GB/T9652.

2-1997

National Standard of the People’s Republic of China

GB/T9652.2-1997
Replace GB9652-88
Test acceptance codes of governors and pressure oil supply units for hydro-turbines

1. Scope

This standard specifies the test items, methods and conditions of governors and pressure oil
supply units for hydro-turbines, together with general specifications for test acceptance. This
standard is applicable to governors and pressure oil supply units for hydro-turbines with working
capacity at 350N•m and above.

2. Normative Reference

Text contained in the following standards is constituted into the standard through quotation in the
standard. At time of publication, the editions indicated were valid. All standards are subject to
revision, and parties to agreements based on this standard are encouraged to investigate the
possibility of applying the most recent editions of the standards indicated below.

GB2423.2-89 Specification for basic test environment of electrical and electronic products

GB3797-88 Electrical control equipment-Part 2: electrical control equipment with electronic

components

GB9064-88 Test methods for screw pumps

GB/T9652.1-1997 Specifications of governors and pressure oil supply units for hydro-turbines

GB/T13926.4-92 Specifications for industry testing and measurement techniques and

Electromagnetic compatibility of control devices, Electrical fast transient/burst immunity test

3. General rules for acceptance test

3.1. Acceptance test condition----Despite the test conditions given in Chapter 4 of this standard, the
following requirements shall also be abided by:

3.1.1. The characteristic of frequency measurement signal source shall accord with the technical
requirements of the frequency measurement mode of the product (the voltage harmonic
component of sine frequency signal shall be less than 5% of fundamental wave).

3.1.2. Input voltage fluctuation of AC power supply shall not exceed ±10%, and transient fluctuation shall
not exceed +15%~-10%.

3.2. Acceptance test basis----Ex-works inspection and test or plant acceptance test shall be carried out on
the basis of the contract or the technical agreement reached by both parties, GB/T9652.1 and this

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standard.

3.3. Preparation for acceptance test----The guideline for acceptance test shall be prepared by relevant
parties to determine test items, methods, procedures and instruments etc. Refer to Chapter 4 of
this standard for other details.

3.4. Time of acceptance test----According to GB/T9652.1 or within the warranty period given in the contract,
the acceptance test shall be carried out prior to ex works and the plant to be put into formal
operation.

3.5. Acceptance test instruments and cost----The test instruments preparation and the test cost shall comply
with the contract (agreement) stipulations. The calibration and precision of relevant test
instruments shall accord with this standard and the agreement obtained by relevant parties.

3.6. Equipments to be acceptance-tested----Governor and pressure oil supply unit shall be inspected,
adjusted and removed of any defect so as to obtain normal working status. Prior to acceptance
test of the plant, the user shall keep the normal conditions for the unit and other relevant
equipments, and provide relevant technical data and information (e.g. unit inertia time constant T a
and water inertia time constant Tw etc) about power grids, supply water system and unit etc.

3.7. Generally speaking, the test team consists of a sufficient amount of competent test personnel
dispatched respectively from the user and the manufacturer. Otherwise, the test shall be carried
out by the manufacturer personnel and a third party (at the user’s cost) designated by the user; or
an expert team designated by both parties according to a specified procedure.

3.8. Arbitration mode----In the event that both parties hold any dispute on test results and cannot reach any
agreement through consultation, the dispute may be submitted to the product quality supervision
and inspection administration for arbitration. The relevant charge and responsibilities shall be
partitioned according to the arbitration award.

3.9. Test records----The test records shall be made in the original record formats and signed by relevant test
personnel, allowing to be autotyped, photocopied and replicated, but not to be remade.

3.10. Acceptance test reports shall be prepared according to Chapter 7 of this standard. The acceptance
test reports shall be signed by the test principals of both parties, and be noted to be kept as
original records. Both parties shall make assessment on the basis of test results. If necessary, the
tested equipment shall be retested of the item after adjustment and removal of defects.

4 Test Condition
4.1. Preparation work for test

4.1.1. Determination of test type and items, preparation of test guideline.

4.1.2. Preparation of safety and precaution measures, notes on preventive measures against water
intake valve fault, unit overspeed, supply water system trouble, electric shock and other accidents
on equipments and personnel.

4.1.3. Preparation of drawings and information related to the test.

4.1.4. Preparation of necessary tools, equipments, test power supply, calibration instruments and

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sensors.

4.1.5. Well lighting and communication connection on the test site.

4.2. Ex-works test condition

4.2.1. Correct assembly, wiring and pipeline routing for equipments (or elements, circuits), with oil, gas
and electric power supply.

4.2.2. Inspection of oil quality, oil temperature, gas supply, power supply and voltage fluctuation for test
according to relevant technical requirements.

4.3. Test condition of plant

4.3.1. Correct installation, external wiring, pipeline routing for various parts of the unit, with oil, gas and
electric power supply. The oil quality and temperature, high pressure air, power supply and voltage
fluctuation for steam turbine shall comply with relevant technical requirements and manufacturer’s
instructions.

4.3.2. Prior to water addition test, the controlled unit and its control circuits, excitation device and relevant
auxiliary equipments shall have completed installation, adjustment, required simulation test and
preparation work for startup.

4.3.3. After clearing the site and during commissioning, no other construction work that might have
impacts on commissioning shall be permitted.

4.3.4. The working condition shall comply with the stipulation of Chapter 3 in GB/T9652.1-1997.

5. Test items

Test can be divided into four types, i.e. ex-works test, plant test, type test and acceptance test. Refer to the
following table for details:

Accept
Ex-works Plant Type
S/N Clause Test items ance
test test test
test
1 6.1 Inspection and test of speed measurement device Δ Δ
2 6.2 Test of electro-hydraulic transducer Δ Δ
3 6.3 Test of damping device Δ Δ Δ
4 6.4 Adjustment test of electric combined function generator Δ Δ Δ Δ
5 6.5 Temperature drift test of electrical device Δ
6 6.6 Operating test of operational loop Δ Δ Δ Δ
7 6.7 Insulation test of electrical loop Δ Δ Δ
8 6.8 Dielectric strength test of electrical loop Δ Δ
9 6.9 Interference resistant test of electrical device Δ
Practical open loop gain measurement and open loop gain
10 6.10 Δ Δ
adjustment test
11 6.11 Check of command signals of rotational speed, opening Δ Δ Δ

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and power, and permanent speed droop

Check of temporary speed droop bt, damping time constant
12 6.12 Td and acceleration time constant Tn, or check of proportion Δ* Δ* Δ*
gain Kp, integral gain K1 and differential gain KD
13 6.13 Combined drift test Δ Δ
Test of governor static characteristic (including artificial
14 6.14 Δ Δ Δ Δ
dead band) and rotational speed dead band measurement
Measurement test of combined curve and imprecision of
15 6.15 Δ Δ Δ Δ
runner blade servo system
16 6.16 Adjustment of servomotor shutdown and startup time Δ Δ Δ
Measurement of servomotor shutdown and startup time
17 6.17 Δ
range
18 6.18 Measurement of governor overall oil consumption Δ Δ
19 6.19 Measurement test of servomotor response time constant Ty Δ
20 6.20 Measurement test of servomotor motionless time Tq Δ Δ Δ Δ
21 6.21 No-load test Δ Δ Δ
22 6.22 Mutation load test (isolated operation) Δ
23 6.23 Load rejection test Δ Δ Δ
24 6.24 72 hours continuous run test under load Δ Δ Δ
25 6.25 Pressure test of pressure tank Δ Δ Δ
Airproof test of pressure oil supply unit and overall oil
26 6.26 Δ** Δ Δ Δ
leakage measurement
27 6.27 Trial run of oil pump and oil output check Δ Δ Δ Δ
28 6.28 Test of safety valve or valve group Δ Δ Δ Δ
Check of oil pressure and oil level signal adjusted values of
29 6.29 Δ** Δ Δ Δ
pressure oil supply unit
Automatic operation simulation test of pressure oil supply
30 6.30 Δ** Δ
unit
Note: Any item without relevant function can be skipped; any function unlisted in Table 1 shall be tested according to
manufacturer’s instruction.
* Except of microprocessor-based governor.
** Refer to the combined pressure oil supply unit with capacity equal to or below 4m 3.

6. Test method

6.1 Inspection and test of speed measurement device

6.1.1. The signal source shall employ signal generator of sufficient frequency, stability and high precision.

6.1.2. With speed measurement device actually or artificially loaded, change the rotational speed signal
continuously time by time in the same direction to increase or decrease, measure the frequency
(or rotational speed) and relevant output whenever each change reaches a balanced status, and
figure the static characteristic curve, of measuring points not less than ten. In case there are 1/4
measuring points not located on the curve, the test will be construed as invalid. Work out

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amplification factor from the static characteristic curve.

6.1.3. Measure the minimum working signal voltage of electric speed measurement device: when the
frequency signal comes from unit PT, the signal frequency is the rated value and keeps constant;
adjusting the signal voltage from the high end to the low end, at the moment when relevant output
starts to change, the signal voltage is the minimum working signal voltage.

6.1.4. Pendulum escape velocity test: set the pendulum in the middle position of special test desk, then
accelerate its rotational speed to 2 times of pendulum rated rotational speed and keep it
continuously operating for 5 minutes, and check of any abnormal situation.

6.2 Test of electro-hydraulic transducer

6.2.1. Electro-hydraulic transducer, displacement output type

6.2.1.1. Test condition----With electro-hydraulic transducer specifically or actually loaded; under rated
working oil pressure and normal vibration current; the piston shall have no block at any position;
the amplitude is in the specified scope and the middle balance position has been adjusted; oil
temperature is kept at ambient temperature (or ranged in the specified range); the insulation
resistance of winding is up to grade level.

6.2.1.2. Static characteristic test----Increasing or decreasing the input signal (current or voltage)
continuously time by time, every time when it reaches stable and balanced, measure the relevant
output displacement of electro-hydraulic transducer, of measuring points not less than 10; figure
the static characteristic curve; work out the working range, amplification factor (mm/mA or mm/V)
and dead band based on the curve.

6.2.1.3. Oil consumption measurement----Under the working oil pressure, with specified vibration current,
being actually or specifically loaded, measure oil consumption every minute and record the oil
temperature values at corresponding moments.

6.2.1.4. Oil pressure drift measurement----With electro-hydraulic transducer actually or specifically loaded,
electrifying with specified vibration current, change the oil pressure in the normal working oil
pressure range and measure drift value of electro-hydraulic transducer (the ratio between the input
current change required to obtain zero displacement of electro-hydraulic transducer and the rated
current is the relative drift value), and record the oil temperature values at corresponding
moments.

6.2.2. Electro-hydraulic transducer, flux output type

6.2.2.1. Test condition----Similar to Clause 6.2.1.1 (with zero load).

6.2.2.2. Static characteristic test----Increasing or decreasing the input signal current or voltage
continuously time by time, measure the corresponding no-load output flux of electro-hydraulic
transducer whenever obtaining a stable balance, of measuring points not less than 10. Figure the
static characteristic curve. Work out the working range, amplification factor (i.e. flux gain – the
slope of no-load output flux curve in the specified input current range) and dead band based on the
curve.

6.2.2.3. Oil consumption measurement----Under the working oil pressure and the specified vibration

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current, measure the oil consumption every minute, and record the oil temperature values
accordingly.

6.2.2.4. Oil pressure drift measurement----Electrifying with the specified vibration current, change the oil
pressure in the normal working oil pressure range and measure the drift value of electro-hydraulic
transducer (controlling the flux at zero, the ratio between the required input current change and the
rated current is the relative drift value), and record the oil temperature values at corresponding
moments.

6.3 Test of damping device

6.3.1. Hydraulic damping device----Under the actual load condition and the pendulum in working
conditions of the rated rotational speed, employing special tools and devices to give the positive
piston a step displacement input signal respectively from the upper and the lower directions, with
the value generally not less than 1mm. Read manually (micrometer or stopwatch) or transcribe by
means of automatic recorder several groups of displacement values and corresponding time (or
damping curve) during the damping piston naturally damping after restored to the balance position.

6.3.2. Electric damping device----Give a specified positive and a specified negative step input signal
respectively, and transcribe the process curve of output damping by means of automatic recorder.

The time for the output damping from the initial value (100%) to 36.8% is the real measure value of
adjusted damping time constant Td. Testing for three times, take the average as the result.

On the static characteristic curve of damping device, the ratio between the difference and the
addition of two outputs in two directions in the same time coordinates is the relative deviation. In
the same characteristic curve figure, the average of relative deviation value of the point at 3.4 on
line segment of the time that the output restored from the initial value to 10% (the first arrival
prevails) shall be taken for comparison. Damping time constant deviation refers to the ratio
between the difference of the real measure time constant and the theoretical time constant, and
the theoretical time constant. The theoretical time constant refers to the theoretical exponential
damping time constant equal to the time required for the real measure curve output restoring from
the initial value to 10%.

Time constant deviation Δt shall be calculated as follows:

Wherein: T=t0.1/2.3―theoretical damping time constant, s;

t0.1―the damping time required for damping device output from the initial value (100%) to 10%, s.

Only the static characteristic curve is required to be checked when damping time constant is about
5s-6s for micro electro mechanical adjustment.

6.4 Adjustment test of electric combined function generator

Adjust the head signal of combined function generator at the head value to be tested, input and
change the electrical quantities of the simulative guide vale servomotor stroke continuously time by

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time, measure the output of combined function generator, and figure the function generator
combined curve represented by the electrical quantities under the head. Figure the function
generator combined curves of Kaplan hydro-turbine under several head values in the same way.

Check the function generator combined curves with the given theoretical combined curve.

6.5 Temperature drift test of electrical device

6.5.1. Test condition----Tn (or K0) =0, with other adjusting parameters set at middle positions, opening
given value and feedback signal set at the middle positions, amplification factor and load set at
design given values, input signal and frequency given value kept at the rated values, others
accordant with relevant stipulations in GB2423.2.

6.5.2. Temperature drift test ----Keep the voltage steady, test ambient temperature 5℃~45℃, maintaining
the temperature for 30 minutes prior to increase temperature, record the output, and then increase
temperature gradually, with an increasing speed proximately 5℃ every 5 minutes, maintain the
temperature for 30 minutes after every increase of 5℃, record with meter or automatically
transcribe the outputs, find the maximum output deviation value ranged in 5℃~45℃, divided by
40℃ and then divided by the real measure output change of frequency amplifier upon every 1%
change in rotational speed, and work out the output change in every 1℃ change represented by a
relative value of rotational speed deviation.

6.6 Operating test of operational loop

6.6.1. On the premise that the spiral casing without water addition in the manufacturer’s factory or the
plant, carry out the following test items:

Automatic startup, hand/automatic switch, increase/decrease load, automatic shutdown, and fault
condition simulation tests. The relevant test methods shall be determined according to the actual
situation of the plant and other equipments such as governor.

6.6.2. On the premise that the spiral casing of the plant with water addition, carry out the following test
items:

Hand startup, automatic startup, hand shutdown, automatic shutdown and hand/automatic switch
test. The relevant test methods shall be determined according to the actual situation of the plant
and other equipments such as governor.

6.7 Insulation test of electrical loop

6.7.1. Test condition----Ambient temperature 15℃~35℃, relative humidity 45%~75%.

6.7.2. Insulation test shall cover all connections and elements. Measures shall be taken in the test to
prevent electrical elements and instruments from damage (the elements incompatible with the
given megaohm meter voltage, such as semiconductor element and capacitor, shall be short-
circuited during test).

6.7.3. During insulation test, the rated voltage of megaohm meter shall be selected according to the rated
working voltage of various circuits. Refer to Table 2 for details.

Table 2

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Rated working voltage Ui, v Rated voltage of megaohm meter, V

<48 250
48≤Ui<500 500

6.8 Dielectric strength test of electrical loop

6.8.1. Test condition----Ambient temperature 15℃~35℃, relative humidity 45%~75%; the elements
incompatible with the given test voltage shall be short-circuited, or even taken insulation
measures; with the equipment cabinet closed, and side wall and metal housing well installed.

6.8.2. Dielectric strength test shall be carried out after the qualification of insulation resistance.

6.8.3. Between two independent circuits in electrical and mechanical cabinets that without electricity
connected, and between various electrified circuits and metal casings (or ground), the dielectric
strength tests shall be performed according to Table 3:

Table 3

Rated insulation voltage Ui, V Dielectric strength test voltage (valid value), V
≤60 1000
60<Ui≤300 2000
300<Ui≤660 2500
The test voltage shall be started from zero or a value lower than 1/2 of the full value, increased
continuously or stepped up by maximum 5% of the full value. The time of increasing to the full
voltage value shall be less than 10s; then maintain the full voltage for 1 minute. The voltage shall
be lowered back to zero after the test.

6.9 Interference resistant test of electrical device

6.9.1. Test condition----Simulating the unit rated rotational speed signal with stable frequency signal
source, with the governor under automatic working condition, all adjusting parameters set at the
middle values of the scales, and the servomotor stabilized at a certain position.

6.9.2. Electrical fast transient interference test will stipulate the sharp pulse voltage of parameters to be
summed up in a common mode, and impose the given test voltage to the AC control power supply
of the equipment, with two pulse summation methods optional, i.e. row summation of pulse signals
and summation of single pulse signals.

The test method shall abide by GB/T13926.4 and GB3797.

6.10Practical open loop gain measurement and open loop gain adjustment test

6.10.1. Open loop gain adjustment principle

In order to satisfy the imprecision target of rotational speed dead band and servo system, select a
larger value, but not exceeding the actual open loop gain.

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6.10.2. Practical open loop gain measurement of damping type governor

Above all, adjust the switch time of servomotor of guide vane at the given values, then set b p and
bt at the maximum, Td at the middle value; with the servomotor opening to a proper stroke position,
change the relevant amplification factor and lever ratio from the big to the small, change the overall
open loop gain; under automatic working condition, impose an interference of 2% step rotational
speed deviation signal to the governor, observe the servomotor activities upon various open loop
gains; the maximum open loop gain that can keep the servo system stable without overstrike is the
practical open loop gain.

6.10.3. Practical open loop gain measurement of servo system

The startup and shutdown time of servomotor has been adjusted in accordance with the specified
requirements; set amplification factor and lever ratio at the design maximum, impose the servo
system a step interference signal equivalent to 10% of the full stroke of servomotor, observe the
servomotor activities; while the amplification factor and lever ratio decreasing gradually, the
maximum open loop gain that can keep the servo system stable without overstrike is the practical
open loop gain.

6.11 Check of command signals of rotational speed, opening and power, and permanent speed droop

6.11.1. Rotational speed command signal check

It shall be carried out under the hydro-turbine static condition in the manufacturer’s factory or the
plant. Set bp= 2%, bt, Td and Tn at the minimum; when inputting rated rotational speed, adjust the
opening command signal to make the speed regulation system obtain balance status with the
servomotor close to full-close position, then adjust the rotational speed command signals
respectively at two extreme positions and different setting values, change the rotational speed
signal to restore servomotor to the same balance position; at this moment, the measured rotational
speed deviation is the real measure value for zero stroke rotational speed adjusting scope and the
corresponding setting value.

6.11.2. Opening command signal check

Under static condition, set b p= 6%, set the given opening at no-load position, set the servomotor of
guide vane close to no-load position with a given frequency; increase or decrease the opening to
make servomotor correspondingly opening bigger or smaller stably, when the given opening
reaches 100%, the servomotor shall also have 100% opening.

6.11.3. Power command signal check

Under static condition, set bp= 6%, simulate switching of oil switch, input the rated frequency signal
to frequency measurement circuit, adjust the frequency to zero, adjust the servomotor close to no-
load position with a given frequency, then operate the given frequency, increasing or decreasing,
with servomotor of guide vane comparatively stably opening bigger or smaller; send the feedback
signal of simulation frequency transmitter to the frequency contrast circuit; with the given frequency
adjusted to 100%, the unit rating shall also obtain 100%.

6.11.4. Permanent speed droop bp (quadrature current droop compensation ep) check

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Set the gain at the adjusted value, the frequency at the rated value, b t, Td and Tn at the minimum
values or Kp at the middle, K1 at the maximum and KD at the minimum value. Set bp (ep) =2% and
6%, changing the input frequency signal, measure random two output values of servomotor of
guide vane (or two unit frequency output values) and relevant input frequency signal values, work
out the real measure permanent speed droops under various scales.

In order to ensure test precision, the real measuring points shall be selected near to the 25% and
75% stroke (or frequency) positions. The method given in Clause 6.14 can also be adopted to
measure the permanent speed droop.

6.12Check of temporary speed droop b t, damping time constant T d and acceleration time constant T n, or
check of proportion gain Kp, integral gain K1 and differential gain KD

6.12.1. Check of temporary speed droop bt

Set bt at the adjusted value, bp and Tn at zero, block the throttle orifice of damping device or short
circuit the capacitance; with the governor under automatic balance status, operate the opening
limit mechanism to full-open, with input frequency 2Hz higher than the rated frequency, set the
servomotor at 20% position with a given frequency or the rotational speed regulation mechanism,
then record the servomotor stroke after stabilized; decrease input frequency to be 2Hz lower than
the rated frequency, record the servomotor stroke after stabilized, work out the real measure b t
value.

The test method stipulated in Clause 6.12.4 can also be adopted to work out the real measure b t
value.

6.12.2. Check of damping time constant Td

Employ the test method given in Clause 6.3 or 6.12.4 to real measure damping time constant
value.

6.12.3. Check of acceleration time constant Tn

With the electrical device of governor actually or artificially loaded, set b p, bt and Td at zero, input
frequency and given frequency at the rated value, set T n at various scale positions to be checked,
input respectively step deviation signal of rotational speed; transcribe the transition process curve
of the electrical device output by means of an automatic recorder. The time needed for the output
damping from the initial value 100% to 36.8% is the T 1v value under this scale; testing for 3 times,
take the average; then work out the acceleration time constant T n as follows. See Figure 1 for
details.

Figure 1

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Wherein: K=a/b (a and b can be worked out based on Figure 1)

6.12.4. Check of proportion gain Kp, integral gain K1 and differential gain KD

Test condition----With the manufacturer’s factory or the plant without water addition, set b p=0, and
the given frequency at the rated value.

Test method----Set bt , Td, Tn or Kp, K1, Kn at the values to be checked, adjust input rotational speed
signal to make servomotor stabilized at 5% (or 95%) position; impose the governor with a step
rotational speed deviation signal x, transcribe the transition process of governor output y by means
of automatic recorder or oscillograph. Refer to Figure 2 for details.

*It shall be T1v+r for Micro electro mechanical adjustment, r represents sampling cycle, s.

Figure 2

Setting Td at the maximum and K 1 at the minimum, and repeating the above test, the transition
process curve is similar to that in Clause 6.12.3, from which the differential time constant T 1v can
be obtained.

6.13Combined drift test

6.13.1. Test condition----With the manufacture’s factory or the plant without water addition, simulate the
rated rotational speed signal of the unit with a stable frequency signal source; with the governor
under automatic balance status, all adjusting parameters set at the middle values of the scales,
and the servomotor adjusted at approximately 50% stroke position.

6.13.2. Test method----After electrifying the test instruments and the device to be tested for 30 minutes,
record the changes in frequency value, supply voltage, ambient temperature, servomotor stroke
and oil pressure within 8 hours. The input frequency signal during test shall maintain unchanged
and any adjustment or operation on the governor shall not be allowed.

6.13.3. According to the actually adjusted bp, convert the maximum change of servomotor stroke within the
8 hours to a relative deviation of rotational speed, which is called as combined drift value.

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6.14Test of governor static characteristic (including artificial dead band) and rotational speed dead band
measurement

The measurement of governor static characteristic and rotational speed dead band shall be carried
out under the hydro-turbine static condition in the manufacturer’s factory or the plant.

Test condition----bp= 6%, the open loop gain at the adjusted value. Cut off artificial dead band, b t,
Td and Tn at the minimum, or KD at the minimum, K1 at the maximum, and K p at the middle value,
the given frequency at the rated value.

Test method----Input the rated frequency signal with the stable frequency signal source, adjust the
servomotor of guide vane close to 50% stroke with a given opening. Then increase or decrease
frequency to make servomotor full-close or full-open, adjust the frequency signal value to make it
gradually increase or decrease in one certain direction; record the signal frequency value and
relevant servomotor stroke every time when the servomotor of guide vane reaches stable; figure
the governor static characteristic curves respectively with frequency increasing and decreasing.
The servomotor stroke for every curve shall be ranged in 5%~95%, and the measuring points shall
not be less than 8; if 1/4 measuring points are not located on the curve, the test will be construed
as invalid. The maximum zone between two curves is the rotational speed dead band.

The negative of the slope of static characteristic curve is the permanent speed droop.

Testing for two times, take the average as the test result.

6.14.1. Manual (frequency) dead band test

With test condition similar to Clause 6.14.2, test method similar to Clause 6.14.3; enter artificial
dead band, set the artificial dead band at various adjusted values, figure a curve on the basis of
the test result, work out the real measure value of artificial frequency dead band, and check its
scale value.

6.14.2. Rotational speed dead band measurement by step frequency signal

Test condition----Similar to Clause 6.14.2, input rated frequency signal, operate the servomotor to
the stroke position of 20% or 80% with a given opening. On various positions, impose
positive/negative step rotational speed deviation signal on the basis of the rated rotational speed,
and gradually increase deviation signal; the signal shall be imposed not less than 4 times (two
times of continuous positive/negative steps respectively) at the position when the servomotor
starts to correspondingly motion to the signal; the moving direction of servomotor shall be
corresponding to the signal each time, otherwise to further increase signal amplitude until the
minimum signal satisfying the above requirements worked out. Record the values such as step
signal and servomotor stroke by means of automatic recorder. The maximum positive/negative
step rotational speed deviation signal on the two positions is the obtained rotational speed dead
band.

For large-sized governor, the servomotor volume for test shall not be less than 40L.

6.15Measurement test of combined curve and imprecision of runner blade servo system

Under the hydro-turbine static condition in the manufacturer’s factory or the plant, set the head

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signal as the design value; test condition similar to Clause 6.14.2. By changing the input frequency
signal or employing the manual opening limit mechanism, increase or decrease the electric
regulator output (or middle servomotor stroke) and the servomotor of guide vane stroke in one
direction continuously time by time; when it reaches a new balance position, measure the relevant
servomotor stroke of guide vane servo system, of measuring points not less then 8 in the range of
servomotor of guide vane (5%~95%). In case there are 1/4 measuring points not located on the
curve, the test will be construed as invalid.

Figure the combined curve and work out the imprecision of servo system and the deviation
between the actual combined curve and the theoretical curve based on the above test data. The
test shall be carried out more than two times, and take the average as the test result.

In the event that the plant under test shall still require verification, the combined curve under the
minimum and maximum heads shall also be checked.

6.16Adjustment of servomotor shutdown and startup time

6.16.1. The test shall be carried out under the hydro-turbine static condition in the manufacturer’s factory
or the plant (sufficient safety measures shall be taken in the case of plant). Adjust the piston limit
stroke of main proportioning valve (or throttle orifice on oil path), set the opening limit mechanism
at full-open position, and make the servomotor full-open or full-close in the below-mentioned way.

6.16.2. Under the automatic balance status, give a rotational speed deviation signal to the governor
suddenly, which absolute value not less than 30% of full-open and full-close, or operate the
solenoid valve of emergency shutdown to act or restore.

6.16.3. While the servomotor in motion, record the time required for the servomotor moving between
25%~75% stroke, take 2 times of the value as the startup and shutdown time of servomotor.
According to the adjusting guarantee requirements of the hydro-turbine manufacturer or design
institute, set the shutdown and startup time of servomotor, and record the piston stroke of main
proportioning valve or the throttle orifice size.

6.17Measurement of servomotor shutdown and startup time range

6.17.1. The test shall be performed under the hydro-turbine static condition in the manufacturer’s factory
or the plant (sufficient safety measures shall be taken in the case of plant), adjust the piston limit
stroke of main proportioning valve or the throttle orifice on oil path to the maximum and minimum
status, set the opening limit mechanism at full-open position.

6.17.2. Under the automatic balance status, impose rotational speed deviation signals to the governor,
which absolute value shall not be less than 30% of full-open and full-close, or operate the solenoid
valve of emergency shutdown to act or restore; record the time required for the servomotor moving
between 25%~75% stroke, take 2 times of the value as the startup and shutdown time for
servomotor.

According to the test result, servomotor volume and the measured time, work out the
corresponding actual oil output range.

6.18Measurement of governor overall oil consumption

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Under the hydro-turbine static condition in the manufacturer’s factory or the plant, cut off the oil
supply pipeline of pressure oil supply unit to the unit automatic elements, except of the governor;
with the governor under the automatic balance status at the rated rotational speed, according to
the lowered oil level in pressure oil tank during a certain period and the oil tank inside diameter,
work out the governor’s overall oil consumption per unit time.

6.19Measurement test of servomotor response time constant Ty

The test shall be performed under the hydro-turbine static status in the manufacturer’s factory or
the plant. Cut off feedback, set the main proportioning valve on different strokes respectively; fast
move the main proportioning valve from the middle position to the set position in the opening
(closing) direction continuously time by time, measure the displacement of main proportioning
valve and the relevant average speed of servomotor, convert the displacement into a relative
value, figure the relation curve, work out the response time constant T y of the servomotor; while
main proportioning valve moving from the middle position to the startup or shutdown side, measure
at more than 6 points respectively.

If adopting throttle orifice to adjust the servomotor startup and shutdown time, and the test is being
performed in the plant, the throttle orifice size shall be set as per relevant requirements prior to the
measurement of Ty value.

6.20Measurement test of servomotor motionless time Tq

6.20.1. In the manufacturer’s factory, the servomotor diameter for testing big-sized governor shall not be
less than Ø350mm. With the governor under automatic balance status, adjust parameters at the
middle values, open loop gain at the adjusted value. Open the opening limit mechanism to full-
open position, input stable rated frequency signal, servomotor stabilized at proximately 50%
stroke, make the input frequency signal step changed 4 times of the given value of rotational
speed dead band, record the input frequency signal and servomotor displacement by means of
automatic recorder, determine the servomotor motionless time T q started from the moment when
the frequency increases/decreases. Testing for three times, take the average.

6.20.2. After the unit load rejection test has been carried out in the plant, and unit 25% load rejection
oscillogram has been obtained, work out the servomotor motionless time T q directly from the
figure, which starts from the disappearance of generator stator current, or 10%~15% load rejection
and unit rotational speed increased up to 0.02%, to the moment when the servomotor starts
motion; during the test, the oil switch auxiliary connection signal of governor shall be short
circuited. Record the unit rotational speed, servomotor stroke and generator stator current by
means of automatic recorder, the time resolution of chart speed shall not be more than 0.02s/mm,
the resolution of servomotor stroke shall not be more than 0.2%/mm.

6.21No-load test

6.21.1. Manual type----Under no-load working condition, measure the rotational speed swing of the unit
within 3 minutes; testing for three times, take the average.

6.21.2. Automatic type-----Under no-load working condition, impose the speed regulation system with
frequency step interference, record the transition process of the unit rotational speed and the

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servomotor stroke etc, select a group of adjusting parameters with smaller rotational speed swing
and overstrike, less fluctuation times and faster balanced, for application for no-load operation.
Upon this group of adjusting parameters, measure the unit rotational speed swing within 3
minutes; testing for three times, take the average.

6.22Mutation load test (isolated operation)

After the unit isolatedly loaded, with the combination of different adjusting parameters, increase
and decrease load suddenly in different ways based on the actual situation of the site, to make the
change not larger than 25% of the unit rated load, observe and record the parameter transition
process of unit rotational speed, water pressure, frequency and servomotor of guide vane stroke
etc, on which basis to determine the adjusting parameters of working conditions for isolated
operation.

6.23Load rejection test

Set no-load and load adjusting parameters at the selected values, with the governor under
automatic balance status. Reject 25%, 50%, 75% and 100% of the rated load in turn, automatically
record the parameter transition process of unit rotational speed, guide vane, servomotor stroke of
runner blade (or needle, deflector), spiral casing water pressure, and generator stator current etc.

6.2472 hours continuous run test under load

After all adjusting tests of regulation system and device and all other tests of unit have been
finished, all test wiring shall be removed so as to restore the unit to its normal working status;
completely clear up the site, and then carry out continuous run test for under load for 75 hours.
Itinerate inspection shall be performed for various parts during the test and detailed record of
operational condition shall be made.

6.25Pressure test of pressure tank

After the welding of pressure tank in the manufacturer’s factory has been finished, pressure test
shall be performed according to GB150, with the test pressure determined as follows:

Wherein: Pt― test pressure, MPa;

P― design pressure, MPa;

[δ]― allowable pressure of pressure tank material at test temperature, MPa;

[δ]t― allowable pressure of pressure tank material at design temperature, MPa.

Keep 30 minutes under test pressure P t, with the test media temperature not lower than 5 ℃.
Inspect weld of leakage, pressure meter reading of any significant decrease. If all are in order,
relieve the pressure to the rated value, lightly knock on the area 25mm away at the two sides of
weld with a 500g hand hammer, no leakage shall occur.

6.26Airproof test of pressure oil supply unit and overall oil leakage measurement

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The oil pressure and oil level of the pressure tank shall be kept in the normal working range; close
all valves connected with the external; after increasing pressure for half an hour, start to record the
oil pressure change, oil level decrease within 8 hours, and the ambient temperatures before and
after the 8 hours.

6.27Trial run of oil pump and oil output check

6.27.1. Trial run of oil pump

Prior to startup, inject oil to the pump, open the inlet/outlet pressure regulating values; safety valve
or valve group shall be under closing status; run for 1 hour under no load, then run for 10 minutes
respectively with oil pressure at 25%, 50% and 75% of the rated value; then run for 1 hour under
the rated oil pressure, no abnormal situation shall occur.

6.27.2. Oil output check

Oil pump output measurement at pressure point

Under the rated oil pressure and ambient temperature, start oil pump to send (or adopt flow meter)
oil to the dosing container, write down the real measure oil output Q i at real measure pressure
point, or the dosing volume Vi and measuring time ti; work out the real measure Qi value as
follows:

Wherein: Qi― real measure oil output of oil pump at pressure point, L/s;

Vi― real measure volume at pressure point, L;

ti― real measure time at pressure point, s.

Testing for three times, take the average.

Oil pump output measurement under given rotational speed at zero pressure point

While testing, the inlet/outlet pressure regulating valves shall be full-open (if inlet pressure
indication not larger than 0.03MPa, outlet pressure indication not larger than 0.05MPa, then the
inlet/out pressure indication will be construed as zero), measure the real measure oil pump output
Q0 at zero pressure point according to the method mentioned in Clause 6.27.2.1.

When the test rotational speed, viscidity and given value are different, make conversion as
follows:

Wherein: Qin― output of oil pump under given rotational speed at pressure point, L/s;

y ― specified viscidity, mm2/s;

yi ― actual viscidity, mm2/s;

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n ― specified rotational speed, r/min;

ni ― actual rotational speed, r/min;

K ― conversion exponent;

Q0― real measure flux of oil pump at zero pressure point, L/s;

If yi＜Y, K=0.5; if yi>y, K=0.25.

6.27.3. Oil pump type test shall be performed according to GB9064.

6.28Test of safety valve or valve group

6.28.1. Test condition

The motion simulation test of safety valve or valve group can be carried out on the full-scale unit or
a test pressure tank (the test of valve group shall simulate the actual unit oil system).

6.28.2. Adjustment test of safety valve

Start the oil pump to transfer oil to the pressure tank, measure the opening, closing and full closing
pressures of the safety valve according to the pressure meter on the pressure tank. Testing for
three times, take the average.

6.28.3. Test of relief valve

Adjust the throttle orifice diameter of the throttle piston in relief valve, change the load relieving
time. It requires the load-relieving oil orifice to be fully blocked just at the moment when the oil
pump motor reaches the rated rotational speed, if the oil flow is stopped through observation from
the sight hole, the adjustment is correct.

6.29Check of oil pressure and oil level signal adjusted values of pressure oil supply unit

Manually control the oil pump startup or the oil/gas flow of pressure tank, change oil level and oil
pressure, record the working values of pressure signal generator and oil level signal generator, the
deviation between the working value and the setting value shall not larger than the given value.

6.30Automatic operation simulation test of pressure oil supply unit

Carry out the simulation automatically; control oil pressure and oil level changes by manually
discharging of oil and gas to make the pressure signal generator and oil level signal generator act,
and to control oil pump automatically added with gas in various operational modes. By the
simulation test, check the correction of control circuit of pressure oil supply unit and the motion of
oil pressure and oil level signal generators. Manual dial connection for signal generator shall not
be allowed to carry out the simulation test.

7. Test report

7.1. Purpose of test report

It is the formal record of measured data and calculation results. It shall have sufficient data to
verify that all tests have been carried out according to the acceptance test specification and have

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attained the test purpose. Moreover, various test results shall be listed as tables or be figured as
curves, which may include verified original records (or copies); the readings of measure
instruments shall accord with the records obtained by observation.

7.2. Format of test report

All test reports shall include the following contents:

► Bases and purpose of test

► Manufacturer model, ex-works number and ex-works date of tested equipments

► Main technical parameters of the plant, unit and tested equipments

► Test items (including condition, method, instruments and data)

► Test result (including curve, figure and photograph)

► Acceptance comments and host, attending parties and personnel

► Appendix

Appendix A
(Normative appendix)
Test instruments

A1 General precision requirements of test instruments

Measurement error of rotational speed fx≤±0.25%
Measurement error of temperature ft≤±0.5℃
Measurement error of hydraulic pressure fpw≤±10%
Measurement error of oil pressure fpD≤±1.5%
Measurement error of time ft≤±5%
Measurement error of power fN≤±1%
Measurement error of flow fQ≤±1.5%
Measurement error of command signal fd≤±5 %
Measurement error of servomotor stroke fy≤±1 %

A2 Special precision requirements of test instruments

Measurement error of rotational speed signal source (temperature drift, combined drift, rotational
speed dead band)

Shall be less than 1/10 of the given value of rotational speed dean band.

Measurement error relative value of servomotor stroke (rotational speed dead band, imprecision)
shall not be more than 2.5 times of the given value of rotational speed dean band.

A3 Main test instruments

Ultra-low frequency signal generator (resolution 0.001Hz )

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Digital frequency meter (resolution0.001Hz )

Displacement sensor (precision lx10-3)
Pressure transformer (precision class 0.5)
Simulation wave generator for interference(0.1kV~2.5 kV )
Various flow meter (precision class 1.5)
Frequency measurement transmitter (precision class 0.2~0.5)
Vacuum pressure gauge (precision class 1.5)
Frequency meter (cycle counter) (precision class 0.2~0.5)
AC/DC current meter (precision class 0.2~0.5)
AC voltage meter (precision class 0.2~0.5)
DC voltage meter (precision class 0.2~0.5)
Automatic plotting aids (3~6 pens)
PC-based dynamic tester
Digital timer
Oscilloscope (10~16 lines)
Pressure meter (precision class 1.5)
Megaohm meter

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