fix the pullback weight in the hanging basket according to specification, conduct
load test under various specified load. Installation subcontractor should be responsible for
crane test operation, equipment custody and monitor, organize date of load test. On-site test
counterweight plan should be carried out by installation subcontractor and approved by
owner.
1.4.3 Test Items and Requirements
1.4.3.1 Test of overhead crane including load operation, static load test and dynamic load test.
1.4.3.2 Whole machine operation test should be conducted only if the mechanical and
electrical equipment have completely installed and meet the technical requirements of design,
manufacture and installation.
1.4.3.3 Before test, crane test procedure and test regulation should be compiled according to
requirements of equipment supplier and design technical document, and can be carried out
after submitted for owner’s review and approval.
1.4.4 Test procedure and inspection
1.4.4.1 Main and auxiliary hook (hereafter refer to electrical hoist) will conduct test separately,
that is conduct auxiliary hook load test after all tests of main hook are completed.
1.4.4.2 Idling load test (idling load operation of each unit)
1.4.4.3 Rated load (100% rated load) test
1.4.4.4 Static load (125% rated load) test
1.4.4.5 Dynamic load (110% rated load) test
1.4.5 Idle load test
1.4.5.1 Check following items before test running
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1) Electrical device installation have been completed, all the electrical circuit wiring
should be correct and firm, mark clearly.
2) Check the circuit and insulating resistance value of the power and electrical
equipment with megohm meter, it should meet the national standard. Conduct insulation and
pressure test with alternating voltage and meet relevant regulation.
3）Electrical equipments like electrical motor, controller, contactor, brake, remote control,
voltage and current relay should be checked debugged and should be qualified. Safety
protection device should go through simulation test and debugging.
4）Lead in working power supply, conduct simulated operation test of each electrical
apparatus, action should be correct.
5) Check working reliability of brakes.
6）Check correctness of rope winding on the drum and pulley block and reliability of
rope end fastening.
7）Clear all the obstacles that may obstruct safe operation, hang warning signs around
test area, put operator on duty at erection room.
1.4.5.2 Idle load test (main hoisting mechanism, auxiliary hoisting mechanism will conduct
separately)
1）Each electrical control operation system works well, logic locking function well,
electrical protection action is reliable, measure idle load current of electrical motor of each
mechanism, crane and trolley travel along rail without rail gnawing, direction of operational
mechanism and operating direction of each mechanism should meet design requirement,
travel and hoisting mechanism shall be back and forth at least 3 times and travel normally,
brake reliably. Power mechanism of conductor line and trolley flexible cable should work
well during operation.
2) During first idle load test, operate each travel and hoist mechanism, hoisting direction
should be correct. Continuous operation without failure should last 10-15 minutes to check
following items:
⑴ Adjust limitation switch, interlocking switch, master controller and head pumping
indicator should act correctly and reliably.
⑵ Conductor line centralized device is well contact with conductor line, no block or
jumping, contact terminal of master controller should be no burning damage.
⑶ Action of electrical motor and transmission agent should be steady, no impact or
noise.
⑷ Radial vibration of transmission shaft and brake wheel working surface should meet
requirements of design and regulation.
⑸ Wheel and rail should contact in whole line, no rail gnawing at wheel rim.
⑹ After completing the idle load test, load test should be conducted only after approved
by supervisor.
1.4.6 Rated load test
(main hoisting mechanism, auxiliary hoisting mechanism will conduct separately)
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1.4.6.1 During this test, the load (test block) will be gradually increased from 50% rated load,
80% rated load to 100% rated load, at least 3 times of hoisting, descending with low speed
and rated speed, crane and trolley back and forth associated operation (only allow two or less
actions conduct in same time), operation time should not be less than 30min. Brake function
well and reliably while hoisting, electrical motor counter-clockwise is not allowed. Electrical
device and each mechanism function well, conduct hoisting, brake, crane and trolley single
and associated operation test according to work cycle and allowed electrifying duration factor
of electrical motor. Structure and mechanism of crane should not be damaged, connection
should not be loosening. Brake should act flexibly and reliably, electrical device should
function well, measure the startup and operating current of electrical motor.
1.4.6.2 Rated load test aims at measuring stiffness and capacity of each structure under the
crane rated capacity, main girder stiffness can be measured according to following:
1) Drive trolley to end of crane, measure the main girder camber at end of two main
girders and in the middle of span, make a record.
2) Drive the trolley with 100% rated load to the middle of main girder, stop the trolley in
the middle of girder, measure the deflection of the two main girders, record deflection change.
3) The main girder deflection should recover when idling load, then drive trolley to end
carriage, check the camber of main girder, it should not be less than (0.7/1000)S, S stands for
crane span.
4)Load test for electrical hoist only include trolley operating, hoisting and lowering test,
operating test may not conducted on crane.
1.4.7 Static load test
1.4.7.1 During this test, the load (test block) will be gradually increased to 125% rated
capacity, starting with low speed, electrical device and each mechanism work normally, when
hoisting 125% rated capacity load to the height of 100-200m, the suspending time should not
be less than 10min, electrical device should function well, defects like crackle, joint loosening
or component damage which will affect performance and safety of crane are not allowed.
1.4.7.2 Static load test aims at measuring intensity and stiffness of the crane and capacity of
each structure under condition of static load, static test for measuring intensity and stiffness of
the main girder should be carried out as follows:
1) Drive the trolley to the end of crane, suspend piano wire to measure and record
distance between wire and girder, or hang a steel measuring tape in the middle of main girder
to the ground, measure and record the changing data.
2) Drive trolley to middle of crane main girder, lift 75%, 100% and 125% of rated
lifting weight in sequence, stay still for 10min when the load is 100m from ground, then
unload, check if the bridge has permanent distortion.
3) Deflection of main girder should recover after unload, then drive trolley to end
carriage, check the camber of main girder, it should not be less than (0.7/1000)S, S stands for
crane span.
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4）Load test for electrical hoist only include trolley operating, hoisting and lowering test,
operating test may not conducted on crane.
1.4.8 Dynamic test
1.4.8.1 Lift 1.1 times of rated capacity, conduct hoisting, brake, crane and trolley single and
associated operation test according to work cycle and allowed electrifying duration factor of
electrical motor and the test should last no less than 1 hour. Structure and mechanism of crane
should not be damaged, connection should not be loosening. Brake should act flexibly and
reliably, electrical device should function well, measure the startup and operating current of
electrical motor.
1.4.8.2 During test, load of 110% rated capacity should be lifted and lowered 3 times, trolley
should travel back and forth on the whole rail 3 times, then drive trolley to one end of bogie,
wheel of crane sustain the maximum pressure, drive the crane go back and forth 3 times
within possible distance, during the process of test mentioned above, working condition of
each transmission mechanism should be monitored and should function well.
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2. Turbine-Generator Unit and its Auxiliary Equipments Installation

2.1 Turbine Installation
2.1.1 Turbine Installation Flow Chart
Turbine installation flow chart is shown as follows:
Draft tube elbow anchor
installation
Turbine shaft lifting and installing
Draft tube elbow liner
installation
Turbine shaft and runner coupling
2nd stage concrete placement
of draft tube elbow
Head cover lifting and installing
Draft tube cone liner
installation
Wicker gate end and side gaps
alignment
stay ring & Spiral case Generator
anchor installation Wicket gate operation installation
mechanism installation
Concreting for stay ring & Turbine-generator shaft coupling

Spiral case buttress
Unit hand-turning and axis alignment

Spiral case installation
Main shaft seal installation

Pit liner installation
Turbine bearing installation
Concrete placement of
spiral case outside Electrical parts
Pipe lines and auxiliaries installation
installation
Pit dimension inspection
Unit dry test

Distributor pre-assembly
Water combination test
Head cover lifting out of pit
Trial
Runner lifting and installing
Figure1-2 Turbine Installation Flow Chart
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Turbine installation flow chart sketch is shown as Sketch 01-16
Sketch 01.Draft Tube Elbow Installation
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Sketch 02.Draft Tube Cone installation. Draft tube, stay ring and spiral case anchorage
plates concrete.
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Sketch 03.Stay ring installation.
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Sketch 04.Spiral Case assembling
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Sketch 05.Pit Liner assembling.
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Sketch 06.Spiral Case reinforcement.
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Sketch – 07.Spiral Case Embedded parts concreting.
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Sketch – 10.Runner and Shaft installation.
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Sketch – 11.Wicket gates installation.
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Sketch – 12.Turbine head cover assembling and upper bushings installation.
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Sketch – 13.Regulating system assembling &Turbine and generator shaft coupling.
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Sketch – 14.Shafts Run Out
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Sketch – 15.Shaft seal and turbine guide bearing, remaining parts assembling.
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2.1.2 Draft Tube Elbow Installation

2.1.2.1The “U” ring should be embedded in base concrete according to manufactory drawing,
during civil concrite construction.
2.1.2.2The draft tube elbow will be lifted into the pit by motor crane and mounted onto the
foundation.
2.1.2.3The elevation of draft tube elbow inlet and outlet shall be checked and aligned to
meet design requirements.
2.1.2.4The center of draft tube elbow inlet and outlet shall be checked and adjusted to meet
design requirements.
2.1.2.5The leveling of draft tube elbow inlet shall be checked and adjusted to meet design
requirements.
2.1.2.6The draft tube elbow shall be fixed as per design requirements.
2.1.2.7The second stage of concrete for draft tub elbow shall be poured after checked and
accepted by supervisor.
2.1.3 Draft Tube Cone Installation

2.1.3.1 The draft tube cone should be installed after the draft tube elbow is poured concrete
for 7 days.
2.1.3.2 The draft tube cone will be lifted onto the draft tube elbow inlet flang.
2.1.3.3 The elevation of draft tube cone inlet shall be checked and aligned to meet design
requirements.
2.1.3.4 The center of draft tube cone inlet shall be checked and adjusted to meet design
requirement.
2.1.3.5 The leveling of draft tube cone shall be checked and adjusted to meet design
requirement.
2.1.3.6 The draft tube cone shall be fixed as per design requirement.
2.1.3.7 The welding seams between draft tube elbow and draft tube cone shall be welded,after
checked and accepted by supervisor.
2.1.3.8 The buttress of stay ring and spiral case shall be poured, after the draft tube cone is
installed.
2.1.4 Stay Ring and Spiral Case Installation

2.1.4.1 The stay ring and spiral case is fabricated to one-piece structure, at the manufacture
2.1.4.2 The stay ring shall be lifted onto erection foundation by 70t motor crane.
2.1.4.3 The elevation of stay ring shall be checked and aligned to meet design requirements.
2.1.4.4 The center of stay ring and spiral case inlet shall be checked and adjusted to meet
design requirements.
2.1.4.5 The leveling of stay ring shall be checked and adjusted to meet design requirements.
2.1.4.6 The tongue plate of stay ring shall be checked and adjusted to ensure spiral case and
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penstock in centerline.
2.1.4.7 The stay ring and spiral case shall be fixed as per design requirement.
2.1.4.8.The pit liner will be installed, after the stay ring and spiral case is fixed firmly.
2.1.4.9 Install the pipe system under turbine floor,refer to design drawing.
2.1.4.10 The second stage concrete of stay ring ,spiral case and pit liner shall be poured after
supervisor checked and accepted.
2.1.4.11 The welding seam between stay ring and draft tube cone shall be welded, after it is
poured for 21 days.
2.1.5 Distributor Installation
2.1.5.1 The bottom ring, head cover and wicket gate shall be transported to erection bay and
cleaned, furthermore the relative matching dimensions shall be checked.
2.1.5.2 The centerline, elevation, levelling and circularity of bottom ring shall be aligned to
meet design requirements, then the dowel pins shall be installed as per drawing. The center of
bottom ring will be taken as the datums of the other parts.
2.1.5.3 The wicket gates shall be installed in symmetric.
2.1.5.4 The head cover shall be lifted onto the pre-installed wicket gate by powerhouse crane.
2.1.5.5 The center of head cover shall be checked and aligned, the pins between head cover
and stay ring shall be installed.
2.1.5.6 The side and closing gaps of wicket gate shall be checked and aligned.
2.1.5.7 The head cover shall be lifted out and placed in erection bay.
2.1.5.8 All wicket gates shall be installed.
2.1.5.9 The head cover shall be finally installed after hoisting and coupling the runner and the
turbine shaft.
2.1.6 Runner Installation

2.1.6.1 The runner shall be inspected and cleaned at erection bay, and the flange surface shall
be check against height spot.
2.1.6.2 The pairs of wedge plates shall be placed uniformly on discharge ring, the height is
15mm.
2.1.6.3 The runner shall be lifted into pit by powerhouse crane, and placed on wedges.
2.1.6.4 The levelling of runner and main shaft shall be aligned with wedges.
2.1.6.5 The center of runner shall be aligned from the lower sealing ring.
2.1.6.6 The elevation of runner and main shaft coupling flange shall be measured.
2.1.7 Turbine Main Shaft Installation

2.1.7.1 The turbine main shaft shall be inspected and cleaned at erection bay, and the coupling
flange surface shall be check against height spot.
2.1.7.2 The turbine mian shaft shall be lifted onto the runner by powerhouse crane.
2.1.7.3 The coupling bolts of turbine main shaft and runner shall be installed and elongated
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with hydraulic tensioning device to meet design requirements.

2.1.7.4 The elevation of turbine shaft and generator shaft shall be measured.
2.1.8 Servomotor Installation

2.1.8.1 The servomotor pit and back flange shall be cleaned, and checked the center, elevation
and verticality of servomotor bottom plate.
2.1.8.2 The servomotor shall be lifted and installed, the backside flange of servomotor shall
be tightened symmetrically with nuts.
2.1.8.3 Mark centerline on servomotor connecting head, check the distance between the head
center and the centerline in full open and close position，and check stroke and deviations of
servomotor.
2.1.8.4 Check the elevation of the servomotor connecting head and the elevation of
connecting hole on regulating ring.
2.1.8.5 Align the leveling and center of servomotor connecting head.
2.1.8.6 Align the servomotor to full close position and set the mark on piston rod for wicket
gate over-stroke.
2.1.8.7 Mark the radial of regulating ring to ensure that in full close position.
2.1.8.8 Loose the big nut for locking connecting head, and align the position of connecting
pin-hole.
2.1.8.9 The counter thrust shims, locking device of connecting pins and eccentric pins shall be
installed, the stroke marking on the piston rod shall be checked, the clearances between
connecting head and piston rod shall be measured and recorded.
2.1.8.10 The servomotor accessories shall be installed (such as mechanical locking device,
limit switch, movement sensor, opening indicator etc.), the tightness test of servomotor shall
be conducted.
2.2 Generator Installation Scheme

2.2.1 Generator Installation Flow Chart
The Generator Installation Flow Chart is shown as Figure 1-3,
2.2.2 Generator Installation Flow Sketch
The Generator Installation Flow Sketch is shown as Sketch #1 - #8,
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Preparation
Stator sole plate installation
Rotor rim cleaning and inspection

Stator installation and upper
bracket pre-assembly Lower bracket pre-assembly
Rotor pole installation Concreting for stator Concreting for lower bracket
Sole plate Sole plate
Pole joints connection

Lower bracket installation
Rotor electrical test and painting

Breaker system installation
Rotor lifting device installation Stator high voltage test
Upper bracket hoisting and installation

Rotor hoisting and installation
Upper bracket installation
Thrust bearing installation and adjustment
Generator hand turning
Generator-turbine coupling
Generator-turbine hand turning
Unit axis alignment
Guide bearing installation and adjustment
Carbon brush holder installation
Generator accessories installation

Electrical equipment installation Bearing oil pot filling
Unit system regulation
Combination commissioning
Trial
Figure1-3 Generator Installation Flow Chart
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SKETCH # 1 – Turbine and generator pit concreting. Lower and upper bracket stator
sole plates installation.
SKETCH # 2 – Lower bracket assembly.
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SKETCH # 3 – Stator installation
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SKETCH # 4 – Rotor assembly (erection bay)
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SKETCH # 5 – Rotor assembly (generator pit)
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SKETCH # 6 – Upper bracket, oil pot, springs and thrust pads, thrust runner assembly
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SKETCH # 7 – Combined bearing assembly
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SKETCH # 8 – Remaining parts assembly
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2.2.3 Stator Installation

1) Stator Assembling and Welding
 Clean the pit and lay out the reference points
 Intall the roundness measuring pedestal and the soleplate
 Transport the stator to erection bay，and lift onto the soleplate in pit.
 Install the center device in pit and hang up piane wire, set the unit centline basing on
the turbine bottom ring center.
 Adjust leveling, roundness and elevation of stator.
 The leveling, roundness and elevation of stator shall be rechecked.
2) Stator Winding Insert

 Check the winding slot, if necessary, the winding slot shall be trimed.
 Paint semi-conducted coat and epoxy resin glue.
 Set the slot number and mark the winding bar, measure the slot width and resistance.
 Install the foundation plate of circuit ring insulation support.
 Install the bracing ring.
 Pre-assembly the lower winding bars.
 Insert the lower winding bars and test.
 Insert the upper winding bars, wedge and test.
 Weld the winding electrical connector.
 Install the insulation box and bind up using insulating tapes.
 Stator winding dry test and integral test shall be performed.
 The winding shall be painted.
2.2.4 Rotor Installation

1) Rotor Rim Inspection
 Place 4 steel piers with each height of 800mm on erection place uniformily, then put
the wedges onto the piers, the rotor rim shall be placed onto the wedges.
 Clean the flange surface of rotor rim against height-points.
 Align the leveling of the rotor.
 Install the rotor roundness measuring device to check the roundness and the radius of
rotor arm.
 The contact surface of rim and pole shall be checked by flat ruler, if necessary, the
height- points shall be removed.
2) Rotor Magnetic Pole Hanging-up and Installation
 Check the pole against any damage, clean the dovetail slot of the rim and the contact
surfac.
 The insulation checking and AC withstand test of sigle pole shall be performed.
 Measure the length of pole body, find the physic center, and mark it.
 Work out the drawing of magnetic pole position according to the weight and the
polarity of magnetic pole.
 Hoist and install the magnetic pole symmetrically with special tools as per the drawing,
adjust the elevation of the magnetic pole, install and compress the pole key, and check
the roundness, verticality and radius of magnetic pole.
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3) Brake Plate Assembly

 Clean the brake plate, and measure the thickness.
 Measure the flatness of brake plate at erection position. According to the thickness and
the flatness of brake plate, calculate the shimming thickness between joint nuts and
clamping bolts.
 Basing on the calculation, the joint nuts shall be planed in match or the shims shall be
added prior to brake plate installation, then the joint nus can be installed.
 Assembly the brake plate as per the requirements, check the leveling and the stagger of
brake plates, the afterward brake plate can not exceed the forward brake plate in the
rotating direction of the unit.
4) Damp Ring Connection
 Clean the connector of damp winding.
 Install the tensioning device of damp ring, and lock the nuts.
 Install the chain plate with sharp of Ω, lock the nuts.
 Inspect the fit gap by feeler gauge.
5) Magnetic Pole Lead Installation
The cample of excitation circuit shall be connected with spider arm, the lead of
magnetic pole shall be connected to rotor hub.
6) Magnetic Pole Withstand Test
 Check the polarity of magnetic poles.
 Measure the AC impedance of the winding.
 The withstand test of rotor winding shall be performed, the resistance values shall be
recorded before and after testing.
 After pass the testing, the baffle plate shall be installed and the overall painting shall
be done.
7) Rotor Hoisting and Installation
 The rotor shall be hoisted with cranes. Before hoisting, the main powerhouse crane
shall be checked in order to ensure the well working status and reliable power resource
supply.
 During the rotor hoisting and installation, the special person shall be assigned to
ensure the safety of rotor hoisting and installation.
 The lifting device for rotor shall be installed.
 The rotor shall be lifted and leveled.
 While lifting the rotor to the top of pit, fall slowly the main hook of crane. When the
rotor is falling near to stator, stop and adjust the rotor and stator center, then continue to
fall slowly. In course of falling, the wooden plate with thickness 1/2 of air gap shall be
placed into rotor and stator, and move up and down until the rotor fall onto wind gate.
2.2.5 Lower Bracket and Thrust Bearing Installation

 Assembly the lower bracket at eretion bay, and adjust the leveling of the lower bracke.
 Lift the lower bracket onto the foundation in pit, align the leveling of the lower bracke,
and align the lower bracket center according to the turbine bottom ring and adjust the
elevation according to the stay ring upper flange elevation.
 After concreting the foundation of the lower bracket, lift out the lower bracket. The
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lower bracket will not be installed until turbine equipments in position.

 Install the lower thrust bearing.
2.2.6 Upper Bracket Installation and Guide Bearing Installation

 Lift the upper bracket onto the stator by powerhouse crane.
 Align the leveling, the center of the upper bracket according to the turbine bottom ring
and align the upper bracket elevation according to stay ring upper flange elevation.
 Install the pins between the upper bracket and the stator.
 The upper bracket shall be lifted out, which can be installed after hoisting and
installing the rotor.
 Install the upper guide bearing and accessories.
 Install the upper cover and baffle plate.
2.2.7 Generator Axis Adjusting and Centering
 The coupling bolts between generator-turbine shafts shall be installed and tightened as
per design torque. The elongation value of the coupling bolts must meet design
requirements.
 Adjust the thrust bearing under load uniformly.
 Install 4 to 8 bearing pads of upper guide bearing and turbiner guide bearing, the gap
between segment and collar is about 0.05mm；
 Mark 8 points on air gap, thrust bearing, upper guide bearing, lower guide bearing,
turbine guide bearing and sealing ring along the circle of the unit.
 The rotating parts shall be run by outside force. The pendulosity of above marking
points shall be checked.
 Calculate and adjust the linearity of the unit rotating parts.
 Adjust the center of the unit rotating parts as per the air gap and the sealing ring gap.
 Install the bearing pads of upper guide bearing, lower guide bearing and turbine guide
bearing.Adjust the gaps between the pads and the collar.
2.3 Installation of turbine inlet butterfly valve

2.3.1 General
2.3.1.1 Main properties and parameters
 Heavy-hammer hydraulic control butterfly valve is adopted as the water inlet valve of
Langogan Hydraulic Power Plant. The opening and closing of valve are automatically
controlled by hydraulic pressure. If the power supply is gone, the valve can open using
hand-operated pump and automatically close by means of the weight’s gravity.
 The valve’s nominal diameter is 1700mm, and the maximum application water head is
160m.
2.3.1.2 The main components and their structure features
 1) Main components: The valve consists of butterfly valve body, weight device,
servomotor, hydraulic control station, upstream connection pipe, expansion joint,
downstream connecting pipe, bypass valve and bypass pipeline.
 2) Structure features of the main components:
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 A. The butterfly valve body and servomotor are of integral structure ex-works.
 B. The hydraulic control station is of integrated structure, directly installed on the main
body.
 C. The expansion joint integrally leaves the factory, with its inlet/outlet flanges as well as
the main body inlet/outlet flanges directly connected with the downstream connecting
pipe inlet flange during installation.
 D. The weight is of integral structure, directly connected with the main body rotating
shaft during installation.
2.3.2 Installation scheme
2.3.2.1 Butterfly valve installation procedures
 For the installation procedures see Chart 2.3-1.
2.3.2.2 Installation method for the main components of butterfly valve
 1. Butterfly valve installation is carried out in the valve pit; before installation, carefully
measure the inter-nozzle distance between the water inlet steel pipe end and the spiral
case inlet elbow pipe head, and trim the two nozzle cross-sections to make them
perpendicular to the ground with the cross-section non-perpendicularity less than 3mm.
 2. Put in the sealing rubber strip between the butterfly valve body and the upstream
connecting pipe, connect and tighten the connecting bolt, hoist and emplace the main
body together with the upstream connecting pipe to the installation position, and place the
butterfly valve body on the concrete abutment.
 3. Connect the expansion joint inlet and the butterfly valve body outlet, and tighten all
connecting bolts; after connection, push in the inner telescopic tube of expansion joint
20mm towards the butterfly valve direction for the convenience of connection of
downstream connecting pipe and expansion joint outlet.
 4. According to the dimension of distance between water inlet steel pipe end
cross-section and spiral case water inlet elbow pipe intake cross-section measured, cut the
downstream connecting pipe to make the length matching.
 5. Couple the downstream connecting pipe and the expansion joint outlet, and tighten the
connecting bolt.
 6. Adjust the butterfly valve elevation and the valve shaft levelness up to standard using
the wedge plate on valve abutment.
 7. Assemble the water inlet steel pipe end and the upstream connecting pipe inlet.
 8. Assemble the downstream connecting pipe outlet and the spiral case inlet elbow pipe
intake.
 9. Weld the assembling weld seams when the assembly is completed; after the welding
and acceptance upon inspection, place second stage concrete to the anchor bolt of
butterfly valve body.
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Preparation for butterfly valve installation



Hoisting and emplacement of upstream/downstream connecting pipes, butterfly valve body and expansion
 joint
 Assembly of upstream connecting pipe and penstock
pipe

Assembly of downstream connecting pipe and spiral case inlet


Welding between upstream connecting pipe and penstock


Welding between downstream
connecting pipe and the spiral case
 inlet

Weight installation Bypass pipeline installation
 Concrete placement for
butterfly valve anchor bolt

 Hydraulic control station and electric part installation


Waterless adjustment, interlock test
Water filling adjustment, dynamic closing test
 Chart2.3-1 Butterfly Valve Installation Procedures
2.3.2.3 Installation of other components

 Install the following components after the main body anchor bolt placing and achieving
certain strength.
 Installation of the weight, the hydraulic control station and the pipeline between hydraulic
control station and servomotor;
 Installation of bypass valve and bypass pipeline;
 Installation of electric control part.
2.3.2.4. Perform adjustment test to the butterfly valve
2.4 Governor System Installation

2.4.1 Installation Flow Chart
The governor installation flow chart is shown as Figure1-4。
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2.4.2 Governor System Installation

 Lift oil pressure parts (such as pressure tank, oil return tank and oil reservoir) onto the
erection place by powerhouse crane, adjust ther elevation, leveling, verticality and
distance to axis X, Y to meet design requirement, then fix them.
 Lift mechanical cubicle and electrical panel in position, adjust elevation,verticality and
position, then fix them.
 Place 2nd stage concrete on equipment foundation.
 Cut and weld the pipeline, after that, the pressure test shall be done, then clean and
install the pipeline.
 Install the accessories (pressure gauge, pressure switch, pressure sensor, hydraulic
sensor, oil level indicator, oil level switch, compress air atomatic supply unit) as per
drawing,
2.4.3 Governor System Oil Filling

 Fill oil into oil return tank until the setting level via. station turbine oil system.
 After operation of oil pump, fill oil from the oil return tank to the pressure tank via.
governor system oil pump.
 In course of filling oil, check the oil leakage carefully.
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1st stage embedded parts inspection and

reference points layout
System oil cycle test

Equipment foundation cleaning
Oil return tank, pressure tank and electrical Oil system pressure rising to
panel lifting, adjustment and fixture rated value
2nd stage concrete placement of equipment Valve regulation, gate

foundation open-close test
Pipeline installation and cable wiring Governor analog test, gate

open-close time inspection and
adjustment
Oil pressure system (oil return tank and
pressure tank) and accessories cleaning Governor static characteristic
and closing testing
Governor body oiling and electrify Combination commissioning

with station computer , remote
operation test
Oil pump running and oil pressure unit

operation test Unit filling water regulation
Automatic admission air, oil level and

temperature signal test
Figure1-4 Governor System Installation Flow Chart
2.4.4 Governor System Regulation

(1) Oil Pump Test
 Turn oil pump manually to check the rotation of oil pump flexibly.
 Check the correctness of oil pump motor rotating direction by pick-up without oil.
 Check the correctness of oil pump control circuit, and operate in analog.
 Open the valves of oil return tank to oil pump.
 Set the working mode of oil pump as manual mode, operate oil pump and fill oil into
pressure tank, then check the performance of oil pump.
(2) Operation Test of Oil Pressure Unit
 Set the working mode of oil pump as manual mode, start and stop the oil pump
manually to assure normal operation.
 Set oil pump as automatic working mode. When oil level of pressure tank drops to the
start position of oil pump, oil pump can startup automatically, then oil level of oil pump
rises to the stop position, oil pump can stop automatically. If oil level drops to the start
position of reserve pump, reserve pump can startup.
 If oil level of oil return tank is too low, oil pump can stop automatically.
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(3) Operation Test of Automatic Admission Unit and Oil Level Signal Unit
 It adopts the way to drain oil from pressure tank manually and refill oil from pump
station and oil return tank to pressure tank.
 The pressure of oil pressure tank falls to the setting value of air admission, operate the
solenoid valve to supply air to pressure tank automatically. When the pressure rises to
the setting value of stop suppl, the air admission unit can stop air supply automatically.
 Adjust oil level signals for correctness.
(4)Oil Cycle and Oil Pipeline System Filling and Rising
 Open the main supply oil valve, fill oil from pressure tank and main distributing valve
to governor oil pipeline.
 Rise pressure to operate the main distributing valve for flushing pipeline by oil cycle,
clean governor filter. The oil in oil return tank shall contiune to be filtered via. pressure
filtering machine, open oil return tank, and check the oil.
(5 ) After cleaning pipeline, the oil in oil return tank shall be inspected, after qualified, the oil
pressure in tank shall rise to the rated working pressure and will last for several hours, close
the main supply oil valve and stop the oil cycle test after supervisor confirmed. When the
servomotor is operated in lower oil pressure, the gate will be fully close.
 Check the closing gap of the gate, measure the position of servomotor piston rod d1,
and continue to close the gate under oil pressure of servomotor compress stroke as per
design requirements, recheck piston rod position d2，d2- d1, finally adjust the coupling
bolts to assure servomotor compress stroke to meet design requirements.
(6) System Analog Test
 Under the condition of spiral case without water, the governor shall be set in mannual
and automatic mode respectively.
 Operate governor, open and close the wicket gate smoothly, adjust the openings
indicated on governor meter to correspond with servomotor stroke and gate actual
opening. The max. opening of wicket gate shall be more than 80％ of servomotor
stroke.
2.5 System Pipeline and Auxiliary Equipment Installation

(1)The system pipline installation flow chart is shown as Figure1-5
(2)The auxiliary equipments installation flow chart is shown as Figure1-6
（as example of compressor）
2.5.2 Installation Sequence
(1) Lay out the reference point.
(2)Check and clean the equipmets.
(3)Transport the equipments to erection place, adjust elevation, flatness, leveling and
verticality to meet design requirement.
(4)Fix equipments and place 2nd stage concrete on foundation. Cut, fit and weld the pipeline.
After withstand test, the pipeline can be installed. The electrifying, pressure rising and
integral withstand test shall be conducted.
(5)The system pipeline shall be cleaned in cycle.
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(6)The system regulation and trial shall be performed.
Pipeline accessories machining and

pre-fabricating
Working area
arrangement Pipeline embedding, welding and fixing
Scaffolding Concrete placement

putting up
System equipment installation
Pipe cutting and fabricating
Pipeline welding
Pipeline withstand test
Pipeline cleaning（oil pipe pickling）
Pipeline and accessories installation
Water, air and oil filling and system flushing
System regulation
Corrosion protection and painting
Trial
Figure1-5 System Pipeline Installation Flow Chart
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Foundation pre-embedding
Body center and elevation

measurement
Gas(oil) reservoir Foundation cleaning

foundation cleaning
Frame installation
Gas(oil) reservoir foundation
Foundation 2nd stage
cleaning, inspection and
withstand test concrete placement
Compressor(pump)
centering
Gas (oil)reservoir
lifting and adjustment Motor centering and connection
Accessories and
instrument
Pipeline, instrument and inspection
accessories installation
Equipment commissioning
Trial
Figure1-6 Auxiliary Equipment Installation Flow Chart
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3. Electrical Parts Installation

3.1 Transformer Installation Scheme
3.1.1 Transformer Installation Flow Chart
The transformer installation flow chart is shown in Figure 1-7,
3.1.2 Installation Scheme

 Transport and lift the transformer onto the maintenance rails.
 Fill with oil, discharge the Nitrogen, filter the oil and drain the residual oil inside
of transformer.
 Inspect transformer inside in good weather(sunshine) and environment (avioding
rain, snow, windsand) with temperature more than 0℃.
The temperature of transformer body shall exceed 10℃ of environment
temperature.
 The high voltage and low voltage bushing test shall be conducted. Install the
elevated seat and the high and low voltage bushing in the same time as internal
inspection.
 Install pipeline and accessories, change sealing rings when installation of
pipeline.
 Connect well the vacuum equipment, pipeline, oil filling equipment and piping,
vacuum the transformer oil tank to a required degree.
 After the insulated oil is qualified, fill the oil into the transformer (under a
vacuum status) till the level is lower 200 mm than the transformer upper core,
or follow design requirements.
 Destroy the vacuum, carry out a warm oil circulation for the transformer with
filtering machine (not less than 72 hours), take a random inspection after
completion, the result must meet requirements.
 When the transformer inside oil is qualified, open radiator, release valves and
holes till the oil comes out and the oil level of tank is over normal oil level. The
trsnsformer shall be standby for above 72 hours , then release the gas many
times from the holes at every position.
 After transformer oil filling under a vacuum status is finished, it can install the
transformer neutral point parts and protection, secondary wiring. The field test of
the transformer shall be performed according to the required testing items.
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Patrind 3x50MW Hydropower Project Installation for EM
Preparation
Insulated oil Rail elevation and Dry air Accessories lifting

device preparation
disposal system center rechecking device
Transformer body
Positioning
Residual oil analyzing and insulation checking
Oil filing and nitrogen discharging
Accessories open case

Heat-oil circulation inspection
Bushing test Oil discharge

Accessories installation (oil cabinet,
cooler and pressure release device)
Internal inspection
High and lower voltage bushing

installation
Vacuum oil filling Local terminal cabinet installation
Neutral point
equipment
Heat-oil circulation Cable-duct and cable layout
installation
Sealing test for oil Secondary wiring

compensation
Grounding, touch-up painting

and cleaning
Electrical test
Trial Acceptance and handing-over
Figure1-7 Transformer Installation Flow Chart
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3.2 Non-Seperated Phase Bus Installation

The non-seperated phase bus installation flow chart is shown as Figure1-8.
Preparation
Survey point layout and Lifting device arrangement Scaffolding

foundation centering putting up
Frame installation
Open case inspection
Horizontal busbar positioning and

installation
Vertical busbar positioning and

installation
Busbar integral adjustment
Accessories installation
Busbar welding and earthing
Busbar cleaning completely
Field test
Connection with other equipments
Acceptance and
handing-over
Figure 1-8 Non Separated Phase Bus Installation Flow Chart

a) Install busbar framework as per design requiremets.
b) Align concentricity of busbar.
c) Lift and install busbar in position.
The busbar shall be lifted using synthetic fibre sling instead of steel
sling.
When lifting vertically, it shall take protective measures to avoid
conductor sliding out.
d) After locating each section of the busbar, they shall be adjusted roughly
first. The encloes busbars shall not be welded and bolted until the
integral busbar positioned and the interfaces distance to generator and
main transformer meeting design requirements.
e) The enclosed busbars shall be welded by qualified welder. In course of
welding, the busbars shall be protected to avoid damage of insulator by
spark.
f) Install busbar accessories including excitation transformer, brake switch,
PT cubicule and surge arrester etc.
g) The busbar shall be connected with other equipments. After high
voltage testing for 1min, the busbar can be flexibly connected. During
flexible connection, tighten bolts by torque( the torque value specified
by manufacturer).
3.3 132KV Switchyard Equipment Installation

3.3.1 Installation flow chart
Outdoor switchyard installation flow chart is shown as below:
Open case inspection
Equipment support Test prior to installation

installation
Lifting and positioning
Leads cutting and

clamping
Equipments connection
Field test
Acceptance and
handing-over
Figure1-9 Switchyard Installation Flow Chart

 Install and inspect steel structure and foundation.
 Install circuit breaks.
 Install disconnecting switches and earthing switches.
 Install current transformers, voltage transformers and surge arresters.
 Install bus bar.
 Connect leads.
 Install other parts.
 Earthing and painting.
 Field test and commissioning.
3.4. Computer Monitor and Control System Installation

The installation flow chart of computer monitor and control system is shown in
Figure 1-10,
Foundation installation
Panel and other equipment installation
Cable and optical fiber cable layout
Secondary wiring
Unit commissioning
System commissioning and trial
Acceptance
Figure1-10 Computer Monitor and Control System Installation Flow Chart
3.4.2 Installation scheme

 The computer monitor and control system equipments shall be located, fixed and
connected.
 The internal wiring, input and output wiring shall be installed and verified, and
the power supply equipment, computer, control table and other outer
equipments shall be checked.
 The UPS field with continuous power supply shall be performed.
 The energizing test of the computer main control station shall be conducted, start
up the system, the trial of hardware diagnosing sequence shall be performed.
 The local control unit (LCU) shall be installed, located and connected.
 The function of LCU data collecting shall be checked. The control flow
sequence shall be inspected in stage.
 The communication test for main station via. panel I/O and LCU shall be
conducted, collect signals to compare with the CRT menu.
 The signals indicated on CRT, analog screen, and alarm record and display,
event record and display shall be chcked to assure the correctness.
 The simulation testing of LCU and the main control station to start/ stop unit
shall be performed. The turbine faults and the electrical shut-down flow
sequence shall be simulated.

 The turbine-generator startup and shutdown test shall be carried out.
3.5 11KV switch equipment installation

Reference set and foundation installation
Locate, alignment and install of the switch gear
Bus bar installation
Control and protection cable installation
Switch equipment site test
High voltage cable distributing and connecting
System commissioning and test run
Figure1-11 Installation flow chart
3.5.2 Installation description

1) Foundation installation, foundation corrosion protection and earthing for switch
gear;
2) Switch equipment transported to installation site. Parts located and aligned.
3) Distribute and install the main busbar and earthing busbar, and install the switch
earthing part.
4) Control, protection and signal cable distributing, wiring and checking.
5) Energize the switch gear controlling system, site test and commissioning
6) High voltage cable distributing, cable shoe making and cable connecting.
7) System energized and put into operation.
3.6 Cable tray and cable installation

1) Cable tray foundation installation and earthing
2) Use theodolite and level to identify the installation elevation and location for the
columns in the same row. Fix these columns well right in direction. For the metal
supporting columns, grounding must be done after fixed.
3) Transversal arms alignment and installation
4) Install the transversal arms to the right direction and to a good fixing situation. When
it goes to the slope areas like in the cable tunnels or in other buildings, the arm
should be in the same slope position.
5) Check first the cable tunnels for smoothness and the cable themselves for no
damage and good insulation before installing the power cables and control cables
for high and low voltage.
6) During distributing the cables, the high voltage cable and low voltage cable, the
strong power cable and weak power cable should be distributed stage by stage. The
cables in the same tray should be laid in order.
7) After confirming that in a certain hole or pipe all the cabling, which passed through
have been all installed, these holes or pipes should be sealed.
8) Make the intermediate connections and terminals for high voltage strong power
cables.
9) Connect the cable and the terminals.
10) Site inspections and tests
3.7 Low voltage power supply system installation

The low voltage power supplying system means the 400V/.230V AC power supplying
system and DC power supplying system and diesel generator units.
1) Foundation installation
2) Align the leveling, straightness and elevation for these panels and cubical and
diesel generators and make a reliable grounding for them.
3) After box opening of the panel and cubical, put them on the foundation, align
them and locate them, make a well a good grounding.
4) Bus bar inside the AC power supplying panels of 400V/230V, as well as the
control cable, secondary cable will be installed. After this, they will be energized
and commissioning work for them will be done.
5) After the DC panels are located, install the battery units. Check the battery for no
distortion, damage, measure the voltage of terminal of the batteries. Put the
battery on the support and make a proper connection and fix the connections.
6) Do the site test and commissioning for the battery and put them into operation.
7) For the diesel generator installation, the co-axial position should be watched out.
After installation, do a test running and measuring the vibration of the generator.
3.8 Control and protection system installation

Foundation installation
Locate and install the panels
Bus bar installation
Cable distributing and bracing

DC power supply system installation
Secondary wiring and connecting
Device unit commissioning
General commissioning
Figure1-12 Control and protection general installation procedure

1) Foundation installation and reliable grounding
2) Equipment box opening, inspect and counting.
3) Panel installation and reliable grounding after wards
4) Cable distributing and wiring
5) Reliably connect the secondary wiring inside the panel and clearly make the
marks for the circuits.
6) Verify the correctness of the wiring. All the circuits, electrical equipment wire coil
resistances are all according to the requirements.
7) Site test.
8) Current transformer and voltage transformer inspection and test; checking and
calibrating for the control and protecting devices.
9) Energizing for check and check the activating of the device.
10) System commissioning. Carry out the joint commissioning for control system,
protection system, excitation system, governor system, auxiliary system and public
system.
3.9 Lighting and grounding installation

1)Lighting system installation flow chart
Box opening and inspection
Cable distributing Lighting power cubical install
Lamp, breaker etc. lighting instruments Input cabling
Circuit check and insulation measuring
Energize and test lamps
Figure1-13 powerhouse lighting system installation flow chart
2) Gorunding system installation

Material cutting for fabricate grounding embedded parts embed grounding
line connecting grounding line connect electrical device, equipment
to the grounding net grounding device check and grounding resistance
measuring.

1) Lighting system installation will be done in periods according to the unit
installation progress.
2) Lighting system piping work
3) During distributing the cable pipes, connecting box should be set near by the
position where lamps will be installed or set the cable pipe inside the
lamp-connecting box. The cable pipe should be displayed in line in order and will
be fixed by average fixing points.
4) Lighting cable distributing.
5) Core of the cable must be properly and reliably connected. The connecting for
lighting protection grounding must be reliable as well.
6) Install the lamps, switches and sockets. The fixing system for lamps, switches and
sockets must be proper. The switch will be installed on the phase line. The inserted
lamps will be installed at the same time as room decoration. After each line of
lamps is installed, the insulation will be checked and the lamps will be tested.
7) Grounding device installation
8) Set compensating device for the grounding device there where grounding line will
be across buildings or whose elevation will be changed up and down.
9) Grounding object will be normally be connected by over lap of welding.
4. Commissioning and Trial Operation

4.1 Set up a committee for unit start-up check and accept
The committee for unit start-up check on delivery should be constituted of Owner,
Supervisor, Design, Manufacturer and Installation Company. The manager of the committee
should be Owner. The subordinate of the committee: Unit trial run command department,
check and accept group, General office and technical group. The committee is the super
organization and unit trial run organized by Owner.
4.1.2 The function for subordinate of the start committee for unit start-up check and accept
4.1.2.1 Unit trial run command department: Unit trial run command department works under
the leading of the start-up committee, and is responsible for execution of unit trial run. The
director of unit test run command department should be taken on by installation personnel.
Important processes in unit trial run should be approved by the committee for unit start-up
check and accept.
4.1.2.2 Check and accept group: Check and accept group is responsible for check and accept
of the whole trial run. Supervisor personnel should be taken on the manager.
4.1.2.3Technical group: Technical group is consist of design and manufacture personnel, and
should be responsible for information management and technical support of trial run.
4.1.2.4 General office: General office is constituted of Owner and Installation personnel, and
should be responsible for security, goods and materials supply and logistics guarantee.
4.2 Inspection and test before unit start-up trial run

4.2.1 Preparation before unit start-up
4.2.1.1 Check and accept for Penstock
4.2.1.2 Check and accept for turbine
4.2.1.3 Check and accept for governor system
4.2.1.4 Check and accept for generator
4.2.1.5 Check and accept for excitation system
4.2.1.6 Check and accept for oil, air and water system
4.2.1.7 Check and accept for primary electricity
4.2.1.8 Check and accept for secondary electricity
4.2.2 Test before unit start-up
4.2.2.1 Water filling test for draft tube
1) Close access door of spiral case and draft tube fully
2) Close relief valves of spiral case and penstock fully.

3) Close water intake valve of spiral case
4) Powerhouse drainage pumps are on automatic working condition.
5) Lift draft tube gate slowly and fill water to draft tube.
6) During filling water, check each connecting flange of draft tube under tailrace water level.
All draft tube and flange should not leak, and each connecting part of pressure regulating
valve under tailrace water level should not leak.
7) When everything is in good condition, open draft tube gate fully and lock it on the gate
slot.
4.2.2.2 Water filling for penstock and spiral case
1) Check air exhaust hole of penstock is flowing freely.
2) Check governor oil pressure unit is in good condition, and oil pressure and level of
pressure tank is normal. Operate governor manually to make sure that wicket gate is
controlled by governor freely. After check, close guide vane fully and put in servomotor lock.
3) Close fully unit water inlet butterfly valve and by-pass valve
4) Put in generator air brake to make sure that unit is in braking condition.
5) Open the by-pass valve of intake gate to fill water into penstock.
6) During filling water, Inspect tightly the leakage of penstock expansive joint and upstream
flanges of inlet butterfly valve, and the leakage of each part of intake butterfly valve.
7) During filling water, if there is serious leakage, close the by-pass valve immediately.
8) If everything goes well, fill water to stable pressure and record the time of water filling.
9) After pressure stably, open butterfly valve to do hydrostatic test for Open and close
butterfly valve, check the action of valve body open and close, and record the time of open
and close. After manual operation is acceptance, automatic open and close test should be
made locally and remotely. After test, open butterfly valve fully and close by-pass valve.
10) During filling water for the spiral case, check the leakage of butterfly valve expansive
joint, spiral case entrance, turbine head cover, unit pressure measuring pipe, wicket gate and
main shaft sealing device.
11) After pressure stably, make hydrostatic action test of the butterfly valve.
4.2.2.3 Adjustment and test for technical water supply
1) Close valves at water branches and open the main valve of water supply to fill water into
the main pipe of technical water supply system. Check the water pressure of relief valve inlet
and outlet.
2) Regulate the relief valve to make its outlet water pressure become design value.
3) After steady operation of water filling to main pipe, fill water to each branch in turn:
(1) Cooling water supply and drainage system for generator air cooler
(2) Cooling water supply and drainage system for bearing lubricating oil cooler of unit
(3) Water supply and drainage system for turbine main shaft sealing
(4) Water extinguishing system.
(5) Regulate each branch supply and drainage water pressure value to the requirement of
manufacturer.
4) During filling water, check the following items:
(1） There should not be leakage in each pipe, valve and joint of all the technical water supply
system.
(2）Each pressure gauge, thermometer and flow indicator indicates correctly. Automatic
elements such as pressure switch, pressure difference transmitter, solenoid valve and
magnetic flow meter should work normally.
(3）Water pressure of each branch should meet the design requirements of manufacturer.
4.3 Unit Start Wet Test

4.3.1 Initial start
4.3.1.1 Confirm that all problems which were found during filling water have been resolved.
4.3.1.2 Confirmed there are no sundries in air gap and around of that.
4.3.1.3 The measuring instruments for units vibration and swing have been already installed.
4.3.1.4 The carbon brushes in bus ring of generator rotor have been already pulled out from
brush holders.
4.3.1.5 Make sure circuit breaker of generator exit have been already opened.
4.3.1.6 Make sure the unit temperature measuring device and shaft bush temperature
protecting device have been turned on.
4.3.1.7 Relife brake valve manually, and make sure generator brake valve is off flywheel fully.
Turn manually to establish oil film.
4.3.1.8 Governor oil pressure device set to automatic condition.
4.3.1.9 Powerhouse water leakage drainage pumps switch to automatic condition.
4.3.1.10 Set the electrical opening restrict of governor to zero, then open main oil supply
valve between pressure oil device and mechanical cabinet.
4.3.1.11 In order to monitor unit speed of start up and running, connect to a normative
Cymometer beside of governor cabinet,
4.3.1.12 Start cooling water system manually, check water pressure of all parts is normal or
not, close generator main inlet valve of air cooler temporarily.
4.3.1.13 Dismantle all of earth wires and shorting stubs which used for all kinds of testing
before unit start up.
4.3.1.14 Start main shaft sealing water.
4.3.1.15 Withdraw servomotor lock manually.
4.3.1.16 Manual operation of starting up: operate governor manually, open guide vane slowly,
make unit running speed rising to about 50%nN. Then make unit running speed rising to
75%nN—100%nN step by step after checking there is no abnormal situation.
4.3.1.17 Stop immediately, if meet following condition during unit start up and speed-rising.
1） There is abnormal sound inside of unit (eg.: metal clash sound)
2） Temperature of unit bearing rise suddenly.
3）Oil sink of thrust bearing or guide bearing is swinging out lots of oil.
4）vibration and swing of unit exceed its standard seriously
5）Other abnormal situations are harm for the unit safe running.
4.3.1.18 Unit initial start and no-load run monitor and record
1）Record upstream water pressure and downstream water level of power station, guide
vane opening of unit starting up and that of non-load situation.
2）Record each bearings running temperature: time interval is 5min at first, time interval
is 10min after half an hour, time interval is 30min one time after an hour.
3）Measure and record value of vibration and swing of unit in each measuring point, and
check the wiring of vibration and swing measuring device.
4）Record unit water consumption at rated speed, and record the value of each meter of
hydraulic measuring system
5）Measure one time residual voltage and phase-sequence of generator at rated speed,
6）.Regulate the water pressure of main shaft sealing to make it run in optimum situation
when unit no-load.
7）Record amount variation of lubrication oil of each bearing after the temperature of
shaft bush is steady.
8）Record start periodic time of water leakage drainage pump, that of governor oil pump,
and that of bearing lubrication oil pump.
4.3.1.19 After bearing pad temperature is steady, adjustment test of speed regulated system at
no-load condition should be done.
4.3.1.20 No-load disturbing test of governor:
1）Turn the governor switch to automatic, choose several groups of PID parameter, do
disturbing test that the disturbance quantity is ±8%（±4HZ）.
2）Record disturbance regulation waveform to make regulation maximum overshoot,
swing times, regulation time agree with operating technical specification of governor, and
then choose optimum PID parameter.
3）Under choose PID parameter, the relative change rate of no-load running speed of unit
should not be more than ±0.25% of rated speed.
4.3.1.21 At rated speed of unit, do switching test between manual and automatic operation,
servomotor should not be obvious swing.
4.3.1.22 Governor frequency regulation range test: under choose PID parameter, changing
governor frequency supply on purpose, and verifying the regulation range of governor agrees
design requirement.
4.3.1.23 At automatic operation of oil pressure device, record the time of oil supplying by oil
pump from oil pressure tank, and record the oil pump working period.
4.3.1.24 After completing adjustment test of governor, stop manually, and the procedure of
manual stop is as flowing:
1）Operating governor manually, close the guide vans step by step to the full closed
position.
2）Start brake valve manually when speed of unit decrease to 15%nN-20%nN.
3）After the unit stopped fully, then get rid of main shaft working sealing.
4）Start servomotor lock.
5）Get rid of air brake manually after the unit stopped fully.
6）If the units would stop for a long time, butterfly valve should be close manually.
4.3.1.25 Check and adjustment after the unit first time stop.
1）In the course of unit stopping and speed reducing, check the accuracy of each fixed
value of speed device; it should be rearranged when necessary.
2）Record the speed-reducing time from rated speed to 35%nN, also record the time from
starting valve to stopping fully.
3）Check the bolts, pins, locking plate and keys of each part of unit whether they are
loose or exfoliated or not.
4）Check welded seam of rotating part has cracked or not.
5）Check the wind screen, wind ring, guide wind vanes are loose or exfoliated or not.
6）Check the abrasion condition of air brake restrictor.
7）Check water leakage quantity of guide vane
8）According to the vibration and swing condition of first starting up and running test,
decide the runner has a dynamic balancing test or not.
4.3.2 Overspeed test
4.3.2.1 Overspeed test should be taken after unit vibration and swing conform to factory’s
design requirements, otherwise, dynamic balance test should be taken first.
4.3.2.2 Speed relay’s 115% and 140% (or according to design values) contacts will be cut
from turbine protect circuit, only act on the signal.
4.3.2.3 Measurement of vibration and swing should be prepared before, in, and after
overspeed
4.3.2.4 The conditions of machinery and electrical overspeed device should under
surveillance by a person.
4.3.2.5 Start and rise to rated speed by manual, make unit running until bearing bush
temperature stable at rated speed.
4.3.2.6 115% rated speed test: operate governor manually, when unit’s speed up to 115% nN
quickly dropped back to rated speed.
4.3.2.7 Record unit’s vibration and swing value when bearing bush’s temperature is steady
and at 115% nN speed, compare with the value before overspeed.
4.3.2.8 140% rated speed test
1） Record the temperature of bearing bush, vibration and swing value before overspeed.
2） Change relevant parameters, operate governor manually, let unit’s speed rose to
140% nN quickly. When unit reached 140% nN speed, reverse operate immediately reduced
the speed to rated value.
3） Check acting situations of machinery and electrical overspeed device, at 140% nN
speed. If overspeed devices not act as the setting value, unit should be shutdown manually.
4.3.2.9 Monitor and record at overspeed test:
1）Monitor unit’s speed signal device and check the setting value in the process of speed
up under manually operate.
2）Record the level of upstream and downstream and the opening of guide vane at
overspeed 115% nN and 140% nN.
3）Record the value of vibration and swing before, in and after overspeed.
4）Record the temperature of bearing bush and the change of oil level before and after
overspeed.
4.3.2.10 The check after unit overspeed test
1) Check the changes of generator foundation board and bearing.
2) Emphasize check the state of generator’s rotor part, include rotor poles key, yoke key,
damping ring, and magnetic poles wire and poles impact screw.
3) Check unit all the items as the item of unitinitial start and shutdown .
4.3.3 Automatically startup and shutdown test
4.3.3.1Put the control of ancillary equipment to automatic, put in hydro-mechanical protection
4.3.3.2 Open the generator circuit breaker
4.3.3.3 Set governor on automatic state, power given on no-load state, frequency given on
state.
4.3.3.4 LCU give unit startup order, unit start automatically to no-load operate.
4.3.3.5 LCU give unit shutdown order, unit shutdown automatically.
4.3.3.6 Unit’s automatic startup and shutdown test should be taken on local (LCU) and remote
(PC Monitoring System) respectively.
4.3.3.7Check and record in Unit’s automatic startup and shutdown test:
1）Check the correctness of automation components, adjust if necessary.
2）Check the correctness of the order of Unit’s automatic startup and shutdown control
program and the completion on the center control room (PC) and local (LCU).
3） Record the duration time from sending out of the startup and shutdown signals to the
unit fully completes.
4）Record the duration time from putting in the brake to the unit complete shutdown
4.3.3.8 This test could also be taken with other test coordinate, including excitation test and
parallel in grid test etc.
4.3.4 Generator short-circuit test
4.3.4.1 Dismantle the connection between excitation transformer and generator busbar,
according to the power situation of site, use high-voltage cable lead appropriate power to
high-tension side of excitation transformer as separately excited power, and connect to the
button in excitation panel for remote trip
4.3.4.2 At the short-circuit test device point of closed busbar, set 3-phase short circuit point,
open the circuit breaker of generator exit.
4.3.4.3 Open disconnect link of neutral transformer for generator
4.3.4.4 Beside the excitation cubicle, set another 3-phase ammeters for stator and rotor,
3-phase voltmeter to monitor generator short-circuit current rising.
4.3.4.5 The secondary side of current transformers, which is in the effect scope of generator
short circuit fault and not useful temporarily, should be short and solid ground.
4.3.4.6 Before units start, fill water to the cooling water supply pipes, then flow to the
generator air cooler and input the hydraulic machinery protection.
4.3.4.7 Withdraw all the generator protection
4.3.4.8 Start the units manually, and make the units run until the temperature of bush shoes
steadily.
4.3.4.9 Transfer the excitation device to manual operation, set to the lowest position, and
input separate power. At the condition of disconnecting the field breaker, check the current of
secondary side for current transformers in the scope of short circuit fault.
4.3.4.10 Close field breaker and increase the stator current to 20% slowly, measure the
secondary side current of current transformers, and check 3-phase current angle and balance,
check the polarity, and neutral line have not the current.
4.3.4.11 Check the current transformers polarity of excitation transformers, and check
connection correctness of differential protection.
4.3.4.12 Increase the stator current to about 75 percent of rated current, and check the right of
items of 2.6.2.3; check the values of generator complete and imperfection differential, and
check the correct of secondary side angle and connection of excitation lose,
negative-sequence overcurrent, overload and other protection. Check the value of transformer
differential. Check the correct of each current circuit meter for measure and indication.
4.3.4.13 Up current tests are done, reduce the current, and trip the field breaker.
4.3.4.14REC the short-circuit characteristic
After field breaker is close, increase the stator step-by-step, meanwhile, fetch 3-phase
stator current and rotor current. The number of step is more than 10, and draw generator
short-circuit characteristic curve.
4.3.4.15 During the test, watch the running conditions of slip ring and carbon brush
rigorously.
4.3.4.16 When stator current is up to rated value, check the secondary current of shaft current
protection device.
4.3.4.17 When the above tests are done, at rated current, trip the field breaker, and REC the
field discharge characteristic of generator.
4.3.4.18 Drying at generator short circuit
1） Before dry, measure the stator and rotor winding insulation resistance to ground and
polarization index by 2500V Megohm meter.
2） According to the requirement of <Specification Installation of Hydraulic turbine
Generator Units> (GB8564-2003), confirm the generator stator winding need to be dry or not.
3） Start the units to no-load manually, when the unit steadily, then give the separately
excitation, and close the field discharge switch, increase the generator current gradually (at
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 though
the air cooler is not higher than 400C, and the temperature of stator is between 600C and 650C,
must not be exceed 800C.
4） During drying, once the stator winding current is up to the controlling value, it
should be keeping about 8 hours. In keeping time, the cooling water should be used as adjust
the temperature.
5） After the keeping 8 hours, the current should be lower, the lower speed is 10℃ per
hour. When the temperature is lower than 40℃, the field discharge switch should be tripped
and stop the unit.
6） During drying at short circuit, the air cooler should have cooling water; the cooling
water can adjust the temperature of cooling air.
4.3.5 Generator step-up voltage test
4.3.5.1 Open circuit breaker of generator exit, close the disconnecting switch of neutral point.
4.3.5.2 Put the generator protection and hydro-mechanical protection in. change the value of
generator over-voltage protection as 1.3UN, 0.5 second.
4.3.5.3 Put vibration and swing measuring device in.
4.3.5.4 Transfer governor and other auxiliary control device as automatic control.
4.3.5.5 The unit is adopting separately excitation. Excitation device is transferred to manual,
and set to the lowest value.
4.3.5.6 Step-up voltage operation
1） Auto start comes true by LCU near the unit. Make the units run until the temperature
of bush shoes steadily
2） Put separately excitation power in, close generator field breaker, set the voltage by
manual and increase voltage slowly. Classify four grades as 25%、50%、75%、100%Un. Check
relative items at each grade.
4.3.5.7 Check in step-up test
1） Check running condition for each electriferous equipment
2） Check 3-phase voltage balance and phase sequence of generator terminal. Check the
output voltage of open-delta, and confirm the phase of each PT.
3） Check the indication of secondary voltage meter of PT correct or not.
4） At U=100%UN, check the vibration and swing value of generator shaft
4.3.5.8 The REC program no-load characteristic curve
1） Operate the excitation regulator by manual to set the generator voltage minimum.
2） Operate the excitation regulator by manual to increase the generator voltage
gradually and meanwhile read the stator 3-phase voltage and excitation current of rotor and
the frequency of unit.
3） At U=10%-60%UN, increase voltage by the step of 10%UN; At U=60%-100%UN,
increase voltage by the step of 5%UN; at 100%-120%UN, read the UF and IL value twice at
least. The voltage is restricted below 1.3UN, and the current is restricted below the rated
excitation current. When each of above two values is reached, stop increasing voltage
immediately. During the time of increasing voltage, read stator voltage, rotor current and
frequency of unit at each point.
4） When the voltage is up to the highest value, read the values quickly and return to the
rated voltage quickly.
5） Operate the excitation to be down generator voltage by manual, at the same time read
stator voltage, rotor current and frequency of unit at each point.
6） Draw generator no-load characteristic curve
4.3.5.9 Generator single phase grounding test and set the value of load resistance
1） After increase generator voltage, reduce field to turn down the current, trip the field
breaker of generator to run no-load of unit. In the time, the governor is running by auto.
2） Take off one phase of HV fuse at the Unit PT cabinet, and make single phase ground,
and connect an ammeter A1 into the ground line, and reconnect the fuse.
3 Connect another ammeter A2 between load resistance and grounding line

4） Operate governor to make unit run steadily at the rated speed.
5） Open the disconnecting switch of neutral grounding cabinet, then close field
discharge switch.
6） Operate excitation regulator by manual, and increase the generator voltage to half of
UN, read the single grounding capacitance current I1.
7） Transform the capacitance current I1 to the relative current Ic at the rated current,
according to compensation principle, choose the suitable value of load resistance.
8） After close the disconnecting switch of load resistance, operate the excitation
regulator to increase the generator voltage to half of UN, record the grounding current I1 and
the current I2 through load resistance, discharge field and reduce voltage
9） According to the current IL of setting load resistance, transform to single grounding
current IC at rated current, to calculate the difference of load resistance, which is not more
than 20 percent.
10） During the time of increasing voltage, check the action condition of generator single
grounding. Before the test, release the protection exit and only send the signal.
11） After the test has been done, resume the normal connect of generator exit and
neutral.
4.3.5.10 Automatic stop
4.3.6 Testing and adjustment of excitation system on no-load condition
4.3.6.1 Trip the Generator Circuit Breaker
4.3.6.2 Input the hydro-mechanical protection system of the turbine generator set
4.3.6.3 Input the Generator Protection system; coordinate the setting of over-voltage to 1.3Un,
0.5s. Input excitation protection system.
4.3.6.4 Prepare and wiring the Wave Record Instrument beside the excitation panels.
4.3.6.1.5 Restore the Excitation system to permanent self shunt excitation model
4.3.6. 6 Start the generator, close the Filed Breaker, and input the excitation system
4.3.6.7 Manual Field Flashing Test
Set the rated Voltage point, Field Flashing by manual, Record the flashing wave of each
excitation channel, record the flashing overshoot,
4.3.6.8 Manual inverse discharge test
Flashing and increasing the voltage to rated voltage, discharge, then record the wave and
discharge time
4.3.6.9 Measure the adjusting range of manual voltage regulation: set the voltage setting value,
the voltage of the generator output should be smooth adjusted in the scope of 20-110%Un.
4.3.6.10 Check the voltage regulation range of the excitation system, make sure that the range
can be complied the design requirement. The Automatic excitation system could regulate the
no-load voltage of the generator in the range of 70%-110%Un steadily and smoothly.
4.3.6.11 Excitation system Manual-Auto control model change-over test: switch over two
sets of regulator, the difference of generator exit voltage should be less than 5% UN
4.3.6.12 No-load disturbing test of excitation system: Change the control model of excitation
system to Automatic model, input a transient disturbance (Phase step value) of about 10% of
generator rated voltage to regulator setting value, oscillation time，regulation time。Test
regulator A and B separately.
4.3.6.13 Frequency characteristic test of excitation system: Change the control model of
excitation system to Automatic model, change the RPM of the turbine in the range of ±3HZ
by operating the governor manually, then check the variation of the generator voltage and
record the voltage-frequency characteristic curve.
4.3.6.14 Discharge test in no-load condition: Trip the field circuit breaker when the voltage is
50%Un and 100%Un separately. Check the arc blow-out situation, record the wave, and
calculate the discharge time-constant.
4.3.7 Generator-Transformer group and HV switchgear current increasing test
4.3.7.1 Check before generator-transformer group and HV switchgear short circuit current test
1）Generator circuit breaker, isolating switch, generator voltage equipment and HV
related equipment should be all test qualified and conditional for running.
2） Main transformer test is OK, oil level and tap switch are normal.
3） HV switchgear test is OK.
4） According to the main wiring diagram and protection configuration, confirm current
increase path.
5） Set reliable three path short current point at the suitable position in the switchyard.
6） Confirm the anti-pump device of the circuit breaker and isolating switch according to
current increase circuit.
7） Input generator protective relay, automatic device, main transformer cooling device,
control signal circuits.
8） The excitation is also adopt separately excitation model
4.3.7.2 Start the turbine generator set by automatic model, and then closing the field circuit
breaker after all are ok
4.3.7.3 Increase current to 10% manually; check the CT secondary circuit current, wiring,
meter indication in the short circuit area.
4.3.7.4 Increase current continually, check the correct of protection set-point and action, and
draw the current phasor diagram of the main transformer, busbar differential protection,
wiring protection.
4.3.7.5 Check over, decrease excitation current, trip the field circuit breaker.
4.3.8 Generator-Transformer group and HV switchgear voltage increasing test
4.3.8.1Check before generator-transformer group and HV switchgear voltage increasing test
1）Generator circuit breaker, isolating switch, generator voltage equipment and HV
related equipment should be all test qualified and conditional for running.
2） Main transformer test is OK, oil level and tap switch are normal.
3） HV switchgear test is OK.
4） Input generator protective relay and switchyard equipment protection.
5） The excitation is also adopt separately excitation model
6） Confirm the voltage increasing path and switching according to the main wiring
diagram.
4.3.8.2 Start the turbine generator set by automatic model and all the conditions are ok, and
then close the field circuit breaker.
4.3.8.3 Start the excitation system by manual, increase the generator voltage 25%, 50%, 75%,
100%Un step by step, stay 30 minutes at each step, monitor the station service transformer
and main transformer condition.
4.3.8.4 Check the live line running condition of main transformer, station service transformer
and 132kV HV switchgear, etc.
4.3.8.5 Check the phase sequence and phase of the PT circuit and synchronization circuit;
make sure right wiring and measuring indication.
4.3.8.6 Check over, decrease exciting voltage.
4.3.8.7 Simulate Turbine emergency shutdown.
4.3.9 Impact test for main transformer
4.3.9.1 Breaker and isolating switch for generator are opened.
4.3.9.2 Confirm the impact route and breakers for high voltage side of main transformer,
according to the main wiring.
4.3.9.3 Put the relay protection for main transformer and signal of controlling and protection
for cooling system on.
4.3.9.4 Put the neutral ground switch for main transformer on.
4.3.9.5 The line protection should be put on or off or setting temporarily according to the
system.
4.3.9.6 Put the fault recorder Oscillograph on.
4.3.9.7 The power transmitted to one side of breakers used for impact test in the switchyard
by power system.
4.3.9.8 Close the breaker; make the power system impact the main transformer 5 times,
interval is 10 minutes.
4.3.9.9 Inspect the main transformer, and pay attention to the actions of differentially
protection and buchholz protection.
4.3.10 Synchronization test of the water-turbine generator set
4.3.10.1 Check the synchronous circuit correct
4.3.10.2 Synchronization test for simulation:
1） Open the synchronization breaker and corresponding isolator.
2） Power will be transmitted to the synchronization breaker side of power system.
3） The generators will be started up to no-load condition, and the power will be
transmitted to the synchronization breaker side of generator
4） Do the synchronization test in manual and automatic model on unit and switchyard
LCU synchronization devices.
5） In automatic mode, the switching signal of breakers should be satisfactory and the
synchronization indicator is also correct by inspection.
4.3.10.3 Formal synchronization test
1）Open the breaker of synchronization，decrease the unit voltage and demagnetization
after finished simulation test
2）Close the isolator that opened during doing simulation synchronization test.
3）Increase the unit voltage again, do the formal synchronization test in manual and auto
using LCU devices on unit and switchyard
4.3.11 Load Test of Turbine Generator Set
4.3.11.1 Put generators, transformers, HV distribution devices and various line relay
protection and automatic devices into operation (it is executed as the notification in schedule),
the operation mode of switch station is executed as requirements in schedule.
4.3.11.2 Use the operator workstation or LCU to start unit automatically.

4.3.11.3 Put automatic synchronized device into operation, the unit paralleled to the grid is
implemented by the generator outlet circuit breaker.
4.3.11.4 Operate manually to make the unit be on-load step by step as 25%、50%、75%、100%
of PN, it should avoid unit vibration area.
4.3.11.5 Check the unit at load test
1）Check the unit vibration and swing value on various loads. If the swing value is too
large at load condition, dynamic balance should be executed.
2）Check the bearing bush temperature and the oil temperature of each bearing.
3） When the unit load is raising step by step，check the unit load vibration area at
current head.
4） Check the unit draft tube admission area at load condition.
5） Measure the water consumption flow on various loads, record water levels of
upstream and downstream.
4.3.11.6 Governor test at load condition
1） Use the method of adjustment test, choose the governor operational parameters in
condition of generator being on-load.
2） In the operation mode of generator being on-load, check the capability of governor
responding to the active power setting and the operational stabilization of governor.
3） In the operation mode of generator being on-load, check the correctness of AGC
function which is realized by the cooperation of the LCU and governor.
4.3.11.7 The excitation test at load condition.
1） In the operation mode of generator being on-load, check the regulation coefficient
polarity of field regulator.
2） When the active power respectively reaches to 0%、50%、100% of rated power,
adjust generator reactive load to rating, the adjustment should be uniform and not have jump.
3） Check the capability of excitation system responding to reactive power setting.
4） Check the setting value which is limited by the maximum and the minimal exciting
current of excitation system.
5） In the operation mode of generator being on-load, check the correctness of AVC
function which is realized by the cooperation of the LCU and the excitation device.
4.3.12 Load rejection test for turbine-generating unit.
4.3.12.1 The PID parameter of governor should be chosen at the best value confirmed by
no-load disturbing test.
4.3.12.2 Adjust the monitor meters well. The monitor items are vibration and swing of unit,
the pressure of penstock, the speed of Unit, the stroke of servomotors
4.3.12.3 All the protection relays and automatic devices have operated.
4.3.12.4 Parameters of auto-field regulator have been chosen at the best value.
4.3.12.5 The load rejection test should be finished for 4 times as rejecting 25%, 50%, 75%,
and 100 %(or maximum load of the current head ) of rated active load.
4.3.12.6 According to the testing record sheet of load rejection, the related value should be
recorded. The various parametric variation curve and procedural curve of transition should be
drawn at the same time.
4.3.12.7 When the turbine-generating unit rejected the load suddenly, the stability and
overshoot of the auto-field regulator should be checked. When the generator rejected the rated
active load, the overshoot of generator voltage should be not more than 15%-20% of rated
voltage; oscillating times should be not more than 3-5times, adjustable time should be not
more than 5s.
4.3.12.8 After the unit rejected load suddenly, the dynamic quality of governor should reach
the requirement as follows:
1） When the 25% rated load has been rejected, the dead time of servomotor should be
not more than 0.2s.
2） After the 100% rated active load has been rejected, the wave crest over the
steady-state more than 3% in the speed variation process should be not more than twice.
3） After the 100% rated active load has been rejected, the total time from servomotors
move to closed direction at the first time to oscillating value of unit speed are not more than
±0.5% should be not more than 40s.
4.3.12.9 The action situation of PRV should be noticed in the load rejection process, the
pertinent parameter of guide vane opening and others should be recorded, when PRV
operated.
4.3.13 The turbine-generating units run in test continuously for 72 hours with load
4.3.13.1 After all the above test have been finished and have been acceptance, the units have
had the condition for merging into electric power system with the rated load running in test
continuously for 72 hours.
4.3.13.2 At that time, under the head of maximum load continuous 72hours test run when
generator is paralleled in the grid by work station
4.3.13.3 According to the formal operation system on duty, the entire pertinent parameter of
the operation should be recorded.
4.3.13.4 If the units interrupted because of the problems of manufactured and installation and
quality of the units and Aux. equipments in the process for the running in test continuously
for 72 hours, restarted the running in test continuously for 72 hours after inspected and treated
for certified, the running time for the fore and after interrupted should not be accumulated.
4.3.13.5 After the units run in test continuously for 72 hours, the water in the penstock and
spiral case should be drained fully, the overflowing parts of units and hydraulic structure and
drainage system should be checked; the defects discovered by the running in test for 72 hours
should be slaked and treated.
4.3.13.6 After the units run in test continuously for 72 hours, stopped the units and treated the
entire defects, then open the units and removed to the operation company.
4.4 Multiple unit test

According to the contract agreement, carrying out the multiple unit test.
4.5 Stable and reliable operation test

According to the contract agreement, carrying out the Stable and reliable operation test.
4.6 Performance Tests

According to the contract agreement, carrying out relative performance test. These test will be
performed by manufactory and installation sub-contractor.

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Wampu 3x15MW Hydropower Project Installation for E&M

WAMPU HEPP PROJECT

1.Powerhouse Crane Installation............................................................... 4

2. Turbine-Generator Unit and its Auxiliary Equipments Installation ......10

3. Electrical Parts Installation ..................................................................45

3.1 Transformer Installation Scheme ..................................................................... 45

1.Powerhouse Crane Installation

Track foundation bolt

Track correction and installation

Track beam two-stage concrete

Metal structure main beam hoisting

End beam hoisting and connect main beam

Bridge crane trolley hoisting

Trolley equipment installation

Other accessories installation

Bridge crane test (no load, static load, dynamic load)

Figure1-1 Powerhouse Crane Installation Flow Chart

1.2 Crane Rail Installation

1.3 Crane Installation

1.4 On-site inspection & test

2. Turbine-Generator Unit and its Auxiliary Equipments Installation

Concreting for stay ring & Turbine-generator shaft coupling

Unit hand-turning and axis alignment

Main shaft seal installation

Unit dry test

Figure1-2 Turbine Installation Flow Chart

Turbine installation flow chart sketch is shown as Sketch 01-16

Sketch 01.Draft Tube Elbow Installation

Sketch 03.Stay ring installation.

Sketch 04.Spiral Case assembling

Sketch 05.Pit Liner assembling.

Sketch 06.Spiral Case reinforcement.

Sketch – 07.Spiral Case Embedded parts concreting.

Sketch – 10.Runner and Shaft installation.

Sketch – 11.Wicket gates installation.

Sketch – 12.Turbine head cover assembling and upper bushings installation.

Sketch – 13.Regulating system assembling &Turbine and generator shaft coupling.

Sketch – 14.Shafts Run Out

2.1.2 Draft Tube Elbow Installation

2.1.3 Draft Tube Cone Installation

2.1.4 Stay Ring and Spiral Case Installation

2.1.6 Runner Installation

2.1.7 Turbine Main Shaft Installation

with hydraulic tensioning device to meet design requirements.

2.1.8 Servomotor Installation

2.2 Generator Installation Scheme

The Generator Installation Flow Chart is shown as Figure 1-3,

2.2.2 Generator Installation Flow Sketch

The Generator Installation Flow Sketch is shown as Sketch #1 - #8,

Stator sole plate installation

Rotor rim cleaning and inspection

Pole joints connection

Rotor electrical test and painting

Rotor lifting device installation Stator high voltage test

Upper bracket hoisting and installation

Upper bracket installation

Thrust bearing installation and adjustment