附件2典型出口发电机项目文件ge0试验程序

1、GE NuovoPignone - Electronically Approved Drawing - Checked: H L G.; Approved: Chiarlitti M. - Internal DT-'N'Generator Test ProceduresProject: MEGHA CSP - INDIAManufacturer: Nanyang Explosion Protection Group Co.,.PO: 439763073GE job number: 1908191-92 Nanyang job number: 12K6Q002B Document

2、 code: SOK0895374Nanyang document code: HT12W098-23TITLEGenerator test proceduresDOCUMENT CODESOK0895374REVISION0REVISION DESCRIPTION: ISSUEDATE29-Apr-13APPROVED Electronically StoredSECURITY CODENCHECKEDElectronically StoredVENDOR SUPPLIED DRAWINGSCALEN/AREPLACES/DERIVED FROMN/A1st ISSUE29-Apr-13OR

3、IGINAL JOB1908191-92SIZE4LANGUAGEATHIS DOCUMENT IS FILED UNDER Nuovo Pignone S.r.l. DRAWING NUMBER. THIS DOCUMENT WILL BE REVISED N ITS ENTIRETY ONLY BY ORIGINATOR.Nuovo Pignone S.r.l. REVISION NUMBER MAY DIFFER FROM ORIG NAL TITLE BLOCK.SHEET1 of 50CUSTOMERMEIL GREEN POWER LIMITEDLOCALITA' - PL

4、ANT LOCATIONANANTAPUR, INDIAIMPIANTO - PLANSOLAR POWER PLANTNuovo Pignone S.r.l. REVISION NUMBER MAY DIFFER FROM ORIG NAL TITLE BLOCK.ContentPart 1: Test procedure of main generatorPart 2: Test procedure of generator excitation panelPart 3: Test procedure of line side cubicle & neutral side cubi

5、cleTITLE:Generator test proceduresDOCUMENT CODESOK0895374REVISION7REVISION DESCRIPTION: REVISEDPAGE MARKERN/ASECURITY CODENORIGINAL JOB1908191-92SIZE4LANGUAGEATHIS DOCUMENT IS FILED UNDER Nuovo Pignone S.r.l. DRAWING NUMBER. THIS DOCUMENT WILL BE REVISED N ITS ENTIRETY ONLY BY ORIGINATOR.SHEET2 of 5

6、0Part 1:Test procedure of Main generatorTITLEGenerator test proceduresDOCUMENT CODESOK0895374REVISION7REVISION DESCRIPTION: REVISEDDATE12-Apr-13APPROVEDSECURITY CODENCHECKEDVENDOR SUPPLIED DRAWINGSCALEN/AREPLACES/DERIVED FROMN/A1st ISSUE18-Oct-12ORIGINAL JOB1908191-92SIZE4LANGUAGEATHIS DOCUMENT IS F

7、ILED UNDER Nuovo Pignone S.r.l. DRAWING NUMBER. THIS DOCUMENT WILL BE REVISED N ITS ENTIRETY ONLY BY ORIGINATOR.Nuovo Pignone S.r.l. REVISION NUMBER MAY DIFFER FROM ORIG NAL TITLE BLOCK.SHEET3 of 501.Scope of applicationThe test procedure is applicable to 12K6Q0002B / QFW55-2 / 3-phase synchronous g

8、enerator.Test procedure of generator excitation panel and generator main terminal boxes as per Part 2 & Part 3.2.Test conditions & test preparation2.1Basic Test conditions2.1.1Accuracy of winding DCmeasuring instrument shall be at least grade 2; Max. Allowanceallowed for temperature detector

9、 shall be ±1.2.1.2Instruments and their ranges shall be selected properly according to actual need.2.1.3The selection of range shall make the measured value stands within 20% to 95% of their max. range.2.2Preliminary work before tests2.2.1The operators must be familiar with relevant rules and r

10、egulations for safety operation.2.2.2The operators must be familiar with purpose, requirements, methods, procedure and some other points of attention of test.2.2.3Everyone shall has clear responsibility and cooperate with each other during test.2.2.4Before test, the instrument, test equipment, switc

11、h, protection device, measuring instrument shall be in good order, the specifications shall be suitable, and the regulation device shall in correct position. The operators shall know in advance how to use and regulate these instruments.2.2.5The positions of instruments and equipments shall be taken

12、into consideration before wiring in order to make the line simple, reasonable, and convenient for regulating and reading. The main circuit shall be connected first and then for the other loops. The section area of the wires shall be chosen according to their corresponding currents.2.2.6It is not all

13、owed to switch on without permission of the test director.2.2.7Lubrication oil should be checked prior to testing, and bearing bush will not be dismounted for inspection after test.1. 适用范围本试验程序适用于 12K6Q0002B QFW55-2 三相同步发电机。2. 试验基本条件和试验前的准备2.1 试验基本条件2.1.12.1.2绕组的直流电阻测量仪准确度应不低于 0.2 级，温度测量仪的最大合理选择仪表、仪

14、器及其量程。误差为±1。2.1.3仪表的选择应尽可能使所测数值在 20%95%仪表测程范围内。2.2 试验前的准备工作2.2.1必须了解试验区的安全操作细则及有关规章制度；2.2.22.2.3必须了解试验目的、要求、方法和步骤以及一些注意事项；试验中要分工明确，操作中互相配合并各负其责；2.2.4检查仪器、仪表、试验设备、开关、保护装置、检测仪器是否完好，规格是否合适，调节设备是否在正确位置，预先了解仪器、仪表设备使用及调节方法；2.2.5 接线前应考虑仪器、仪表及设备位置，力求线路简单，合理，保证调节和读数方便；先接主回路再接其它线路，接线时应按电流大小选择导线；2.2.6 试验前

15、主试检查，不得闭合电源开关。2.2.7 试验前对润滑油质进行检查，整机试验完成后不再拆开轴瓦检查。3.Main machine data, lube oil data and cooling system data主发电机数据，油站数据和冷却系统数据3.1Generator dataManufacturer & Type Frame Size & Shaft HeightRatedpower32° temperatureLagging power factor Leading power factorNANYANG, QFW55-2 BTA90-24W, 1575mm

16、65000 kVA (55.25 MW 32O C cooler water inlet temperature)0.850.95 as minimumCwaterdesignNote: It is requested that t factor at rated MWRated voltageerator must be capable of providing 0.95 lagging power11000 V (tolerance acc. to IEC34-1 figure 11 Zone A)50 Hz (tolerance acc. to IEC34-1 figure 11 Zon

17、e A)3412 AAs per <HT12W098-2 Generator Characteristic Curves & Data_Rev 1>3Left Right 23000 rpm3600 rpmRated frequencyRated currentOutput power curveversuscoolanttemperatureNumber of phasesLocation of line leads (facing from LP-DE) Location of neutral leads (facing from LP-DE) Number of po

18、lesRated speedOver-speed主发电机数据供应商、型号南阳，QFW55-2 BTA90-24W, 1575mm65000 kVA (32 度进水温度下 55.25MW)0.85最小 0.95机座号、中心高32 度进水温度下的额定功率滞后功率因数超前功率因数注：要求发电机在额定功率下提供 0.95 的欠励功率因数。11000 V （偏差参见 IEC34-1 表 11-A）50 Hz（偏差参见 IEC34-1 表 11-A）3412 A见HT12W098-2 发电机性能曲线及数据表_Rev 13额定电压额定频率额定电流输出功率冷却剂功率曲线用电线侧引线位置（从低压侧轴伸端看）左侧

19、中性点侧引线位置（从低压侧轴伸端看） 极数额定转速右侧23000 rpm3600 rpm超速3.2Lube oil systemOil typeSupply temperature max /normal /min Mechanical design temperature Supply pressure min/normal Mechanical design pressure inlet/outlet Test pressure inlet/outletOil flowOil flowISO VG 46 65/50/35 °C100 °C0.9/2.5 bar 14 b

20、ar21 bar66 l/min (for generator bearings) 27 l/min (for exciter bearing)159 l/min (2 Generator brgs. +1 Exciter brg.)80 kW (for generator bearings) 14 kW (for exciter bearings) 500 PaRequired22 micron abs.Total Oil FlowOil heat rejection Oil heat rejectionum allowable backpressure Bearing ventFilter

21、ing degreePiping connectionto provide acommonNot Required - (Refer - SOL04569 P&ID)Inlet/Outlet interface flange (including generator bearings)allInlet/Outlet flange location (facing LP-DE) Inlet/Outlet connection flange rating Piping materialProject Lube Oil Line SpecificationInlet: Right, Outl

22、et: downward ANSI 150# / ANSI 150 # SS304SOK6756597油站数据：ISO VG 4665 / 50 / 35 °C100 °C0.9 / 2.5 bar 14 bar 21 bar66 l/min (发电机轴承)27 l/min (励磁机轴承)159 l/min (2 发电机轴承+1 励磁机轴承)80kW （发电机轴承）润滑油类型进油温度（最大/名义/最小）机械设计温度供油（最小/名义）机械设计（进口/出口） 进口/出口试验油量油量总油量油的热消耗油的热消耗14kW （励磁机轴承）500Pa需要22 微米（绝对值）不需要（见 S

23、OL04569 P&ID）最大背压轴承通风过滤等级发电机轴承油路共用进出油接口所有发电机轴承）（包括位置（从低压侧轴伸端看）进口：右侧；出口：ANSI 150# / ANSI 150#304 不锈钢SOK6756597油管材质项目润滑油规范3.3Cooling systemWater-cooledFresh water (Water characteristics asperAppendix1ofcustomerCoolant type Glycol contentInlet temperature min/maxDesign water temperature (mechanical

24、) Allowed temperature risespecification 16861-RQ-503)N.A.32 °C80 °C10 °C37°C(55.25MW32°C,inletOutlet temperaturetemperature & Class B rise)38 °C (60MW32 °C, inlet temperature & Class F rise)6 bar10.5 bar2.5 bar< 1 bar173 m³/h (with 2x50% coolers in

25、use) 4x50%SingleOutlet temperature Design Pressure Test Pressure Operating pressureAllowed water pressure drop Cooling water flowNumber of cooler sectionsTube executionInlet/outlet water valvesCooler materials Cooler positionmanifoldsandrelevantNot Required 90-10 Cu-NiTop100 % (class B temperature r

26、ise)0.1 m2K/Kcal 1.5-2.5 m/s RightANSI DN50 RF11”Power output with one section out of service Fouling factorVelocity over heat exchange surfaces: Inlet/outlet flange location (facing LP-DE)Inlet/Outlet connection flange rating冷却系统数据水冷却系统冷却介质洁净的自来水（水质特性见用户规范16861-RQ-503 附件 1）无32801037（55.25MW, 进水温度为

27、32，B 级）38（60MW, 进水温度为 32，F 级温升）6 bar10.5 bar2.5 bar< 1 bar173 m³/h （正常运行时使用 2x50%冷却器）4x50%85 m³/h单层管乙二醇含量进水温度 最低值/最高值设计水温（机械）出水温度出水温度设计试验运行的水压降冷却水流量冷却器单元个数每单元耗水量冷却管类型进出水歧管以及相关阀门不需要90-10 Cu-Ni顶部冷却管材质冷却器位置100%（B 级0.1 m2 K/Kcal 1.5-2.5 m/s右侧ANSI DN50 RF11”一个冷却器单元失效时的总输出污垢系数热交换器表面流速）进出水进出水位

28、置（从低压侧轴伸端看）4.Test bed information4.1Lube oil system test dataLP oil pressure: 0.4MPa; HP oil pressure: 31.5MPa; Filtering accuracy: Class 1: Oil supply temperature: Oil:flow (adjustable): 100+200+700l/min flow: 12l/min；0.08mm; Class 2: 0.01mm. 40±3L-TSA46(ISO VG46)4.2Cooling water system test d

29、ata:Water supply pressure: Total flow (adjustable): Water inlet temperature: Water quality:0.5MPa,400t/h32Clean tap water4.3Major test equipments4.3.1 Variable frequency power supply: 5000kW, 6kV, 0100Hz; Driving machine: 2800kW-2P，6kV，50Hz (over-speed available up to 60Hz)4.3.2 High-voltage panel f

30、or measurement: 15kV, 4000A4.3.3 DC excitation system 1: 500V, 3000A; DC excitation system 2: 230V, 50A;4. 试验站数据4.1 试验数据：低压油：0.4MPa ，流量（可调）：100+200+700l/min； 高压油：31.5MPa ，流量：12l/min；过滤精度：一级：0.08mm，：0.01mm. 供油温度：40±3油质类型：L-TSA464.2 试验站供水系统：0.5Mpa ，总流量（可调）：400t/h. 水温：32，水质：洁净自来水。4.3 主要设备：4.3.1供电变

31、频电源：5000kW，6kv，0100Hz，拖动电机：2800kW-2P，6kV，50Hz（可超速至60Hz）4.3.2测量高压柜：15kV， 4000A4.3.3直流励磁系统1：500V 3000A；直流励磁系统2：230V 50A；5. Test items and test procedures 试验项目和试验步骤5.1 Generator data to be checked 主要需要测试的发电机参数序No项目Test Item符号 MarkUnit1电枢绕组直流相电阻 95 Armature Winding DC Phase95 R12磁极绕组直流电阻 95 Magnetic Pol

32、es Winding DC Phase95R13铁耗 Iron lossesPfekW4机械耗 Mechanical lossesPfwkW5电枢满载铜耗 Armature Full Load Copper LossesPcuakW6磁极绕组满载损耗 Magnetic Poles Winding Full Load LossesPcufkW7杂散损耗 Total Stray LossesPdkW8满载效率 Full Load Efficiency%9满载励磁电流(Cos=0.85) Full Load Excitation Current(Cos=0.85)IfnA10满载电枢电流（(Cos=

33、0.85)Full Load Armature Current(Cos=0.85)I1A11绝缘电阻电枢/转子 InsulationArmature/RotorM12轴伸端轴承温度 DE Bearing Temp.13非轴伸端轴承温度 NDE Bearing Temp.14过电流 30 秒 Over Current 30 secondsA15超速(1.2n) 2 分钟 Overspeed(1.2n) 2minutesr/mi16电枢耐电压1 分钟 Armature HV test 1 minuteV17转子耐电压1 分钟 Rotor HV test 1 minuteV18振动Vibration

34、mm/s19满载定子Full Load Stator Temp. Rise1K20满载转子Full Load Rotor Temp. Rise1K21噪声 （声压级）Noise(SPL)LpdB(A)22波形畸变率 Waveform Distortion Rate%23极化指数 Polarization indexR10min/R124进水温度 In water Temp.25出水温度 Out water Temp.26水流量 Water fluxt/h27测温元件绝缘电阻 RTD InsulationM28永磁机电压 PMG VoltageV5.2 Tests before type tes

35、t of complete generator(rotor not inserted into stator)整机前试验项目(转子未定子之前)5.2.1 Run out Checks on BN Tracks 跳动检查5.2.2 Rotor earth fauetector check转子接地检测模块检查QCP Ref对应的质量计划段落号SOK0895370-A 2.3.2 para. SOK0895370-A- 第 2.3.2 段Referred std.试验标准PPI 接地检测模块检验程序PPI earth fauetector inspector procedureProcess des

36、cription试验步骤根据 PPI 接地检测模块检验程序As per PPI earth fauetector inspector procedureEquipment测量仪器相机 示波器Camera, OscilloscopeAcceptance criteria1.波形符合 PPI 检测程序内图形要求，没有接地故障。QCP Ref对应的质量计划段落号SOK0895370-A 2.3.2 SOK0895370-A- 第 2.3.2 段Referred std.试验标准SOK0895351API617Process description试验步骤The rotor should be sup

37、ported and rotate so that the electrical and mechanical run-out on the Bentley Nevada proximitor tracks can be measured.Run out check will be done when the rotor is on lathe or in over speed pit.支撑并 转子，然后通过 侧振装置测量机械和电气跳动值。转子跳动检查在车床或者超速地坑内上进行。Equipment测量仪器ACCUSCAN run-out inspection system ACCUSCAN 跳

38、动检测系统Acceptance criteria验收标准um combined electrical/mechanical run-out: < 16 m p-p最大机械/电气总跳动值: < 16 m峰峰值验收标准1.Wave shall be in line with the picture as shown in the spec to demonstrate there is no earth fault.5.2.3 Polarity check of PMG poles 永磁机极性检查5.2.4 Rotor dynamic balance and over-speed te

39、st 转子动平衡和超速试验5.2.5 Measurement of AC impedance 交流阻抗的测定QCP Ref对应的质量计划段落号SOK0895370-A Section 2.3.3 SOK0895370-A 第 2.3.3 段QCP Ref对应的质量计划段落号SOK0895370-A Section 2.3.3 SOK0895370-A 第 2.3.3 段Referred std.试验标准IEC60034-3 ISO11342 PPI-019-024Process description试验步骤Drive terator rotor to run from low speed t

40、o high speed, while recording and taking vibration spectrum analysis at different speeds, then add balance weights at proper positions of rotor according to analysis result. After several corrections, the rotor vibration can be controlled within required range. Then make terator run to the specified

41、 over-speed and then last for 2 minutes.Bode plot during run up (up to 120% of rated speed) and run down to be recorded.拖动发电机转子运转，由低速到高速，在不同转速下，利用 频谱分析仪器进行振动频谱分析，根据分析结果在转子对应角度添加平衡块。经过反复校正，最终将转子振动 在标准范围内。超速至规定转速并维持 2 分钟。数据应包括启动（120%额定转速）和停机时候的 。Equipment测量仪器Dedicated high-speed dynamic balance analyz

42、er, stopwatch高速动平衡分析仪、秒表Acceptance criteria验收标准G1.0 at cold and G1.5 at hot to ISO11342. ISO11342 中的冷态 G1，热态 G1.5For generator with speed above 1800rpm, the shaft vibration shall be no more than 65 micro meter Peak to Peak.额定转速>1800rpm 时 ，轴振动不超过 65 微米 峰值-峰值。QCP Ref对应的质量计划段落号SOK0895370-A 5.2 SOK08

43、95370-A 第 5.2 段Referred std.试验标准IEEE115Process description试验步骤Check the polarity of rotor magnets one by one with compass.用指南针逐块检查转子磁钢的极性。Equipment测量仪器Compass 指南针Acceptance criteria验收标准The magnetic poles shall be placed in the sequence of N, S alternatively.磁极应为 N、S 交替排列。Referred std.试验标准IEC60034-2,

44、 JB8446-2005Process description试验步骤1) Run terator rotor, and then engage required AC voltage on the rotor;2) Record AC voltage and current at different speeds;3) Calculate the impedance value according to voltage and current. The insulationat different speeds shall be measured and recorded, and then

45、 the HV test at rated speed shall be taken and recorded after over-speed.Note:a) On the rotor during the hot over-speed test to check for shorts between turnsb) On terator after running tests as a reference for the customerc) During the hot over-speed a rotating High voltagecarried out at nominal sp

46、eed.d) When taking this test, the rectifier shall be disconnected withterator rotor (with the internal copper bars disconnected). 由拖 拖动转子运转，对转子绕组施加规定的交流电压，在不同转速下 交流电压和电流值，根据电压和电流值计算阻抗值。不同转速下测量、 转子绝缘电阻， 超速后额定转速下耐压值。注：a) 在热态超速试验时测量转子的交流阻抗，以检查匝间短路；b) 在运转试验后测量发电机的交流阻抗，从而为用户提供参考；c) 在热态超速试验后，需要在额定转速下进行旋转状

47、态的耐压试验。d) 做该项试验时注意整流盘与主机转子断开（拆开内部铜排）。Equipment测量仪器AC impedance test station交流阻抗测试台Acceptance criteria验收标准1. The impedance difference between adjacent 300r/min shall not exceed 5% of the max. value.2. After the hot over-speed test, the machine shall withstand the rotating HV test at 1500V for 1 minut

48、e.1. 每隔 300r/min 之间的阻抗差值，不得大于最大值的 5% 。2. 在热态超速试验后，在额定转速下进行旋转状态的转子耐压试验：1500V 1min 通过。5.3 Inspection items of complete machine 整机检查项目5.3.1 Inspection before type test 整机试验前的检查项目5.3.1.1 Air gap check 气隙检查QCP Ref对应的质量计划段落号SOK0895370-A Section 4.1.2 SOK0895370-A 第 4.1.2 段Referred std.试验标准Drawings1AP.252.

49、0078图纸 1AP.252.0078Process description试验步骤Measure the gap between rotor outer diameter and stator inner diameter with air gap feeler. Caution shall be taken that the position of rotor & stator slots shall be avoided.Note: 1) Take 3 or 4 data for rotor at each 90° 2) Measurement shall be tak

50、en at HP end and LP end at the same time when the rotor is at different angle.用气隙塞尺在转子本体外圆与定子内圆之间测量两者之间的间隙。注意，测量位置应避开转子、定子槽的位置。注意：转子每转 90°测量 3 或 4 个数据；转子在不同的圆周位置时，高压端、低压端同时测量；Equipment测量仪器Self-made air gap feeler气隙塞尺Acceptance criteria验收标准Air gap for main generator: 53 mm ± 5% Air gap for

51、exciter: 3mm ± 5%Air gap for PMG: 5.5mm ± 5%主机气隙理论值为 53mm,励磁机气隙理论值为 3mm，永磁机气隙理论值为 5.5 mm；偏差不大于 ±5%5.3.1.2 Bearing insulation 轴承的绝缘5.3.2 Type test of complete machine 整机试验项目型式试验在发电机整机 (由于接线柜会严重影响接线端子的操作空间，特别是部分试验还需要在接线端子上进行试验，因此试验时候主接线盒不安装在主机上）上进行。Typecarried out on complete machine (M

52、ain cubicles will not be mounted on terator during test since it is impractical to tests with the cubicles in position as it severely restricts access to the main terminals, especially on some test where thecarried out at the mains terminal.)5.3.2.1 Shaft-bearing insulation 轴承对地的绝缘的测试QCP Ref对应的质量计划段

53、落号SOK0895370-A Section 4.1.6 SOK0895370-A 第 4.1.6 段Referred std.试验标准IEEE43Process description试验步骤1. Thisperformed when the drive motor is not connected with terator.2. Put the rotor onto the bearings.QCP Ref对应的质量计划段落号N.A.Referred std.试验标准1AP.252.0078Process description试验步骤After machine assembly and before connecting to the drive motor, check the insulationbetween shaft and bearing housing. 整机装配后，连接到拖之前，测量瓦与座之间的绝缘电阻。Equipment测量仪器250V Mega Ohm meter 250V 兆欧表Acceptance criteria验收标准The i