100
F 23
File No.: 11439-2003
Table of Contents
Foreword ..................................................................................................................................................... II
1 Scope ....................................................................................................................................................... 1
2 Normative references ............................................................................................................................... 1
3 Terms and definitions ............................................................................................................................... 1
4 Basic principles......................................................................................................................................... 2
5 Basic requirements for management of maintenance ............................................................................. 3
6 Maintenance intervals and time limit for maintenance ............................................................................. 3
7 Maintenance items and maintenance plans............................................................................................. 5
8 Management for maintenance materials, spare parts and maintenance costs ....................................... 7
9 Management for foreign contracted projects ........................................................................................... 8
10 Management for the whole process of maintenance for power generating equipments ....................... 8
Annex A (Informative) Table of reference items in A class maintenance ................................................. 12
Annex B (informative) Table of three-year ( — ) maintenance project rolling planning ........................... 43
Annex C (informative) Table of ( ) annual maintenance project plan ....................................................... 44
Annex D (informative) Table ( ) annual maintenance duration plan ......................................................... 45
Annex E (informative) Main contents of maintenance file package .......................................................... 46
Annex F (informative) Block diagram of management procedures for the whole process of A/B classes
maintenance for generator units ............................................................................................................... 47
Annex G (informative) Final reports on cold/hot state evaluation for A/B classes maintenance and on
maintenance for primary equipments ........................................................................................................ 48
Annex H (informative) Reference table of technical documents for A/B classes maintenance ............... 61
I
DL / T 838 一 2003
Foreword
Compared with the “Regulations of Maintenance for Power Plants” (SD 230-1987), this standard covers
some main changes as follows
— Revised compulsory standard to recommendatory standard;
— Implemented new maintenance modes in power plants;
— Implemented requirements of GB/T19001 Quality Management System for quality management of
maintenance;
— Re-classified maintenance grade system and combinations of maintenance grades;
— Revised compilation and application and approval procedures of maintenance item plans;
— Added items and acceptance summary contents of maintenance for equipments including control
systems and wet desulphurization devices, etc. and
This standard takes place of SD230-1987 from the date of implementation.
All annexes of this standard are informative.
This standard is proposed by the Power Generation and Transmission Operational Department of the
State Electric Power Corporation.
This standard is drafted by the Power Generation and Transmission Operational Department of the
State Electric Power Corporation, Shandong Electric Power Group Corporation and Northeast Company
of the State Electric Power Corporation.
Main draftpersons of this standard: Jin Donglai, Li Zhenkai, Yu Hongliang, Pan Chunguo, Zhang
Zongzhen, Yang Ke, Cao Xiaohua.
II
DL / T 838 一 2003
Introduction
This standard is revised in accordance with arrangement of Electric Power Corporation of the State
Economic and Trade Commission “Notice on Confirmation of Planned Project for Formulation and
Revision of Electric Power Industry Standard 1999” (Power [2000] No.2.)
The original “Regulations of Maintenance for Power Plants” (SD 230-1987) is a compulsory provision of
the national regulatory authorities for compilation, approval and implementation of maintenance plan for
power plant equipments and plays important roles for well conducting equipment maintenance and
guaranteeing safe, stable and economic operation of power generating equipments and power grids.
With the development of China national electric power industry, large-capacity and high-parameter units
have been increasingly put into operation, and different units are quite different in reliability, safety and
economy, so the provisions in the original standard for maintenance items and intervals, etc. are no
longer applicable. Meanwhile under the new electric power system of “separating power plants from
power grids and bidding in the generation market”, power plants participate in market competition as
independent operating entities, as a result, management of equipment maintenance has been part of
internal operation and management of enterprises and compulsory provisions are not appropriate any
more. However, maintenance for power generating equipments exhibits common characteristics, and
arrangement of maintenance for generator units as important part of electric power system exerts major
influences on safe and stable operation of power grids. Therefore, an industry standard is still required to
regulate maintenance. As a consequence, the original compulsory standard is hereby revised to
recommendatory standard and renamed as the “Guide of Maintenance for Power Plant Equipments”.
III
DL / T 838 一 2003
2 Normative references
The following standards contain provisions which, through reference in this text, constitute provisions of
this standard. For dated references, subsequent amendments (excluding corrected contents) to or
revisions do not apply to this standard, however, parties to agreements based on this standard are
encouraged to investigate the possibility of applying the most recent editions of these references. For
undated references the latest edition applies to this standard.
Requirements of GB/T19001 Quality Management System
3 Terms and definitions
The following terms and definitions apply to this standard.
3.1
Maintenance Grades
Maintenance grades are based on the principles of maintenance scale of the units and time limit for
maintenance to divide the maintenance for power plant units into A, B, C and D classes.
3.1.1
A Class Maintenance
A class maintenance refers to overall discomposed inspection and repair for generator units to maintain,
recover or improve performance of equipments.
3.1.2
B Class Maintenance
B class maintenance refers to decomposed inspection and repair for part of equipments in the units to
settle the existing problems. B class maintenance can be targeted to implement part of A class
maintenance items or time-based rolling maintenance items in accordance with the results of evaluation
for conditions of the unit equipments.
3.1.3
C Class Maintenance
C class maintenance refers to inspection, evaluation, repair and cleaning of the units with emphases in
accordance with wear and aging laws of equipments. C class maintenance can perform replacement of
a small amount of parts, elimination of defects and adjustment of equipments and preventive tests, etc.
as well as implement part of A class maintenance items or time based rolling maintenance items.
3.1.4
D Class Maintenance
D class maintenance refers to elimination of defects in ancillary systems and equipments of primary
equipments when overall operation of the units is in good condition. In addition of elimination of defects
in ancillary systems and equipments, D class maintenance can implement part of C class maintenance
items in accordance with the results of evaluation for equipment conditions.
3.2
Time Based Maintenance (TBM)
1
DL / T 838 一 2003
Time based maintenance refers to a preventive maintenance based on time. In accordance with
statistical laws for wear and aging of equipments, maintenance grades, maintenance intervals,
maintenance items and required spare parts and materials, etc. are determined in advance.
3.3
Condition Based Maintenance (CBM)
Condition based maintenance refers to evaluation for equipment conditions in accordance with the
information on equipment conditions provided by condition monitoring and diagnosing technologies and
maintenance before occurrence of failures.
3.4
Proactive Maintenance (PAM)
Proactive maintenance refers to transformation in accordance with the current level of equipments and
technologies and development tendency against congenital defects or frequent failures of the equipment
so as to eradicate equipment defects to improve technical properties and availability of the equipments
in combination with maintenance process.
3.5
Run Till Failure (RTF)
Run till failure refers to unscheduled maintenance when faults or other failures occur to the equipments.
3.6
Primary Equipment and Ancillary Equipment
Primary equipment refers to boilers, steam turbines, gas turbines, hydroturbines, generators, main
transformers, unit control devices and their accessory equipments; ancillary equipment refers to
production equipments other than primary equipment.
3.7
Interval of A class maintenance for units
The interval of A class maintenance for units refers to the period of time from recommissioning of the
units after the previous A class maintenance to start of the next A class maintenance.
3.8
Time Limit for Maintenance
Time limit for maintenance refers to total time from disconnection (or quit for standby) of the units from
system to the end of maintenance and recommissioning of the units.
3.9
Hold point and Witness point
Hold point and witness point (H and W points) refer to the quality control points of key working procedure
set in management of working procedures in accordance with importance and difficulty of some working
procedure, the next working procedure shall not be conducted if these control points are not inspected
and certified for quality. H point is the hold point that cannot be overstepped, and W point is the witness
point.
3.10
Disaccord
Disaccord refers to the items which quality becomes unacceptable or cannot be judged due to
insufficiency of properties, files or programs.
4 Basic principles
4.1 Power plants should arrange equipment maintenance in a reasonable way in accordance with
technical supervision regulations specified by the government, design documents provided by
manufacturers, experiences on maintenance for the units of the same type and the results of
assessment for equipment conditions, etc.
2
DL / T 838 一 2003
4.2 Equipment maintenance should carry out the “safety first” policy to eradicate various violations of
rules and regulations and ensure personal and equipment safety.
4.3 Management of maintenance quality should carry out GB/T19001 Quality Management Standard,
implement management for the whole process and practise standardized operation.
4.4 Equipment maintenance should carry out budget management and cost control.
4.5 Maintenance for generator units should increase the proportion of condition based maintenance
gradually on the basis of time based maintenance and finally form the optimized maintenance mode
integrating time based maintenance, condition based maintenance, proactive maintenance and run till
failure as a whole.
approximate 1 year after formal commissioning. However, the first A class maintenance for main
transformers can be determined according to test results and is in general carried out in approximate 5
years after commissioning.
Table 1 Intervals and grade combinations of A class maintenance for units
4
DL / T 838 一 2003
generator units corresponding to the output on nameplate of boilers, and can be added by 1d~3d as the
case may be.
6.3.3 For hydro-generator units in rivers with more sediment and serious corrosion, the time limit for
maintenance can be the time limit for maintenance specified in Table 3 multiplied by a correction factor
not more than 1.3; the time limit for A class maintenance for bulb tubular hydro-generator units is 20d
more than axial-flow adjustable blade generator units in the same size.
6.3.4 For replacement of important parts in equipments or other special needs, if any, the time limit for
maintenance for the units can exceed the values specified in Table 2 or Table 3 as appropriate.
6.3.5 The time limit for maintenance for hydro-generator units in seasonal operation may not restrained
by Table 2 and Table 3, but should not affect power generation and scheduling.
6.4 Intervals, grades and time limit for maintenance for gas turbines
The intervals, grades and time limit for maintenance for gas turbine units are executed in accordance
with the provisions of the manufacturers.
Table 3 Time limit for maintenance for standard items in hydro-generator units
Diameter of runner Mixed-flow or axial flow fixed blade Axial-flow adjustable blade Impulse
mm A class d B class d C class d A class d B class d C class d A class d B class d C class d
< 1200 30~40 20~25 3~5 15~20 10~15 3
< 1200~2500 35~45 25~30 3~5 25 (30) 20 (25) 4
< 2500~3300 40~50 30~35 5~7 ~30 ~25 (30) 6
< 300~4100 45~55 35~40 7~9 60~70 35~40 7~9 (35) 25 (30)
< 4100~5500 50~60 40~45 7~9 65~75 40~45 7~9 30 (35) ~30
~35 (35)
< 5500~6000 55~65 45~50 8~10 70~80 45~50 8~10
(40)
< 6000~8000 60~70 50~55 10~12 75~85 50~55 10~12
< 8000~10000 65~75 55~60 10~12 80~90 55~60 10~12
>10000 75~85 60~65 12~14 85~95 60~65 12~14
Note 1: the values in () represent time limit for maintenance of vertical shaft impulse units.
Note 2: the time limit for maintenance of the units which runner blades are made of stainless steel is executed based on
the lower limit.
Note 3: the time limit for maintenance has included the time required for on-load test.
Note 4: the time limit for maintenance of the units subject to D class maintenance is approximate half of the time limit for
maintenance of the units subject to C class maintenance.
5
DL / T 838 一 2003
b) Emphasizing on sweeping, checking and processing vulnerable and quick-wear parts, and if
necessary conducting measurement and test;
c) Items to be checked as per the provisions in various technical supervisions.
7.1.1.4 D class maintenance mainly covers elimination of defects in equipments and systems.
7.1.1.5 Power plants can adjust items of maintenance at various grades in accordance with conditions of
equipments, and in principle all standard items in one A class maintenance cycle must be maintained.
7.1.1.6 Special items refer to the maintenance items other than standard items and the items such as
anti-accident measures, energy-saving measures and technical improvement measures, etc.; major
special items refer to the items with complicated technology, long construction period, high costs or
major changes to structures of system equipments. Power plants can arrange them in maintenance of
various classes.
7.1.2 Maintenance items of ancillary equipments and accessory equipments of primary equipments
should be determined in accordance with equipment conditions and requirements of manufacturers.
7.1.3 Maintenance of production buildings and non-production facilities.
7.1.3.1 Power plants should check and maintain production buildings (structures) (plants, coal yards,
ash dams and waterworks, etc.) and important non-production facilities (roads and revetments) at
regular time and arrange necessary maintenance items in accordance with the actual conditions.
7.1.3.2 Maintenance for waterworks and flood-discharge devices of hydropower generation enterprises
should be completed before flood season, and sluice gates and hoists should be checked and tested
before use.
7.2 Compilation of maintenance project planning and plan
7.2.1 Power plants should compile a three-year maintenance project rolling planning and the next annual
maintenance project plan every year and submit to their competent authorities before August 15 of every
year.
7.2.2 Compilation of three-year maintenance project rolling planning.
7.2.2.1 The three-year maintenance project rolling planning is a pre-arrangement of power plants for
major special items required in A/B classes maintenance in the next three years.
7.2.2.2 Contents of the three-year maintenance project rolling planning should include: project name,
time of the previous A/B classes maintenance, bases for project approval of major special items,
summary of important technical measures, predetermined maintenance time, predetermined shutdown
days, required major spare parts and materials (the format of table of three-year maintenance project
rolling planning is shown in Annex B).
7.2.3 Compilation of annual maintenance project plan.
7.2.3.1 All power plants should compile the annual maintenance project plan in accordance with health
conditions and maintenance intervals of primary equipments and accessory equipments of the plants
and in combination with the three-year maintenance project rolling planning.
7.2.3.2 Compilation of the annual maintenance project plan mainly include: unit project name,
maintenance grades, standard items, special items, bases for project approval, main technical measures,
arrangement of maintenance schedule, working hours and costs, etc. (the format of table of annual
maintenance project plan is shown in Annex C).
7.2.3.3 In the maintenance project plan for primary equipments the unit project is listed based on single
primary equipment.
7.2.3.4 Accessory equipments are listed in the annual maintenance project plan as independent items in
accordance with system classification.
7.2.3.5 The overhaul plan for production buildings lists the unit project based on building name.
7.2.3.6 The overhaul plan for non-production facilities list the unit project based on facility name.
7.2.3.7 Special items should be listed in the annual project plan one by one.
7.3 Compilation and declaration of annual maintenance duration plan
6
DL / T 838 一 2003
7.3.1 Power plants should compile the next annual maintenance duration plan in accordance with major
requirements for annual maintenance proposed by competent authorities. The annual maintenance
duration mainly includes: maintenance grades, time from the previous maintenance, maintenance
duration, maintenance schedule arrangement and its description, etc. (the format of table of annual
maintenance duration plan is shown in Annex D).
7.3.2 Power plants should submit the next annual maintenance duration plan to power grid operating
enterprise before October 15 every year.
7.3.3 After receiving the annual maintenance duration plan of power plants, the power grid operating
enterprise balances maintenance plans for power transmission, transformation and generation
equipments next year in combination with load forecasting of power grids, hydrological forecasting data
and energy policies and on the basis of fair, open and just principles, and approve the next annual
maintenance plan for the whole power grids before November 15 every year. For the units to be
maintained at the first season of next year, pre-arrangement should be made.
7.4 Adjustment and execution of annual maintenance duration plan
7.4.1 In the annual maintenance duration plan issued by power grid operating enterprise, time for
commencement of A and B classes maintenance is not adjusted in principle. Adjustment if required for
special cases should be submitted to power grid operating enterprise for approval and made clear in
seasonal and monthly maintenance plans. Parties causing adjustment of annual, seasonal and monthly
maintenance plans should assume corresponding responsibilities as per the relevant provisions.
7.4.2 In the annual maintenance duration plan issued by power grid operating enterprise, time for
commencement of C and D classes maintenance and maintenance for accessory equipments that may
affect output and operating modes of power grids as well as power (heat) consumption of important
users can be confirmed in monthly maintenance plan.
7.4.3 Power grid operating enterprise should issue the next seasonal unit maintenance plan before the
10th of the last month of every season and the next monthly unit maintenance plan before the 20th of
every month in accordance with the annual maintenance duration plan.
7.4.4 On the premise of not affecting power grid scheduling and emergency standby and being approved
by power grid operating enterprise, power plants can carry out D class maintenance on holidays and at
valley load of power grid.
7.4.5 After commencement of maintenance construction, if increase of time limit for maintenance is
required for some reason, power plants should apply for power grid operating enterprise for approval
before half of the scheduled time limit for maintenance of the units expires.
7
DL / T 838 一 2003
maintenance effects and quality targets. The procedure of management for the whole process of
maintenance is shown in Annex F.
10.2 Preparatory phase before commencement
10.2.1 Power plants should assess conditions of the units in accordance with operating conditions of
equipments, technical supervision data and all previous maintenance occasions, and confirm and adjust
maintenance items as necessary and take countermeasures and technical measures in compliance with
practicalities in accordance with the results of assessment and the requirements of the annual
maintenance project plan.
10.2.2 Implement the plans of maintenance costs, materials, spare parts and accessories, etc., and
complete procurement, acceptance and storage of materials, spare parts and accessories.
10.2.3 Complete signing contracts of all foreign contracted projects.
10.2.4 Check construction machines and tools, safety appliances, which should be qualified upon test.
Test instruments and meters should be enclosed with valid certificates of quality and inspection
certificates.
10.2.5 Compile implementation plan of maintenance for the units, and plot maintenance schedule
network diagram and control table.
10.2.6 Plot fixed location control chart of maintenance site.
10.2.7 Power plants should establish management systems for quality management, quality acceptance
and quality assessment, etc. in accordance with the degrees of importance of management for
maintenance items and working procedures to clarify responsibilities of both maintenance units and
quality inspection departments.
10.2.8 Compile or revise the maintenance file package for standard items, draw up technological
methods, quality standards, technical measures, organizational measures and safety measures for
special items.
10.2.9 All maintainers and relevant administrators should learn safety regulations, quality management
manual and maintenance file package, and should pass the exam.
10.2.10 In one month before commencement of maintenance, power plants should organize the relevant
personnel to check completion of the above work, which should be comprehensively reviewed and
confirmed.
10.3 Organization and management in construction phase of maintenance
10.3.1 Decomposition
10.3.1.1 Maintainers when disassembling equipments on site should carry all required tools, machines
and miscellaneous consumable materials, and should notice whether the safety facilities (such as
scaffolds, platforms and fences, etc.) on site are intact or not.
10.3.1.2 The equipments to be decomposed should be disassembled in accordance with the provisions
of the maintenance file package to achieve correct working procedures and technologies and use
correct tools, instruments and materials. For the equipments to be decomposed the first time, position
marks between assemblies should be well made.
10.3.1.3 The disassembled equipments and spare parts should be placed in accordance with the fixed
location control chart of maintenance site, and the open parts of pipelines connected with the system
should be well sealed.
10.3.2 Check
10.3.2.1 After decomposition of equipments, clear-up work should be completed, various technical data
should be measured in time, and the equipments should be comprehensively inspected to find out
equipment defects, grasp technical conditions of equipments and identify the effects of previous
important maintenance projects and technological transformation items. The mastered equipment
defects should be subject to key inspection and causes be analyzed.
10.3.2.2 An overall assessment should be made for equipments in accordance with the check for
equipments and the measured technical data and in comparison with status quo, historical data and
9
DL / T 838 一 2003
operating conditions of equipments, and maintenance items, schedule and costs should be adjusted in
time according to the results of assessment.
10.3.3 Repair and re-assembly
10.3.3.1 Repair and re-assembly of equipments should be carried out strictly in accordance with
technological requirements, quality standards and technical measures.
10.3.3.2 After repair the equipments should comply with technological requirements and quality
standards, the defects have been indeed removed, and the equipments should be qualified upon
acceptance before re-assembly. During re-assembly equipments should not be damaged, spare parts
not be misplaced, and sundries not be left inside the equipments.
10.3.3.3 Anti-rust and anti-corrosion measures should be taken for re-assembled spare parts.
10.3.3.4 The original nameplates, cases, labels of the equipments as well as handrails and platforms
around the equipments, etc. those are dismantled temporarily for affecting maintenance should be
recovered in time after re-assembly of equipments.
10.3.4 Requirements for decomposition, check, repair and re-assembly of equipments
In the whole process of decomposition, check, repair and re-assembly of equipments, detailed technical
inspections and technical records in clear writing should be available, data should be true, measurement
and analysis should be accurate, and all records should be intact, correct, concise and practical.
10.3.5 Quality control and supervision
10.3.5.1 The management for maintenance quality should implement combination of check of quality
control points and three-level acceptance, and if necessary supervision system can be incorporated.
10.3.5.2 Quality inspectors should check and certify H and W points affecting maintenance quality
directly in accordance with the provisions of the maintenance file package.
10.3.5.3 For disaccords found during maintenance, disaccord notice should be filled in and disaccords
be handled as per the corresponding procedures.
10.3.5.4 Signing responsibility system and quality traceability system should be implemented for
maintenance construction and quality acceptance for all items.
10.3.6 Safety management
10.3.6.1 During maintenance for equipments safety regulations should be carried out, safety
management be strengthened, safety responsibilities be identified and safety measures be practised to
ensure personal and equipment safety.
10.3.6.2 Work ticket system and contracting safety agreement should be strictly executed.
10.3.6.3 Safety check should be strengthened and safety analysis meetings be held at regular time.
10.4 Trial run and report for recommissioning
10.4.1 Branch trial runs should be carried out under charge of operators after segmental tests are
qualified, maintenance items are completed and the quality is qualified, technical records and related
data are complete, reports on abnormal operation of the related equipments and written reports on
maintenance disclosure have been submitted to operating department, disclosure has been made to
operators, clear-up of maintenance site is completed and safety facilities are recovered.
10.4.2 Clod (static) acceptance should be conducted chaired by persons of power plants in charge of
production after all branch trial runs are finished and trial run conditions are perfect with emphases on
examining completion of maintenance items, quality conditions, segmental tests, branch trial runs and
technical data of maintenance as well as on-site inspection.
10.4.3 Integral trial run
10.4.3.1 Conditions for integral trial run: cold (static) state acceptance is qualified, protections are
qualified upon verification and can all be put into operation, fire inspection has been completed,
equipment nameplates and identifications are correct and complete, reports on abnormal operation of
equipments and precautions in operation have been all submitted to operating department, trial run
program is reviewed and approved and operators have prepared for operation.
10
DL / T 838 一 2003
10.4.3.2 Integral trial run is conducted chaired by persons of power plants in charge of production and
covers various cold (static), hot (dynamic) state tests and on-load tests.
10.4.3.3 During trial run maintainers and operators should jointly check technical and operating
conditions of equipments.
10.4.3.4 On-load tests after maintenance run continuously for not over 24h, in which full-load tests
should last for 6h~8h.
10.4.4 If the units are confirmed normal after integral trial run and comprehensive check on site,
recommissioning is reported to power grid dispatcher.
10.5 Assessment and summary of maintenance
10.5.1 After recommissioning of the units, power plants should carry out summary and technical and
economic assessment for safety, quality, items, work hours, materials, spare parts, accessories,
technical supervision, costs in maintenance and trial runs of the units, etc. in time. The contents of cold
(static) state and hot (dynamic) state assessments for primary equipments are shown in Annex G.
10.5.2 The efficiency test is carried out within 20 days after recommissioning of the units, test reports are
submitted and efficiency is evaluated.
10.5.3 Final report of maintenance is submitted within 30 days after recommissioning of the units, and
the format of final report of maintenance is shown in Annex G.
10.5.4 Revise the maintenance file package, modify quota of spare parts and perfect computer
management database.
10.5.5 Technical data including technical records, test reports, quality inspection reports, reports on
abnormal operation of equipments, maintenance file package, quality supervision acceptance
certificates, maintenance management procedures or maintenance files, etc. with respect to
maintenance for equipments should be archived as specified. The contractors should arrange records
and associated file data of maintenance for equipments in the scope of their responsibilities and hand
over to power plants. Category of technical files for A/B classes maintenance is shown in Annex H.
11
DL / T 838 一 2003
Annex A
(Informative)
Table of reference items in A class maintenance
Table A.1 Table of reference items in A class maintenance for boilers
12
DL / T 838 一 2003
13
DL / T 838 一 2003
15
DL / T 838 一 2003
16
DL / T 838 一 2003
14. Steel frames, (1) Check observation doors, manhole doors, (1) Calibrate steel
boiler top sealing explosion doors and expansion joints, eliminate air frames;
and thermal leakage; (2) Overhaul over 20%
insulation (2) Check and repair dry bottom hoppers, thermal insulating layers;
insulation of water cooled walls and boiler top sealing; (3) Complete
(3) Anticorrosion of local steel frames; anticorrosion of boiler top
(4) Unchoke and repair cooling and ventilating devices covers and steel frames;
of beams; (4) Rework boiler top
(5) Check sinking and bending of steel girders and sealing.
beams.
15. Boiler water (1) Check and repair boiler water circulating pumps Upgrade motor windings
circulating pumps and motors;
(2) Check and repair filters, strainers, high-pressure
valves and pipelines;
17
DL / T 838 一 2003
18
DL / T 838 一 2003
Table A.2 Table of reference items in A class maintenance for steam turbines
Name of parts Standard items Special items
1. Cylinders (1) Check and repair cylinders and nozzles, clean (1) Replace part of nozzle
and check cylinder bolts, drain holes, pressure groups;
gage holes and thermometer sleeves; (2) Scrape junction surface of
(2) Clean and check diaphragm housing rings, cylinders;
diaphragms and stationary blades, measure (3) Replace all insulating
diaphragm deflection, and handle if necessary; layers of cylinders;
(3) Clean and check sliding pin system; (4) Repair weld cylinder
(4) Measure gap of junction surface of upper and cracks in large amount;
lower cylinders and longitudinal and horizontal (5) Replace diaphragm
levelness; housing rings and diaphragms;
(5) Measure and regulate diaphragm housing (6) Lift bearing boxes, check
rings and groove center of diaphragms; and repair sliding pin system
(6) Check and replace membranes of explosion or adjust levelness of
doors, check dehumidifiers and water sprinklers; cylinders;
(7) Replace seals of high and medium-pressure (7) Replace over 30%
inlet steam stub pipes; high-temperature alloy steel
(8) Repair insulating layers of cylinders. bolts.
2. Gland sealing (1) Clean, check, adjust and replace shaft seals Replace over 30% gland
and diaphragm gland sealing in small amount; sealing
(2) Clean and check gland sleeves;
(3) Measure deformation of shaft sleeves,
measure and adjust groove center of shaft sleeves.
3. Rotors (1) Check main shafts, impellers and other on (1) Regulate frequency of
shafts, measure and adjust clearance of flow blades;
passages, journal taper and coupling center; (2) Coupling reaming;
(2) Check and measure journal taper and ovality (3) Replace all coupler
and rotor bending, measure degrees of floating screws;
deviation and shake of impellers, couplers and (4) Dynamic balance of
thrust discs; rotors;
(3) Repair and grind thrust discs and journals; (5) Flaw detection of inner
(4) Clean and check moving blades, tie bars, bore of main shafts;
complex rings, rivets and hard metal tips, and (6) Straighten shafts;
perform anti-corrosion for last stage blades;
(7) Reinstall or replace the
(5) Measure part of blades, perform flaw detection whole set of blades;
for blades and blade roots;
(8) Replace impellers.
(6) Perform flaw detection for impeller keyways
and coupling connecting bolts those need key
monitoring;
(7) Perform flaw detection for rotor weld joints.
4. Bearings (1) Clean and check journal bearings and thrust Re-pour bearingrungsten-gold 批注 [f2]: 查不到,保留原文,请客
bearings, and repair if necessary, measure and or replace bearings 户确认。
adjust clearance of bearings and oil baffles and
tightening force of bearings;
(2) Clean bearing boxes.
5. Turning gears Check and measure abrasion of gears, female Replace complete barring
worm wheels, bearings and guided sliding sleeves, gears
etc., repair and replace if necessary.
6. Speed (1) Wash and check all assemblies of speed (1) Replace the whole set of
regulating system regulating system, check protection and test assemblies of speed
equipments, measure clearance and dimensions, regulating security system;
repair and replace parts if necessary; (2) Perform load shedding
19
DL / T 838 一 2003
20
DL / T 838 一 2003
21
DL / T 838 一 2003
22
DL / T 838 一 2003
Table A.3 Table of reference items in A class maintenance for turbine generators
Name of parts Standard items Special items
1. Stators (1) Check end covers, backplates, air deflectors (1) Replace stator bars or repair
and gaskets; bar insulation;
(2) Check and sweep outgoing lines and sleeves of (2) Reweld stator end winding
stator windings; joints;
(3) Check and sweep core clamping plates, (3) Replace over 25% slot
winding end insulation, check fastening, paint both wedges or end isolating wood;
ends of windings if necessary; (4) Repair part of cores or
(4) Check and sweep core, slot wedge and bar decompose and reassemble;
insulation at ventilating ducts, replace slot wedges in (5) Spot check over 6 internal
small amount if necessary; water-cooled stator winding
(5) Perform backwash, hydrostatic and flow tests hydroelectric joints;
for internal water-cooled stator windings; (6) Replace over 25% internal
(6) Measure clearance of corrugated plates; water-cooled stator winding
(7) Check and verify temperature measuring water conduits;
components. (7) Measure vibration at the end
of stator windings.
2. Rotors (1) Measure air gap; (1) Pull out retaining rings,
(2) Extract rotors, check and sweep rotor end handle interturn short-circuit or
windings, check rotor slot wedges, retaining rings, grounding faults of windings;
thimbles, fans, journals and counterweights; (2) Replace fan blades, slip
(3) Check and sweep brush carriers, slip rings, rings and leads;
leads, polish or turn slip rings if necessary; (3) Replace rotor winding
(4) Perform backwash, hydrostatic and flow tests insulation;
for internal water-cooled rotor windings, perform (4) Replace important structure
ventilation and air tight tests for internal parts such as rotor retaining
hydrogen-cooled rotors; rings and thimbles, etc.;
(5) Check internal water-cooled rotor water (5) Replace rotor water
conduits with endoscope; conduits.
(6) Perform flaw detection of centre holes of main
shafts and retaining rings of rotors, measure static
frequency of rotor fans.
3. Cooling (1) Air-cooled generators. Sweep air chambers, (1) Pickle inner walls of copper
system check tightness, paint air chambers if necessary, pipes;
check and sweep air coolers and gas filters. (2) Replace coolers.
(2) Internal water-cooled generators. Check and
clean cooling system, perform hydrostatic test of
coolers and eliminate leakage.
(3) Hydrogen-cooled generators. Check hydrogen
coolers and hydrogen system and carbon dioxide
system, eliminate air leakage, replace sealing
gaskets of hydrogen-cooled generators, perform
integral air-tight test of generators.
4. Excitation (1) Check and repair AC exciter stator and rotor (1) Replace exciter stator, rotor
system windings and cores, polish or turn slip rings if windings or slip rings;
necessary; (2) Maintain suspended cores
(2) Check and sweep excitation transformers; of excitation transformers;
(3) Check brushless exciter stator and rotor (3) Replace over 30% power
windings and cores, test rectifying elements and rectifying elements;
relevant control and regulating devices; (4) Replace modules of control
(4) Check and test power rectifying devices of devices in large amount.
static excitation system;
(5) Check and repair other equipments of excitation
23
DL / T 838 一 2003
24
DL / T 838 一 2003
Table A.4 Table of reference items in A class maintenance for control systems of thermal power
plants
26
DL / T 838 一 2003
28
DL / T 838 一 2003
Table A.5 Table of reference items in A class maintenance for wet flue gas desulfurization
devices
29
DL / T 838 一 2003
30
DL / T 838 一 2003
31
DL / T 838 一 2003
32
DL / T 838 一 2003
33
DL / T 838 一 2003
6. Speed (1) Decompose, check and clean parts and pipelines of speed (1) Replace main
regulating governors; distributing valves;
system (2) Check and deal with main distributing valves, auxiliary (2)Replace or
servomotors, pilot valves, hydraulic valves, fly pendulum rotating transform
sleeves and needle valve rods; servomotors;
(3) Adjust indication of guide vane opening and blade angle; (3)Replace
(4) Adjust and test bumpers, starting devices and emergency electrohydraulic
distributing valves, etc; converters.
(5) Decompose, check and adjust double reduction devices;
(6) Measure and regulate dead stroke of speed regulating
system;
(7) Verify settings of rotary speed difference mechanisms;
(8) Check and test electrohydraulic converters;
(9) Measure and regulate relation curves of servomotor stroke
and guide vane opening;
(10) Test static characteristics of speed governors;
(11) Measure and adjust switching time of guide vanes and
runner blades;
(12) Replace parts such as fly pendulum rotating sleeves and
needle valve rods, etc;
(13) Check and deal with electrohydraulic converters;
(14) Decompose and check fly pendulum and test
characteristics;
(15) Check and debug DEH system;
(16) Test or replace step motors and controllers.
7. Oil (1) Sweep, check, deal with pressure oil tanks, oil storage tanks, (1) Replace valve
pressure leak oil tanks and conduct anticorrosion; banks;
devices and (2) Sweep and check oil strainers and repair or replace; (2) Replace turbine
leakage oil (3) Decompose, check, repair and test oil pumps, safety valves, oil.
devices emptying valves, check valves and gulp valves and replace if
necessary;
(4) Sweep and check oil coolers, conduct pressure-tight test and
replace if necessary;
(5) Filter and test turbine oil;
(6) Conduct leakage test for speed regulating system;
*(7) Replace oil gauges;
*(8) Replace screws, gears and bushings of oil pumps;
*(9) Conduct pressure-tight test for pressure oil tanks and check
of pressure vessels.
8. Butterfly (1) Measure and adjust switching time before and after (1) Replace inlet
34
DL / T 838 一 2003
9. Oil heads (1) Decompose and check oil heads; (1) Replace operating
(2) Check operating oil pipes of oil heads; oil pipes of oil heads;
(3) Measure clearance of copper bearing bushings and scrape
copper bearing bushings; (2) Replace copper
(4) Check and deal with insulation. bearing bushings.
35
DL / T 838 一 2003
36
DL / T 838 一 2003
38
DL / T 838 一 2003
40
DL / T 838 一 2003
Table A.8 Computer monitoring and control system of hydropower generator units
Name of parts Standard items Special items
Computer (1) Sweep and check workstation (server) and its (1) Replace local control
monitoring and modules, replace spare parts if necessary; unit (LCU);
control system (2) Sweep and check voice alarm machines; (2) Replace remote
(3) Sweep and check communication components, optical cables;
and replace if necessary; (3) Replace or update
(4) Sweep and check power supplies and wiring; network cables;
(5) Sweep, check and test optical fibers and network (4) Update database;
cables; (5) Update or renew
(6) Sweep and check synchronization clock (GPS); application software;
(7) Detect network and perform switchover test (6) Update operating
between main and standby networks; platform;
(8) Test and adjust automatic generation control (7) Replace industrial
(AGC), automatic voltage control (AVC) and automatic personal computer;
frequency control (AFC) functions; (8) Replace data backup
(9) Arrange and backup database; devices;
(10) Update and perfect menus; (9) Transform
(11) Test software functions and backup; tour-inspection devices.
(12) Sweep and check industrial personal computer;
(13) Sweep, check and tour-inspect temperature
tester;
(14) Detect and test I/O contacts and pickup
characteristics of components;
(15) Detect I/O control circuits;
(16) Check and test automation measuring
components and actuators;
(17) Check and test ground system;
(18) Comprehensive simulate and test control and
protection functions;
(19) Detect anti-virus devices or systems at interfaces
of monitoring system with management information
system (MIS) and condition based maintenance
management system, etc.
Note: items without * are B class maintenance items.
41
DL / T 838 一 2003
Table A.9 Table of reference items in A class maintenance for main transformers
Name of parts Standard items Special items
1. Cases and insulating (1) Check and sweep cases and accessories, (1) Replace insulating oil;
oil eliminate oil seepage and leakage; (2) Replace or weld
(2) Check and sweep security protection devices, repair radiators;
such as explosion-proof tubes, pressure release (3) Paint oil on voltage
valves and gas relays, etc.; transformer cases
(3) Check respirators;
(4) Check and sweep oil level indication devices;
(5) Perform electrical and chemical tests of
insulating oil, filter or regenerate insulating oil
according to oil quality;
(6) Check grounding of cases and cores
2. Cores and windings (1) In the first A class maintenance for non-sealed (1) Repair welding of
transformers, if major cover or manhole cover cases;
cannot be opened for internal check, check by (2) Repair or replace
lifting hoods (cores), in A class maintenance later windings;
lifting hoods (cores) should be determined in (3) Dry windings;
accordance with results of operation, check and
test, etc. (4) Repair cores;
(2) After lifting hoods (cores), check grounding of (5) Lift hoods of sealed
cores and iron cases and insulation of through transformers
bolts, check and clean windings and winding
pressing devices, cushion blocks, bolts on all parts
of leads and terminal plates;
(3) Measure clearance of oil passages, detect
aging degree of insulation materials;
(4) Replace all oil resistant rubber pads of
components those have been checked.
3. Cooling system (1) Check fan motors and control circuits; (1) Replace pumps or
(2) Check and repair forced oil circulation pumps, motors;
oil flow relays and their control circuits, pipelines (2) Replace cooler cores.
and valves;
(3) Check and clean coolers.
4. Tap changers Check and repair on-load or no-load tap changer Replace parts of switching
switching devices. devices
5. Sleeves (1) Check and sweep all sleeves; (1) Replace sleeves;
(2) Check insulating oil quality of oil filled sleeves. (2) Decompose and
maintain sleeves.
6. Others (1) Replace all sealing rubber pads; Check nitrogen protection
(2) Perform preventive test and partial discharge devices
test;
(3) Check and sweep devices and cables
distributing power with primary systems of
transformers;
(4) Check and verify measuring instruments,
protecting devices, on-line monitoring devices and
control signal circuits;
(5) Check and test fire-fighting system;
(6) Clean oil drain pits.
42
DL / T 838 一 2003
Annex B
(informative)
Table of three-year ( — ) maintenance project rolling planning
Filled in by: Filled in on:
Date Main
Days Require
( month, bases Costs
Predicted added in d main
year) of Major and (RMB
year of time limit apparatu Remark
Project name previous A specia technica 10,00
implementatio for s and s
class l items l 0
n maintenan spare
maintenan measure yuan)
ce parts
ce s
1. Primary
equipments
2. Accessory
equipments
3. Production
buildings
(structures)
4.
Non-production
facilities
Note 1: Major special items predicted subject to A class maintenance in all three years should be filled in
this table;
Note 2: In “days added in time limit for maintenance” field only days added in time limit for maintenance
in execution of this item more than those for standard items are filled in;
Note 3: In “main apparatus and spare parts” field only apparatus and spare parts those should be
ordered in advance for a great number, difficult ordering and long processing period are filled in.
43
DL / T 838 一 2003
Annex C
(informative)
Table of ( ) annual maintenance project plan
Filled in by: Filled in on:
Unit project Maintenance time
Reasons Requir Costs
name Wor
for special ed Time limit (RMB
Proje (equipment Maintenanc k Remark
items main Time for for 10,00
ct No. name and e items day s
listed in apparat commen maintena 0
maintenance cement s
the plan us nce yuan)
grades)
1. Primary 1. Standard
equipments items
1. x class 2. Special
maintenance for items
unit x
2. x class
maintenance for
unit x
......
2. Maintenance
for accessory
equipments
......
3. Maintenance
for production
buildings
(structures)
4. Maintenance
for
non-production
facilities
Total
Note: for standard items of primary equipments, only work days and costs other than detailed
maintenance contents are filled in; while for special items of primary equipments and major special items
of accessory equipments, items, reasons, work days, costs and main technical measures, etc. should be
filled in one by one.
44
DL / T 838 一 2003
Annex D
(informative)
Table ( ) annual maintenance duration plan
Filled in by: Filled in on:
Previous This maintenance
maintenance grades and
Name and category
Capacity MW grades and scheduled time for Remarks
of units
completion time of commencement
maintenance and completion
45
DL / T 838 一 2003
Annex E
(informative)
Main contents of maintenance file package
Name of power plants List of file samples Edition: In total pages
in file package of
maintenance for
unit equipments
Serial No. Name Content Remarks
1 Maintenance task (1) Maintenance plan; (2) Work permit; Part of items can
order (3) Equipment trial run plan after be added or
maintenance; (4) Disclosure before removed in
maintenance (equipment conditions, accordance with
former work experiences, main defects needs
before maintenance, safety technical
measures for special items)
2 Preparations before (1) Drawings and data required for
maintenance equipment maintenance; (2) List of main
spare parts, accessories and materials;
(3) Preparation of tools (special tools,
general tools, test instruments and
measuring instruments, etc.)
3 Working (1) Work permitted or not; (2) Site
procedures and preparation; (3) Disassembly and
technologies of decomposition, maintenance, working
maintenance procedures and technological standards
during re-assembly; (4) Arrangement of
maintenance records; (5) Self-check; (6)
End of work
4 Records of In accordance with
modification for specific conditions
working procedures
5 Quality certification Certification of quality control points and
order three-level acceptance
6 Disaccord process
sheet
7 Equipment trial run Trial run procedures and measures
order
8 Completion report (1) Maintenance duration; (2) Major
card work of maintenance; (3) Defects
handling (including main defects found
and eliminated in maintenance); (4)
Defects not eliminated yet and reasons;
(5) Equipment changes or
improvements, reports on abnormal
operation and drawing modifications; (6)
Technical records; (7) Quality
acceptance; (8) Equipment and personal
safety; (9) Records of actual
consumption of work days; (10)
Comments on consumption of spare
parts, accessories and materials; (11)
Overall check and acceptance
46
DL / T 838 一 2003
Annex F
(informative)
Block diagram of management procedures for the whole process of A/B
classes maintenance for generator units
Scheduling department
and files
procedures and
maintenance file package
Power grid scheduling
department issues monthly Modify maintenance
management procedures
maintenance plan
and maintenance file
package
and and prepare maintenance
ends
Process acceptance
and check of file package
Equipment repair
network
for
summary to competent
Report unit maintenance
preparations
Compile
authority
Adjust network diagram if
for
for
extension to power grid
application
Propose
plan
tests, technical
quality
Equipment decomposition
Competent authority
approves the next annual Integral trial run
Disaccord handling
project plan
evaluation
47
DL / T 838 一 2003
Annex G
(informative)
Final reports on cold/hot state evaluation for A/B classes maintenance
and on maintenance for primary equipments
G. 1 Report on cold/hot state evaluation for A/B classes maintenance
Power plant No. Unit MW (Month) (Day) (Year)
1. Days of time limit for maintenance
Scheduled: _____ (Month) _____ (Day) _____ (Year) to _____ (Month) _____ (Day) _____ (Year), in
total _____ days.
Actual: _____ (Month) _____ (Day)_____ (Year) to _____ (Month) _____ (Day)_____ (Year), in total
_____ days.
2. Manpower
Scheduled: _____man-hours, actual: _____man-hours.
3. Maintenance costs
Scheduled: _____RMB 10,000 yuan, actual: _____RMB 10,000 yuan.
4. Maintenance and operation
Operating hours from end of previous A/B classes maintenance to start of this A/B classes maintenance ,
standby hours_____ .
C/D classes maintenance from end of previous A/B classes maintenance to start of this A/B classes
maintenance for_____ times, hours of time limit for maintenance_____ .
Unscheduled time limit for maintenance from end of previous A/B classes maintenance to start of this
A/B classes maintenance for times, h, coefficient of unscheduled shutdown___, in which, forced
shutdown for_____ h, and equivalent forced shutdown system_____ .
Calendar hours from end of previous A/B classes maintenance to start of this A/B classes
maintenance:_____ , available hours_____ , equivalent available coefficient_____ , max. continuous
available days_____ , and min. continuous available days_____ .
5. Cold state evaluation for primary equipments after maintenance
5.1 Project execution
Project completion; elimination of major defects of equipments; disaccord handling; handling of
problems found in maintenance; rework rate of poor maintenance and failure rate of man-made damage
to parts, etc.
5.2 Completion of maintenance duration
Completion of the scheduled maintenance duration; reasonable arrangement of maintenance duration of
unscheduled items; application and approval for extension of maintenance duration for special cases,
etc.
5.3 Safety
Examination of safety during maintenance; safety measures and implementation during maintenance,
etc.
5.4 Evaluation for acceptance
Evaluation for excellence rate of three-level acceptance for maintenance items and inspection of H and
W points.
5.5 Branch trial run and major interlocking
Right first time of branch trial run; right first time of major interlocking; health conditions of trial run
equipments (such as vibration of rotary equipments, leakage of equipments, integrity of equipments after
maintenance), etc.
48
DL / T 838 一 2003
49
DL / T 838 一 2003
50
DL / T 838 一 2003
2. Brief summary
(1) Construction organization and safety.
(2) Application of maintenance file package and working procedure cards.
(3) Major defects of equipments removed and main measures taken in maintenance.
(4) Contents and results of major modifications of equipments.
(5) Brief analysis of manpower and costs (including manpower and costs of major special items).
(6) Main remaining problems after maintenance and countermeasures to be taken.
(7) Brief analysis of test results.
(8) Others.
Professional person in charge
Person in charge of production of power plant
G.3 Final report on A/B classes maintenance for steam turbines
Power plant, No._____ steam turbine_____ (Month)_____ (Day)_____ (Year),
manufacturer_____ , model_____ , capacity_____ MW, inlet steam pressure_____ MPa (gauge
pressure), inlet steam temperature_____ ℃, adjusted extraction pressure kPa (gauge pressure) and
_____ kPa (absolute pressure)
1. Overview
(1) Days of time limit for maintenance
Scheduled: perform the _ A/B classes maintenance from (Month)_____ (Day)_____ (Year) to_____
(Month)_____ (Day) _____ (Year), in total_____ days.
Actual: report completion from (Month)_____ (Day)_____ (Year) to_____ (Month)_____ (Day)_____
(Year), in total_____ days.
(2) Manpower
Scheduled: ____man-hours, actual: ____man-hours.
(3) Maintenance costs
Scheduled: ____RMB yuan, actual: ____RMB yuan.
(4) Operation
Operating hours from end of previous maintenance to start of this maintenance , standby hours .
(5) Completion of maintenance items
Technological
Standard Special Increased Decreased
Content Sub-total transformation Remarks
items items items items
items
Scheduled
number
Actual
number
(6) Quality acceptance
51
DL / T 838 一 2003
Disaccord Three-level
H point W point
Content notice acceptance
Total Qualified Unqualified Total Qualified Unqualified
Scheduled
number
Actual
number
(7) Main technical indices of operation before and after maintenance
Serial Before After
Index item Unit
No. maintenance maintenance
1 Max. output at the rated parameters MW
Vibration values of main bearings (or
mm
shafts) (including generators)
No. bearing (or shaft)
2
No. bearing (or shaft)
........................
.........................
Efficiency
3 (1) Steam consumption rate kg/ (kW.h)
(2) Heat consumption rate kJ/ (kW.h)
Characteristics of condenser
(1) Flow rate of condensate t/h
(2) Circulating water inlet
℃
temperature
4
kPa (absolute
(3) Exhaust steam pressure
pressure)
(4) Difference between exhaust
steam temperature and circulating ℃
water outlet temperature
Vacuum tightness (at ______MW
5 a/min
load)
Characteristics of speed regulating
system
6
(1) Speed variation %
(2) Delay rate %
Note: in table the values in 2, 3 and 4 should be test figures of the rated load or possibly the max. load.
The tests before and after maintenance should be carried out at the same load.
(8) Comments on maintenance
2. Brief summary
(1) Construction organization and safety.
(2) Application of maintenance file package and working procedure cards.
(3) Major defects of equipments removed and main measures taken in maintenance.
(4) Contents and results of major modifications of equipments.
52
DL / T 838 一 2003
(5) Brief analysis of manpower and costs (including manpower and costs of major special items).
(6) Main remaining problems after maintenance and countermeasures to be taken.
(7) Brief analysis of test results.
(8) Others.
Professional person in charge
Person in charge of production of power plant
G.4 Final report on A/B classes maintenance for steam turbine generators
MVA,____kV
Power plant, No.______generator (Month)______(Day)______(Year) Manufacturer______,
model______, cooling method______, capacity______MVA, rated voltage kV
1. Overview
(1) Days of time limit for maintenance
Scheduled: perform the _____ A/B classes maintenance from (Month)______(Day)______(Year)
to______(Month)______(Day)______(Year), in total______days.
Actual: report completion from (Month)______(Day)______(Year)
to______(Month)______(Day)______(Year), in total______days.
(2) Manpower
Scheduled: ____man-hours, actual: ____man-hours.
(3) Maintenance costs
Scheduled: ____RMB yuan, actual: ____RMB yuan.
(4) Operation
Operating hours from end of previous maintenance to start of this maintenance , standby hours______.
(5) Completion of maintenance items
Technological
Standard Special Increased Decreased
Content Sub-total transformation Remarks
items items items items
items
Scheduled
number
Actual
number
(6) Quality acceptance
Disaccord Three-level
H point W point
Content notice acceptance
Total Qualified Unqualified Total Qualified Unqualified
Scheduled
number
Actual
number
(7) Comments on maintenance
2. Brief summary
(1) Construction organization and safety.
53
DL / T 838 一 2003
Scheduled
number
Actual
number
(7) Main technical indices of operation before and after maintenance
Serial No. Index item Unit Before After maintenance
maintenance
1 Output after conversion to design MW
head
Opening %
Efficiency %
Water consumption rate m 3/ (kW·h)
2 Vibration and swing mm
(double-amplitude)
Max. vertical vibration of load frame mm
Max. horizontal vibration of upper mm
frame
Max. swing of upper guide bearing mm
Max. swing at connecting flange of mm
main shaft
Max. swing of turbine guide bearing mm
Vibration value of No. bearing mm
(horizontal axis unit)
3 Operating temperature rise of unit
(recording the max. value)
No. thrust bearing bushing ℃
No. upper guide bearing bushing ℃
No. lower guide bearing bushing ℃
No. turbine guide bearing bushing (oil ℃
lubrication)
Max. temperature of stator winding ℃
4 Speed regulating system
Residual unbalance %
Max. insensitive zone %
(8) Comments on maintenance
3. Brief summary
(1) Construction organization and safety.
(2) Application of maintenance file package and working procedure cards.
(3) Major defects of equipments removed and main measures taken in maintenance.
(4) Contents and results of major modifications of equipments.
(5) Brief analysis of manpower and costs (including manpower and costs of major special items).
(6) Main remaining problems after maintenance and countermeasures to be taken.
55
DL / T 838 一 2003
56
DL / T 838 一 2003
Scheduled
number
Actual
number
(7) Reasons of maintenance
Location of maintenance____, weather for maintenance by lifting hood (core)____, ambient
temperature____℃, relative humidity____%, check of lifting shield (core) from
_____(month)____(day)____(hour)____(minute) to_____(month)____(day)____(hour)____(minute) ,
participants in lifting hood (core):________
(八)检修工作评语
(8) Comments on maintenance
2. Brief summary
(1) Construction organization and safety.
(2) Application of maintenance file package and working procedure cards.
(3) Major defects of equipments removed and main measures taken in maintenance.
(4) Contents and results of major modifications of equipments.
(5) Brief analysis of manpower and costs (including manpower and costs of major special items).
(6) Main remaining problems after maintenance and countermeasures to be taken.
(7) Brief analysis of test results.
(8) Others.
Professional person in charge
Person in charge of production of power plant
G.7 Final report on A/B classes maintenance for control systems of thermal generator units
________Power plant No.________unit control system ______(Month)______(Day)______(Year)
Steam turbine manufacturer________type________capacity________, boiler
manufacturer_______type _______evaporation capacity____
Generator manufacturer________type________capacity________, automatic control type________,
manufacturer________
Steam turbine control____, control type of feedwater pump steam turbine____, boiler control type____,
steam turbine/boiler coordinated control____
1. Overview
(1) Days of time limit for maintenance
Scheduled: perform the ______ A/B classes maintenance from (Month)______(Day)______(Year)
to______(Month)______(Day)______(Year), in total______days.
Actual: report completion from (Month)______(Day)______(Year)
to______(Month)______(Day)______(Year), in total______days.
(2) Manpower
Scheduled: ____man-hours, actual: ____man-hours.
(3) Maintenance costs
Scheduled: ____RMB yuan, actual: ____RMB yuan.
(4) Operation
57
DL / T 838 一 2003
Operating hours from end of previous maintenance to start of this maintenance , standby hours______.
(5) Completion of maintenance items
Technological
Standard Special Increased Decreased
Content Sub-total transformation Remarks
items items items items
items
Scheduled
number
Actual
number
(6) Quality acceptance
Disaccord Three-level
H point W point
Content notice acceptance
Total Qualified Unqualified Total Qualified Unqualified
Scheduled
number
Actual
number
(7) Thermotechnical supervision of “three rates”
Before maintenance After maintenance
Content Commissioning Designed Commissioning Remarks
Designed number
rate or accuracy number (sets, rate or accuracy
(sets, pcs)
rate % pcs) rate %
Instrument
accuracy rate
Automatic
commissioning
rate
Protection
commissioning
rate
(8) Comments on maintenance
2. Brief summary
(1) Construction organization and safety.
(2) Application of maintenance file package and working procedure cards.
(3) Major defects of equipments removed and main measures taken in maintenance.
(4) Contents and results of major modifications of equipments.
(5) Brief analysis of manpower and costs (including manpower and costs of major special items).
(6) Main remaining problems after maintenance and countermeasures to be taken.
(7) Brief analysis of test results.
(8) Others.
Professional person in charge
Person in charge of production of power plant
G.8 Final report on A/B classes maintenance for control systems of hydro-generator units
58
DL / T 838 一 2003
Insulation on-line
monitoring
Air gap on-line
monitoring
Cavitation on-line
monitoring
Efficiency on-line
monitoring
Main transformer oil
chromatography on-line
monitoring
Main transformer partial
discharge on-line
monitoring
Main transformer
self-extinguishing system
4. Brief explanation
(1) Major defects of devices removed, analysis of reasons and main measures taken in maintenance.
(2) Contents and results of updating and transformation of devices.
(3) Brief analysis of manpower and costs (including manpower and costs of major special items).
(4) Main remaining problems in devices after maintenance and countermeasures to be taken.
(5) Description of model, manufacturer, main parameters, performance and structural configuration of
new commissioning devices.
(6) Success rate of start/stop before and after maintenance, analysis of reasons and measures taken.
(7) Analysis and evaluation for on-line monitoring system data before and after maintenance.
(8) Analysis for oil chromatography of transformers before and after maintenance.
(9) Others.
Professional person in charge
Person in charge of production of power plant
60
DL / T 838 一 2003
Annex H
(informative)
Reference table of technical documents for A/B classes maintenance
H1 Maintenance preparation and process H1.23 Application forms for abnormal operation of
documents equipments
H1.1 Maintenance plan assignments and annual H1.24 Provisions for transaction of work tickets
maintenance plans during shutdown of units
H1.2 Maintenance project plans (identifying H1.25 Various site record forms for maintenance
standard items and special items) H1.26 Safety, economic and technical indices of
H1.3 Work plans of management for the whole units
process of unit maintenance (or quality manuals for H1.27 Integral trial run programs of units
unit maintenance) H2 Documents in summary phase of maintenance
H1.4 Organizations, job responsibilities and H2.1 Maintenance item schedules (comparison
working procedures of maintenance between the scheduled and the actual)
H1.5 Maintenance item progress and network H2.2 Technical measures and summary of
diagram (comparison between the scheduled and construction for major special items
the actual)
H2.3 Design data and drawings to change system
H1.6 Plans of spare parts and materials unit and equipment structures
maintenance
H2.4 Quality supervision reports
H1.7 Plans of tools and instruments and safety
appliances H2.5 Special summary for technical records and
technical experiences of maintenance
H1.8 Analysis reports on operation of unit
equipments H2.6 Statistical data on workhours and material
consumption of maintenance
H1.9 Test items of units before maintenance
H2.7 Acceptance data on quality supervision
H1.10 Statistics of defects before maintenance
H2.8 Test reports on thermal efficiency of thermal
H1.11 Technological disciplines for unit generator units before and after maintenance
maintenance
H2.9 Test reports on speed regulating system
H1.12 Safety, organizational and technical characteristics of steam turbines (hydroturbines)
measures for maintenance items before and after maintenance
H1.13 Various assessment rules for maintenance H2.10 Test reports on blade frequency of steam
(assessment methods for maintenance turbines
management, quality and civilized production, etc.)
H2.11 Test and authentication reports on materials
H1.14 Quality supervision acceptance plans and welding of important parts
H1.15 Application forms, acceptance certificates H2.12 Check and test reports on various technical
and advice notes, etc. of quality acceptance supervions
H1.16 Advice notes of disaccords H2.13 Adjustment and test records of electric,
H1.17 Working procedure cards (process cards) thermodynamic instrumentation and automatic
and technological procedures of maintenance devices
operation H2.14 Test records of electric equipments
H1.18 Maintenance file package and administrative H2.15 Starting/debugging measures and
regulations for its use debugging reports
H1.19 Technical supervision and supervision plans H2.16 Reports on abnormal operation of
of boilers and pressure vessels equipments and systems
H1.20 Schedules of foreign contracted projects H2.17 Explanations of various specialties for
H1.21 Safety, quality, technical agreements and maintenance (before cold state acceptance)
contracts of foreign contracted projects H2.18 Summary and evaluation reports on cold and
H1.22 Fixed location control chart of maintenance hot state acceptance
site H2.19 Final reports on maintenance for units
_______________________
61