ZUNGERU HYDROELECTRIC POWER PROJECT

CNEEC-SINOHYDRO CONSORTIUM

Unit wet commissioning procedure

Doc No.：R-ME-HC-S-032
Rev. No.: 0

Document preparation, review, approval and acceptance:

Position Name Date Signature

Prepared: Engineer Mr. Zhu Lijin 2022-01-08

Reviewed: Engineer Mr. Wei Xin 2022-01-08

Approved: Deputy Project Manager Mr. He Sai 2022-01-08

Document Revision Table:

Date Rev. No. Description of modifications / revisions

2022-01-08 0 First Submission

 目 录 Contents
1 GENERAL ......................................................................................................................................... 2
1.1 Purpose ....................................................................................................................................... 3
1.2 Reference standard ..................................................................................................................... 3
1.3 Test items ................................................................................................................................... 3
1.4 Pre-conditions of Starting up and wet commissioning ............................................................... 4
1.5 Organization and discipline ........................................................................................................ 6
1.6 Safety measures and precautions ................................................................................................ 6
2 INSPECTION BEFORE WET COMMISSIONING ......................................................................................... 7
2.1 Inspection of intake gate and draft gate...................................................................................... 7
2.2 Inspection of turbine section ...................................................................................................... 7
2.3 Inspection of generator section .................................................................................................. 7
2.4 Inspection of oil, air and water system ....................................................................................... 8
2.5 Inspection of electrical equipment ............................................................................................. 8
2.6 Inspection of fire-fighting system and equipment ...................................................................... 9
3 UNIT WET COMMISSIONING ................................................................................................................ 9
3.1 UNIT WATER-FILLING TEST .............................................................................................................. 9
3.1.1 Draft tube water filling ......................................................................................................... 9
3.1.2 Penstock and spiral case water-filling ................................................................................... 10
3.1.3 Unit cooling water and main shaft sealing water supply water-filling .................................. 10
3.2 Unit first start-up by manual .................................................................................................... 11
3.3 Unit first time manual starting up and bearing pad temperature stabilization test ................... 12
3.4 Measure Unit vibration and swing ........................................................................................... 13
3.5 Manual stopping ....................................................................................................................... 14
3.6 Unit mechanical over-speed test............................................................................................... 14
Unit Operating Sequences according to D-ME-EII-01-01-60~69.................................................. 15
4 GENERATOR ELECTRIC TEST ........................................................................................................... 16
4.1 Generator short circuit test ....................................................................................................... 16
4.2 Generator Open circuit ( Raising voltage) test ......................................................................... 17
5 TEST ON MAIN TRANSFORMER .......................................................................................................... 18
5.1 Current rise of main transformer, ............................................................................................. 18
5.2 Commissioning of excitation device under no-load ................................................................. 19
Refers to document: R-ME-HC-S-018 Commissioning procedure of Excitation system ........... 19
5.3 Raise Voltage Test for Main Transformer and 400kV over head line ....................................... 19
5.3.3 1# main transformer power charger. ...................................................................................... 20
6 UNIT CONNECTION WITH GRID AND LOAD REJECTION TEST.............................................................. 20
6.1 Test of turbine-generator connection with grids ....................................................................... 20
6.2 Unit On load test ...................................................................................................................... 20
6.3 Load rejection test (25%, 50%, 75% and 100%) ...................................................................... 21
6.4 Governor and excitation test under load ................................................................................... 21
6.5 Simulate unit emergency stop .................................................................................................. 21
6.6 Unit heat-run at rated output .................................................................................................... 21

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1 General
General description :
There are four (4) vertical shaft Francis turbine-generators to be installed for the
Nigeria Zungeru hydroelectric project with a total capacity of 700MW. The units are
manufactured by GE hydro power (China),the type is vertical shaft, half-umbrella
type, three- phase generator set. The rated water head is 91.0m and the speed of the
unit is 107.1r/min. Power plant generating system will be arranged at left bank. The
Powerhouse, main transformer chamber and draft tube gate chamber shall be assigned
in parallel. The Powerhouse consists of control a building, main erection bay, unit
section and auxiliary powerhouse. The power plant will connect with the power grid
by the Zungeru 330kV switchyard.
Main Characteristics of Unit
➢ Turbine
Type HL(ZGL)-LJ-528
Max. Head 96.501 m
Rated Head 91.0 m
Min. Head 72. 0 m
Rated Output at Rated Head 183.76 MW
Rated Rotating Speed 107.1 r/min
➢ Generator
Type SF177.3-56/12740
Rated Power 177.3 MW
Rated Capacity 197.0 MVA
Rated Voltage 16 kV
Rated Current 7108.6 A
Rated Power Factor 0.9（Lagging）
Rated Frequency 50 Hz
Rated Rotating Speed 107.1 r/min

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 1.1 Purpose
This manual intends to specify the procedure for starting each unit after water filling
in order to:
1) Verify fabrication and installation quality of each installated equipment of
Zungeru Hydroelectric Project;
2) Verify correctness of relay protection, automatic control, measuring device and
related electric return circuit and electrical equipment.
3) Put each unit into normal operation.
1.2 Reference standard
IEC 60034-4 Methods for determining synchronous machine quantities from tests
IEE Std 115 IEEE guide for test procedure for synchronous.
DL/T 507 －2014 Start-up test code for Hydro-generating units
1.3 Test items
□ Water-filling of draft tube
□ Water-filling of penstock
□ Unit cooling water and main shaft sealing water supply water-filling
□ First time start and stop the unit manually
 Rotor dynamic balance test (if need)
 Bearing heat-run test
□ Unit over-speed test
 Governor system tests during no-load commissioning
□ Unit automatic start up and stop test without excitation
□ Generator 3-phase short-circuit saturation test
□ Generator open circuit saturation test
 Generator current rise test with the main transformer
□ Excitation system no-load test
□ Generator step-up voltage test with the main transformer
□ Unit automatic start up and stop test with excitation
□ Generator synchronize test
 Unit load test
□ Unit load rejection test

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□ Unit Trail Operation
□ Unit take over
1.4 Pre-conditions of Starting up and wet commissioning
1) Before starting wet commissioning of each unit, installation and dry
commissioning of each subsystem shall have been finished.
Each subsystem include as below:
➢ Unit DC 110V distribution panel
➢ Unit UPS AC 230V power panel
➢ Unit AC 415 V power system
➢ Unit LCU system
➢ Generator protection、 main transformer protection system and fault recorder
panel
➢ Governor System
➢ Excitation system
➢ Unit online monitoring system
➢ Unit instrument cubicle
➢ Unit temperature measuring and unit braking cubicle
➢ Generator Auxiliary Equipment Control cubicle
➢ Unit head cover drainage control system
➢ Unit condenser dewatering control system
➢ Unit cooling water system
➢ Generator IPB and generator neutral grounding system
➢ Generator Circuit Breaker
➢ Unit cooling water supply and main shaft seal water supply system
➢ Unit CO2 fire extinguishing system
➢ Main transformer
➢ Main transformer cooling water supply system
➢ Main transformer water firefighting system
2) Common service system equipment for the power station has been installed,
commissioned and passed the inspection. All equipment is in the normal working

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 state. The specific items are to be identified as below:
➢ Powerhouse dewatering drainage and Leakage drainage system
➢ Low pressure air system
➢ Medium pressure air system
➢ Unit condenser air system
➢ Common DC 110V system
➢ Common AC 415V system
➢ Powerhouse 11kV system
➢ Diesel Generator system(if needed)
➢ Central control room Computer monitoring system
3) The installation of all HSS gates is complete.
➢ Commission of Draft tube gates finished
➢ Commission of Intake service gates finished
4) The installation of all Unit mechanical equipment is complete.
➢ Generator and accessory installation finished.
➢ Turbine and accessory installation finished.
➢ Mechanical auxiliary equipment installation finished.
➢ All the air system air pressure is normal.
➢ All the bearing sump oil level is correct.
➢ All the water system is ready for water filling.

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 1.5 Organization and discipline

Commission manager

Chief Engineer Commissioning Coordinators Safety officer

leader

Commissioning Electrical Mechanical manufacturer

Engineer Engineer Engineer commissioning Engineer

Commission manager: In charge of the whole commission activity, decision maker for
the whole commissioning activity, coordinate between the commissioning managers
and coordinators, chief engineer and safety officers.

Commission leader: In charge of the subsystem commission activity, follow the order
from the commission leader and organize its own commission team commissioning
activity.

1.6 Safety measures and precautions

1) Communication during the test process must be free and unblocked.
2) During the test, specialized persons shall be assigned in to the turbine room,
generator room, unit control room and main transformer, in order to monitor the
working situation of all equipment.
3) During the voltage rising and loading process, the specialized person shall be
assigned to monitor charged part and inform the commander when finding an
abnormal situation in order to take emergent measures.
4) During testing, all personnel shall keep a safe distance with charged equipment.
5) During testing, workers within the construction area are not allowed to cross the
screen or fence to enter into the commissioning area. Equipment and areas under
operation shall be provided with related safety warnings;

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6) Personnel engaging in commissioning shall be familiar with test contents and
requirements, as well as make all preparation in advance. During testing,
personnel shall inform the commander once finding abnormal situation and stop
the test at once. The Test will be restarted after technical staff treat and solve the
problem.

2 Inspection before wet commissioning

2.1 Inspection of intake gate and draft gate
1) Unit intake maintenance gate is open.
2) Unit intake service gate is fully closed, and power off.
3) The mandoor of the spiral case is fully closed.
4) The mandoor of the draft tube is fully closed.
5) The draft tube gates of unit 1~4 have been installed and the Tailrace gantry crane
commissioning test is finished, and all these gates are closed.
6) Draft tube water filling value should be closed.
2.2 Inspection of the turbine section
1) Turbine runner and all components、head cover and wicket gates have been
installed.
2) Turbine guide bearing has been installed, and turbine bearing oil sump oil level is
normal.
The Lubrication and cooling system of guide the bearing are qualified by
inspection.
3) Distributor has been installed and the wicket gate are in the closed state. The
Servomotor lock should be in the lock position.
4) All the hydraulic measurement measuring device, pressure meter, pressure
transducer have been installed.
5) Governor oil pressure system oil pressure is normal, the oil level is normal.
6) Governor system has been completed installed, and dry commissioning has been
completed.
2.3 Inspection of generator section
1) Air gap of the generator has been checked and no sundries were found.

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2) Generator has been completely installed. The Generator interior has been cleaned
and no sundry remains in clearance between stator and rotor.
3) Upper guide bearing、thrust bearing, and lower guide bearing installation have
already been finished, such as oil level is normal.
4) Operation of generator braking system have been checked, The operation is
normal. The Air brake is in the braking state before water filling.
5) Air cooler for the generator has been installed.
6) All indicators used for measuring generator working condition, as well as
vibration, swing pick-ups have been installed and commissioned to be qualified.
7) Excitation system has been completely installed and commissioning completed
2.4 Inspection of oil, air and water system
1) The oil sumps of each guide bearing and thrust bearing have normal oil level, as
well as governor oil tank;
2) Cooling water system and main shaft seal water system have all been
commissioned and qualified, and which is under normal operation;
3) PH dewatering and drainage water systems commissioning are finished. Drainage
and dewatering systems are both under auto operation mode during the unit water
filling;
4) The middle pressure air supply and low-pressure air system have already been
installed and finished the commissioning. The middle pressure air system and
low-pressure air system are put into auto operation mode.
5) The Unit condenser air supply system has already been installed and passed the
commissioning. The middle pressure air system and low-pressure air system are
put into auto operation mode.
2.5 Inspection of electrical equipment
1) The installation of IPB and CT has been completed, as well as generator neutral
device.
2) Generator circuit breaker and disconnect switch have been installed and finished
the commissioning, and which are ready for energization.
3) Main transformer and neutral point equipment have been installed and passed

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 through the test. The Oil cooling system is qualified by commissioning and is
ready for energization.
4) The diesel generator has been installed, and finished the commissioning. It has
been put into normal operation.
5) Common LCU has been completely installed and commissioned.
6) Unit LCU has been completely installed and commissioned.
7) Central control room operation station has been completely installed and
commissioned.
8) Main transformer & generator protection shall be completely installed and
commissioned.
2.6 Inspection of fire-fighting system and equipment
1) The installation and commissioning were completed for unit firefighting;
2) The installation and commissioning were all finished for main transformer
firefighting;
3) Required temporary fire extinguisher has been allocated.

3 Unit wet commissioning

3.1 Unit water-filling test
3.1.1 Draft tube water filling
1) Check list before draft tube water filling
➢ Draft tube water filling valve is closed；
➢ Unit draft tube gates are closed；
➢ Draft tube dewatering disc valve is closed；
➢ Connecting valve between the spiral case and the draft tube is closed；
➢ Draft tube manhole should be closed；
➢ Spiral case manhole should be closed；
➢ Cooling water system main inlet valve and main outlet valve should be closed.
➢ Cooling water of HVAC main inlet valve and main outlet valve should be closed.
➢ The main shaft maintenance seal of the turbine is applied.
➢ Unit brake is applied.

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➢ Open wicket gate 3％-5％ for exhaust air.
➢ Head cover drainage pump should be in auto work mode.
➢ Dewatering and drainage should be in auto work mode.
2) Open filling water valve of draft tube slide gate and fill water into the draft tube.
During the water filling, the head cover, distributor, main shaft seals, pressure
measuring piping, draft tube mandoor, spiral case mandoor etc. shall all be under
continuous observation, there shall be no abnormal phenomenon. The water
filling shall be stopped immediately if water leakage is detected. Measures shall
be taken if there is leakage, and the draft tube shall be emptied if necessary.
3) Open two sets of draft tube gates after 12 hours of water filling finished. And then
record the pressure values of the draft tube, spiral case, etc; close the water filling
value. Close wicket gates and put servomotor locking in;
3.1.2 Penstock and spiral case water-filling
1) Check list before draft tube water filling
➢ Draft tube gates are fully open；
➢ The main shaft maintenance seal of the turbine is applied.
➢ Unit brake is applied.
➢ Wicket gate is fully closed, and severmotor is locked in position.
➢ Head cover drainage pump should be in auto work mode.
2) Open the water filling valve and fill water into the penstock. Record the starting
time;
1) Check if the mandoor of penstock has water leakage, and monitor the water level
behind the penstock wheel gate;
2) After the pressures are balanced by water filling, record the water filling full time,
keep water pressure 12hours;
3) Open the unit intake gate;
4) During the water filling, it should be stopped once abnormal occurs during the
test. Whether need to dewatering according to site actual situation, Test can be
re-continued after repairing.
3.1.3 Unit cooling water and main shaft sealing water supply
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water-filling
1) Open the cooling water system main inlet valve and main outlet valve；
2) Open the motorized valve，each branch cooling water and main shaft water filling，
check the water pipe whether leakage point；
3) Operation the water filter with water；
4) Adjust each branch water pressure and water flow，the water flow should meet the
design value；
5) After adjusting，all the manual valves should be in the normal position.
3.2 Unit first start-up by manual

3.2.1 Start-up condition list

1) Governor system is in local and electrical manual mode, Servomotor locking is

applied. Governor oil pressure system in auto control mode, oil pressure and oil
level are normal. Guide vane is fully close. And the governor is no fault.
2) Confirm excitation system out of service.
3) Brake air source pressure is normal and the brake is on the position in electrical
manual control mode.
4) Check upper guide bearing oil level is normal, and check combination
(lower-thrust) guide bearing oil level is normal. and check turbine guide bearing
oil level is normal.
5) Check upper guide bearing pad temperature is normal, and check lower guide
bearing pad temperature is normal, and check thrust bearing pad temperature is
normal, and check turbine guide bearing oil level is normal. All bearing sump
tank oil temperature is normal.
6) The unit two draft tube gates are fully open.
7) The intake service gate is fully open, and work at remote control mode.
8) GCB is open and disconnect switch is also open;
9) Head cover drainage pump is in service position and automatic working mode.
10) High and low pressure air systems are in the auto working state.

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11) Maintenance shaft seal is applied;
12) All LCU protection is in service.
13) Ensure and remove the flexible connection between the excitation transformer
and IPB.
14) Generator outlet PT cabinet is in the working position.
15) Ensure and pull out slip ring brush.
16) The internal of the unit is clean, it has completed check. And check all the unit
rotational part and ensure there is no foreign matter in the unit;
17) Unit on-line monitor system should be in service;
18) Temporary Install frequency meter, the voltage from the primary side of generator
PT to monitor the speed.
19) Middle pressure air system should be worked in auto, low pressure air system
should be working in auto.
20) Dewatering and drainage system should be worked in auto.
21) Jack up the rotor by high pressure oil pump, and form on oil-bound film between
the thrust bearing and the thrust runner. After releasing oil pressure, operation the
brake for 3~4times, check if all the brakes have been fully dropped down.

3.3 Unit first time manual starting up and bearing pad

temperature stabilization test
1) Unit creep device is out of service
2) Brake released operation, and check brake off position.
3) Maintenance seal released operation and check maintenance seal have no
pressure;
4) Start unit cooling water supply and check if the water flow is normal.
5) Start unit main shaft seal water supply, and check the water flow.
6) Pull out the servomotor lock and check it is in the lock out position.
7) Electrical manual open the wicket gate slowly and fully close wicket gate once
unit start rotation, then units will be sliding, monitor if the unit has abnormal. If
there is no abnormal was detected, the next step could be continued, and once

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 abnormal is detected, brake shall be activated for the shutdown of the unit, and
then inspection shall be done after the unit is stopped.
8) Increase wicket gate opening and increase unit speed slowly. Keep the unit
rotation speed at around 10% rated speed for a short time for the confirmation of
no abnormal. And if it is normal, the next step could be continued; if it is not
normal, unit shall be stopped for inspection.
9) Once it is confirmed that there is no abnormal was detected, it shall increase the
unit speed by manual with the step of 25%nN,50%nN,75%nN and100%nN. Then
check the bearing pad temperature and unit swing and vibration value. If the unit
swing and vibration value is meet the design requirements, then the unit shall be
run until the pad temperature is stable.
10) Start generator oil fog eject device.
11) Record guide vane opening at 100% nN.
12) After the unit arrived at the rated speed, the pad temperature shall be recorded
every 10 minutes until the pad temperature is stable. The pad temperature
increase curve shall be drawn. Observation of bearing oil level shall also be done.
After the temperature of bearings pad are stable(temperature rise is less than 1℃
/hour).
13) During the unit startup process, speed rising can only be allowed when all
sections are free of the abnormal situation. In case discovering water or bearing
bush of turbine chamber suddenly gets warming-up, unit swing get over-large or
other problem, it shall give the order to stop the unit immediately.
14) Record the meter readings of the hydraulic measuring system and unit on-line
monitoring devices after the unit reached rated speed.
15) Measure generator primary residual voltage and phase sequence when unit
reached rated speed. The Phase sequence shall be correct.
3.4 Measure Unit vibration and swing
Measure Unit vibration and swing of all bearing and bracket and head cover, if
the value is high than the standard GB8564-2003, Then it is necessary to carry out a
dynamic rotor balance test, if the value is less than the standard value, it is no need to

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do dynamic rotor balance.
3.5 Manual stopping
1) Fully close the wicket gates
2) Apply servomotor lock in.
3) When unit speed reduced to less than 20% nN，start the break dust collector, and
brake on.
4) When unit speed is zero, the unit is fully standstill.
5) Stop cooling water supply;
6) Stop unit main saft seal water supply
7) Maintenance seal apply on.
8) Stop generator oil fog eject device.

3.6 Unit mechanical over-speed test

1) Start the unit by electrical manual and runs until bearing pad temperature is stable,
or do the over speed test after the bearing pad temperature stabilization test
2) Disconnect other electrical over speed signal, connect to LCU spare input.
3) Increase the opening of the wicket gate, Raise the unit speed to 145%nN, check
the signal of command for emergency shutdown, and record the vibration and
swing value. When the speed is reached to 145%nN, then the over speed device
will act, the unit will be emergency stopped. During the speed raising process,
check the other electrical over speed signal.
In case the mechanical over-speed device does not act when over-speed reaches
the setting values, the operator shall press the emergency stop button on the
governor control panel to stop the unit.
4) During the over-speed test, a specialized monitor person shall be assigned in the
generator pit and turbine pit, to monitor the generator and turbine. If there is an
abnormal condition, we will stop doing the over speed test.
5) After the over-speed test and the unit is fully stopped, an overall inspection shall
be made to check if the generator and rotor fixed part and rotating part has
abnormal.

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6) Recover electrical over-speed protection circuit.
3.7 Governor system tests during no-load commissioning
Refers to document: R-ME-HC-S-020 Governor system commissioning
procedure
3.8 Unit automatic start up and stop test （from standstill to idle state）
Unit Operating Sequences according to D-ME-EII-01-01-60~69
1) First time unit automatically starting up and automatic shutdown test shall be
carried out by computer monitor system after confirming all unit protection
circuit have been activated. Check if the circuit for automatically start and
automatic shutdown is correct.
2) During the automatic starting up process, it shall record and check the following
items:
⚫ Check if the automatic element operates correctly and whether the sequence
of unit automatic starting is correct.
⚫ Check the duration between the sending of startup command and unit reaches
rated speed.
⚫ Check governor working condition.
⚫ Check all the auxiliary system auto control follow the unit operation
sequence.
3) Inspection items during and after unit automatic shutdown:
⚫ Record the duration from sending shutdown command to unit total stop;
⚫ Record the duration from brake activated to unit shut down completely；
⚫ Brake can be relieved automatically after the unit is totally stopped.
4) Automatically start and automatic shutdown test by computer control and
monitoring system in the central control room can be conducted combining with
subsequent tests.
5) Simulate 1 time accident stop the unit.
6) Simulate 1 time emergency accident stop the unit.
7) Record the time of unit start and unit stop and unit braking.

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4 Generator electric test
4.1 Generator short circuit test

4.1.1 Preparation

1) Check the insulation resistance of the stator and rotor.

2) Installation three phases Short-circuit bar at reserved short circuit point on IPB
(short-circuit position shall be located at the outlet side of Generator CT)
3) Generator protection shall be applied according to requirement. Generator over
current protection should be in service, Differential current protection should be
out of service.
4) Confirm secondary side of all CT current circuit has no open circuits.
5) Separately power supply for excitation has been properly prepared.
6) All unit mechanical protection should be in service.

4.1.2 Rising the generator current from zero

1) Auto start up the unit and keep unit rotation with rated speed without excitation.
2) Switch governor to electrical manual control mode.
3) Close excitation switch by manual and increase stator current by 5%IN， and check
the current and phase sequence of all the CT circuits, take records. Make sure that
all the CT current circuits are normal during the rising of the current.
4) Increase stator current slowly with steps of 25%, 50%, 75% and 100% to check
correctness and symmetry of current circuits within the increasing range. Check if
the connection of generator differential protection current circuit is correct or not;
5) Generator short circuit characteristics:
⚫ Increase the stator (as 10%IN) current gradually to 110%IN and then decrease
it with 10% IN as a grade. Record the stator current and corresponding rotor
current and draw the curve of generator short circuit characteristic.
⚫ Check the working condition of the carbon brush and collecting ring during
current rising.

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 ⚫ During current rising, it shall monitor if generator outgoing lead and the
frame closed to short circuit point have spark or over-heat phenomenon.
⚫ Draw up generator short circuit characteristics
6) Switch governor to auto and remote control mode Auto stop the unit.
7) Dismantle generator three-phase short circuit plate.
4.2 Generator Open circuit ( Raising voltage) test
1) Pre-conditions of generator raising voltage test:
⚫ GCB is in the open position.
⚫ All the generator electrical protection should be in service.
2) Start the unit by manual to the rated speed. Measure the residual voltage of the
secondary side of the generator PT.
3) Raise the stator voltage from zero with steps of 25%Un、50%Un、75%Un、
100%Un. Record following items during the voltage rising process.
⚫ Different phases PT secondary side voltage shall be balanced within
voltage rising range, voltage value and phase sequence shall correct.
Measure the outlet triangle output voltage value.
⚫ Check if the generator and relatively high voltage equipment (i.e: IPB,
neutral grounding equipment) are operating normally.
⚫ Check if vibration and swing are normal during operation
4) Generator open circuit characteristics:
Increase voltage by every 10%Un from 0 to 110%Un, decrease voltage by
every 10%Un from 110%Un to 0, Record generator no-load characteristic curve. Read
and record all excited current and stator three phase voltage value.
5) Disconnect excitation switch at 50%、100% rated voltage respectively. Then
check arc extinction and record the data of no-load excitation characteristic.

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5 Test on the main transformer
5.1 Current rise of main transformer,

5.1.1 Preparation before the current rise

1) Current and voltage rising tests for the generator have been completed.
2) Activate all generator protection, main transformer protection.
3) Check all transformer CT circuits, all the circuits should be closed.
4) The Main transformer has been installed and qualified after inspection. The Main
transformer is ready for energized condition.
5) Unit GCB and DS are in the closed position, the anti-tripping measure shall be
carried out (switch off its control power supply);
6) Short circuit position: three phase of 1TES should be in the closed position. (the
first ES of main transformer high voltage side , control power MCB of 1TES
should be in off position )

5.1.2 Current rising test for the main transformer

1) Automatically start up the unit to rated speed.

2) After startup, runn the units stably for 20min, then conduct the main transformer
raising current test.
3) Close GCB and DS, and disconnect its control power supply;
4) Close FCB;
5) First check the main transformer CT secondary side value, if the value is too
small,
6) Increase current 5%IN, check all the transformer low voltage CT and high voltage
CT secondary side value. The value should be right, the current phase angle
should be right.
7) Increase current to 15%IN, check all the CT value and phase angle again.
8) Check generator differential protection value;
9) Decrease excitation current and open FCB after the test is completed.

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10) GCB control power should be on after the test,

11) Open the 1TES earthing switch.

5.2 Commissioning of excitation device under no-load

Refers to document: R-ME-HC-S-018 Commissioning procedure of
Excitation system

5.3 Raise Voltage Test for the Main Transformer and 400kV
over head line

5.3.1 Preparations before the voltage increasing

1) Activate generator protection, main transformer protection, should be in service.

2) All the ES in switchyard are open;
3) 1TDS is closed, and 1MDS1 is open, and 1MDS2 is open.

5.3.2 Voltage test for main transformer and overhead lines

1) Auto start the unit to idle state.

2) Close GCB, and measure the secondary side voltages of all PT inside of the
circuit.
3) Excitation work in manual mode.
Rising generator voltage gradually by manual and check the service condition of
primary equipment (the energized conditions of IPB、main transformer and
overhead lines) at 25%、50%、75%、100%UN respectively. Check the operating
situation of the charged main transformer. It should be kept for 10min at each
voltage grade, Check the amplitude and phase of each voltage circuit;
4) Check synchronism voltage in the LCU panel.(frequency, voltage and phase
angle ).
5) Disconnect GCB after the excitation current decreases to 0;

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 5.3.3 1# main transformer power charger.
（1） All transformer protection shall be commissioned and parameters
shall be set.
（2） Remote close 1# main-transformer high voltage side DS 1TDS,
（3） 1GCB is in the open position.
（4） Remote close 1# main-transformer high voltage side CB, charger
1#main transformer, each time energized for 10min, and de-energized
for 10min.
（5） Check the main transformer charge situation.

6 unit connection with grid and Load Rejection Test

6.1 Test of turbine-generator connection with grids
1) Before and during the synchronism test, check the voltage, phase and frequency
at both unit and grid side; the Unit is in the no load state.
2) Synchronism test: The unit LCU sends out a generation command and the
synchronism device will compare the voltage phase and frequency at the unit and
grid side. When the voltage value difference and phase angle value and frequency
difference are less than the setting values of the synchronism device, the device
will close GCB automatically, and the synchronism is successful.

6.2 Unit On load test

1) Unit start up and connected with the grid；
2) Carry out loading test in steps at unit LCU and center control room separately:
Gradually increase the unit active load to check vibration, swing and temperature
variations of the unit;
3) Inspection items for Unit running with load:
⚫ Check the generator protection, main transformer protection and 330kV
switchyard protection voltage value and current value.

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 6.3 Load rejection test (25%, 50%, 75% and 100%)
The unit shall be subject to load rejection test at P=43.75MW, 87.5MW,
131.25MW and 175MW; the unit should run for 15 min at each load point.
Unit 1 GCB shall be used for load rejection;
During the load rejection, the following data shall be recorded (before rejection,
maximum during rejection, and stabilities).
⚫ Unit voltage、current、active power、inactive power，frequency;
⚫ swing values of every bearings, the vibration of each position and opening of
wicket gate;
⚫ Bearing pad temperature;
⚫ Record the variations of voltage, frequency, wicket gate openness and spiral
case pressure;
⚫ During load rejection, record the regulation amount of generator voltage,
times of oscillation, and regulation time;
⚫ After load rejection, take unit speed variation process, pendulum value of
servomotor, and the time that servomotor is out of action;

6.4 Governor and excitation test under load

1) Governor system test on load: Refers to document: R-ME-HC-S-020 Governor
system comm5issioning procedure.
2）Excitation system test on load: R-ME-HC-S-018 Commissioning procedure of
Excitation system.

6.5 Simulate unit emergency stop

When the Unit is in a full load, push the unit LCU emergency stop button, the
unit should be stopped according to the emergency stop sequence.

6.6 Unit heat-run at rated output

When the water head reaches the rated water head, the unit heat-run test will be
carried out, the temperature will be stable, which means the value of temperature
rising ≤1℃ in one hour.

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