水电调试
一、水电调试基础 | Hydropower Commissioning Fundamentals
二、水轮机调试 | Turbine Commissioning
三、机组启动与并网 | Unit Start-Up & Synchronization
四、甩负荷试验 | Load Rejection Test
五、调试文件与移交 | Commissioning Documentation & Handover
Characters: Commissioning Manager (调试经理 CM) / Governor Specialist (调速器专家 GS) · Characters: Commissioning Manager (调试经理 CM) / Project Engineer (项目工程师 PE)
The penstock is filled, the spiral case is pressurized, and the draft tube water level is stable. All mechanical checks on the turbine are complete — guide vanes move freely, the runner turns smoothly on the turning gear. Now, before we do the first hydraulic start, we need to verify the governor static characteristics. Let's run the static test sequence.
压力钢管已充水、蜗壳已加压、尾水管水位稳定。水轮机机械检查全部完成——导叶 动作灵活、转轮在盘车上转动顺畅。首次水力启动前需要验证调速器静特性。跑静态 测试序列。
I have the governor in manual mode. For the static test, I'll inject a simulated speed signal and measure the guide vane position response. First test: frequency dead band — I'll change the speed signal from 50.0 Hz to 50.1 Hz and back. The governor should not respond to changes smaller than 0.02 Hz. The measured dead band is 0.015 Hz — within spec. Next: permanent speed droop setting. I'm stepping the speed signal from 100% to 104% — the guide vanes should close from 100% to 0%. Measured droop: 4.0%, matching the setting. Static tests passed.
调速器在手动模式。静态测试我注入模拟转速信号、测量导叶位置响应。第一项： 频率死区——转速信号从50.0Hz变到50.1Hz再回来。调速器对小于0.02Hz的变化不应 响应。实测死区0.015Hz——合格。下一项：永态转差率设定。转速信号从100%阶跃到 104%——导叶应从100%关到0%。实测转差率4.0%，与设定一致。静态测试通过。
Good. Now let's proceed to the first hydraulic start. I want the governor in manual with the guide vanes closed. Open the turbine inlet valve slowly — let water fill the spiral case completely, then open the guide vanes gradually to about 5% opening. The unit should start rotating. Monitor the bearing temperatures — thrust bearing pad temperature must stay below 75°C. Monitor vibration at the upper, lower, and turbine guide bearings — all must be below 80 μm peak-to-peak at rated speed.
好。现在进行首次水力启动。调速器手动、导叶全关。缓慢打开进水阀——让水充满 蜗壳、然后逐步开导叶到约5%开度。机组应开始旋转。监视轴承温度——推力瓦温须保持 在75°C以下。监测上导、下导和水导轴承振动——额定转速下全须低于80μm峰峰值。
Unit is rotating. Guide vanes at 5%. Speed increasing — 20%, 40%, 60%... At 80% speed, I'm holding to check bearing behavior. Vibration: upper guide 42 μm, lower guide 38 μm, turbine guide 55 μm — all within limits. Temperatures: thrust bearing 48°C and stable. Continuing to rated speed. Speed at 100% — 500 rpm. All parameters stable. First hydraulic start successful. Ready for the generator open-circuit test.
机组在转。导叶5%。转速上升——20%、40%、60%……80%转速时保持检查轴承。振动： 上导42μm、下导38μm、水导55μm——都在限值内。温度：推力轴承48°C且稳定。 继续到额定转速。转速100%——500rpm。参数全部稳定。首次水力启动成功。准备 发电机空载试验。
The unit has been synchronized to the grid for 48 hours. We've progressively loaded to 25%, 50%, 75%, and 100% — all stable. Now we need the load rejection tests. We'll start with 25% load rejection and work up to 100%. Before each step, we brief the team and verify all protection is active. What are the acceptance criteria?
机组已并网运行48小时。逐步加载到25%、50%、75%、100%——全部稳定。现在需要甩 负荷试验。从25%开始到100%。每步前全员交底、核实所有保护投入。验收标准是什么？
Per the contract and IEC 60041: for 100% load rejection, the maximum speed rise must not exceed 145% of rated speed — that's 725 rpm for this 500 rpm unit. The maximum spiral case pressure rise must not exceed 165% of the static head at full load. The governor must bring the speed back to rated within 40 seconds with no more than 2 overshoot oscillations. And critically — no mechanical damage, no excessive vibration, and no water column separation in the draft tube. The draft tube pressure must stay above 3 meters of water column absolute to prevent cavitation-induced damage.
按合同和IEC 60041：100%甩负荷时最大转速上升不超过额定145%——这台500rpm机组 即725rpm。最大蜗壳水压上升不超过满负荷静水头的165%。调速器须在40秒内将转速 恢复到额定，超调振荡不超过2次。关键是——无机械损伤、不过度振动、尾水管无水柱 分离。尾水管绝对压力须维持在水柱3米以上以防空蚀损伤。
25% rejection complete. Speed peak: 535 rpm, pressure peak: 108% — pass. 50% rejection complete. Speed peak: 598 rpm, pressure peak: 125% — pass. 75% rejection complete. Speed peak: 668 rpm, pressure peak: 146% — pass. Now the 100% rejection — all personnel to the control room, no one near the unit. Trip the generator breaker in 3...2...1... Tripped! The unit is spinning up — 550, 600, 650... peak at 708 rpm — that's 141.6% of rated, below the 145% limit. Spiral case pressure peaked at 158% — below 165%. Draft tube pressure minimum: 5.2 meters — well above the 3-meter limit. Governor stabilizing — speed back to 500 rpm in 32 seconds, one overshoot oscillation. All criteria met. Full load rejection successful.
25%甩负荷完成。转速峰值535rpm、水压峰值108%——通过。50%甩负荷完成。转速 峰值598rpm、水压峰值125%——通过。75%甩负荷完成。转速峰值668rpm、水压峰值 146%——通过。现在100%甩负荷——所有人到控制室、机组附近无人。跳发电机断路器 3…2…1…跳了！机组在升速——550、600、650...峰值708rpm——额定141.6%、低于145% 限值。蜗壳水压峰值158%——低于165%。尾水管最低压力5.2米——远高于3米限值。 调速器稳定中——32秒恢复到500rpm、超调振荡1次。全部标准达标。满负荷甩负荷成功！