DL T 838 - Standard of China Power Plant

ICS 27.
100
F 23
File No.: 11439-2003
Electric Power Industry Standard of the

People’s Republic of China
DL / T 838-2003
In place of SD230 1987
Guide of Maintenance for Power Plant Equipments
Issued on 2003-01-09 Implemented on 2003-06-01
Issued by the State Economic and Trade Commission

of the People’s Republic of China
DL / T 838 一 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
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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.
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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”.
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DL / T 838 一 2003
Guide of Maintenance for Power Plant Equipments

1 Scope
This standard specifies intervals, time limit, items and plans of maintenance for power plant equipments
as well as the associated contents of management.
This standard is applicable to maintenance for thermal power generating equipments with the capacity of
single generator at 100MW and above or hydropower generating equipments with the capacity of single
generator at 40MW and below. Maintenance for thermal or hydropower generating equipments in other
capacities can be executed by reference to this standard.
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)
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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.
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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.
5 Basic requirements for management of maintenance

5.1 Power plants should complete all established maintenance operations within the specified period
and achieve quality targets and standards to guarantee safe, stable and economic operation of the units
as well as integrity and fastness of buildings and structures.
5.2 Maintenance for power generating equipments should employ the method PDCA (P-plan, D-do,
C-check and A-action) cycle to stipulate various plans and specific measures starting from preparations
for maintenance and accomplish construction, acceptance and assessment after maintenance.
5.3 Power plants should establish quality management system and organization, compile quality
management manual, perfect program files and practise management of working procedures as per the
requirements of GB/T19001 Quality Management Standard.
5.4 Power plants should develop measures for environmental protection and labor protection during
maintenance, dispose of various wastes in a reasonable way, improve operating environment and labor
conditions, and conduct civilized construction and clean production.
5.5 Equipment maintainers should be familiar with construction, performance and principle of systems
and equipments, with maintenance technology, working procedures, debugging methods and quality
standards, and with safe work procedures; be able to grasp skills of bench worker and electrician and
other skills in close relation with their specialties, and to understand drawings and plot simple spare
parts diagrams and electrical schematic diagrams.
5.6 Maintenance construction should adopt advanced technologies, new techniques and new methods,
popularize application of new materials and new tools to improve work efficiency and shorten
maintenance duration.
5.7 Power plants should establish equipment condition monitoring and diagnosing organization and
implement condition based maintenance for key equipments with big influences on reliability and safety
of the units.
5.8 Power plants should employ advanced computer management system for maintenance to realize
modernization of management for maintenance.
6 Maintenance intervals and time limit for maintenance
6.1 Maintenance intervals
6.1.1 Maintenance for generator units is divided into A, B, C and D classes. The intervals and grade
combinations of A class maintenance for various units can be executed as per the provisions in Table 1.
6.1.2 Power plants can adjust the intervals of A class maintenance as appropriate in accordance with
technical performance and actual operating hours of the units and adopt different grade combinations,
but should carry out technological demonstration and get approval of superior authorities.
6.1.3 For thermal power units with at least twice start/stop peak-load regulation per week, domestic
thermal power units in accumulative operation for 150,000h and above and the units fired by low-grade
fuels (lower heating value less than 14654 kJ/kg), the intervals of A class maintenance can be less than
the values specified in Table 1 and one D class maintenance or time limit of one D class maintenance
can be added per year as the case may be.
6.1.4 The first A/B classes maintenance for new units can be decided dependent on the requirements of
the manufacturers, the provisions in the contract and specific conditions of the units. On condition that
no definite provisions are made by the manufacturers, maintenance is in general arranged in
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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
Intervals of A class Grade combinations of

Type of units
maintenance in years maintenance
Imported steam turbine generator units 6~8 One B class maintenance is
arranged between two A class
Domestic steam turbine generator units 4~6
maintenances; except the years
Hydro-generator units of hydropower 4~6 with A and B classes
stations with more sediment maintenance, one C class
Hydro-generator units of hydropower 8~10 maintenance is arranged, and
stations without more sediment one D class maintenance can be
added per year as the case may
be. If the interval of A class
maintenance is 6 years, the
combination of maintenance
grades is 1-C（D）- C（D）-B-
C（D）- C（D）-A (i.e. one A class
maintenance can be arranged in
the first year, one C class
maintenance can be arranged in
the second year, and one D class
maintenance can be added as the
case may be, and so on and so
forth in the future).
Main transformers Determined according to One C class maintenance per
operating conditions and test year
results, and in general 10
years
6.2 Maintenance for ancillary equipments and accessory equipments
Maintenance grades and intervals of ancillary equipments and accessory equipments of primary
equipments should be determined based on the results of monitoring and assessment for equipment
conditions and the requirements of the manufacturers and in accordance with the principles in article 6.1.
6.3 Time limit for maintenance for generator units
6.3.1 The time limit for maintenance for standard items in generator units is shown in Table 2 or
Table 3.
Table 2 Time limit for maintenance for standard items in steam turbine generator units
Maintenance grades
Capacity of units P
MW A class B class C class D class
maintenance d maintenance d maintenance d maintenance d
100≤P<200 32 〜38 14 〜22 9〜12 5〜7
200≤P<300 45 〜48 25 〜32 14 〜16 7〜9
300≤P<500 50 〜58 25 〜34 18 〜22 9〜12
500≤P<750 60 〜68 30 〜45 20 〜26 9〜12
750≤P<1000 70 〜80 35 〜50 26 〜30 9〜15
Note: time limit for maintenance has included the time required for on-load test.
6.3.2 The time limit for maintenance for boilers and heating steam turbine generator units in header
system can be found out in Table 2 in accordance with the capacity of condensing type steam turbine
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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.
7 Maintenance items and maintenance plans

7.1 Determination of maintenance items
7.1.1 Maintenance items of primary equipments include standard items and special items (for items in A
class maintenance for primary equipments, refer to Annex A).
7.1.1.1 Main contents of standard items in A class maintenance:
a) Items required by the manufacturers:
b) Overall decomposition, regular check, sweep, measurement, adjustment and repair;
c) Regular monitoring, test, verification and authentication;
d) Items requiring regular replacement of spare parts as specified;
e) Items to be checked as per the provisions in various technical supervisions;
f) Elimination of defects and hidden troubles in equipments and systems.
7.1.1.2 B class maintenance items refer to the targeted implementation of part of A class maintenance
items and time based rolling maintenance items in accordance with the evaluation for conditions of the
unit equipments as well as features and operating conditions of the systems.
7.1.1.3 Main contents of standard items in C class maintenance:
a) Elimination of defects in operation;
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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
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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.
8 Management for maintenance materials, spare parts and maintenance

costs
8.1 Management for maintenance materials and spare parts
8.1.1 Power plants should establish a management system for maintenance materials and spare parts,
which contents should include the requirements for compilation of plan, ordering and procurement,
transportation, acceptance and storage, disaccord handling, record and information, etc.
8.1.2 Maintenance materials demand plan should be compiled by professional engineers (or
professional spot inspectors) and be enclosed with technical requirements and quality guarantee
requirements. For bulk materials, special materials, electromechanical products and spare parts
required for special maintenance items, specialized plan should be compiled, technical specification be
worked out, and bidding procurement be conducted. In particular storage and management of
emergency spare parts and accessories should be strengthened.
8.1.3 After major special items proposed in the three-year maintenance project rolling planning are
approved and technical scheme is identified, invitation for bid, ordering and internal/external technical
cooperation research, etc. of spare parts and accessories and special materials should be implemented
as soon as possible.
8.1.4 Materials and spare parts required for standard items should be implemented as per the quota. For
materials and spare parts required for special items, material plan can be compiled by all professional
engineers and submitted to departments concerned for procurement after examination.
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8.2 Management for maintenance costs

8.2.1 Power plants should establish management system for maintenance costs and implement budget
management and cost control.
8.2.2 Maintenance costs should be used and settled based on applications and maintenance grades,
respectively in accordance with financial system
8.2.3 For major special items approved in the three-year maintenance project rolling planning, withdraw
in advance of funds required is allowed.
8.2.4 On the premise that power plants accomplish annual maintenance tasks, maintenance
expenditures for primary equipments, accessory equipments and production buildings are permitted for
transfer each other; but maintenance funds for production equipments and production buildings shall not
be transferred to maintenance and service of non-production facilities.
9 Management for foreign contracted projects
9.1 Power plants should establish management system for foreign contracted projects. In general
maintenance for unit control systems and relay protection systems should not be foreign contracted.
9.2 Contractors should have corresponding qualifications, performances and perfect quality assurance
systems and should be determined in tendering manner.
9.3 Contract management should be implemented for foreign contracted projects. In contracts clauses of
items, safety, quality, schedule, payment terms and obligations for breach of contract, etc. should be
clarified, and appropriate quality guarantee deposit should be reserved.
9.4 Quality management of foreign contracted projects.
9.4.1 Power plants should, beginning from approval for projects, identify technical persons in charge and
quality acceptors of foreign contracted projects to implement quality management for the whole process
of projects.
9.4.2 Power plants should compile maintenance file package (refer to Annex E for main contents) and
set H and W points in accordance with quality requirements and operation procedures and make
technical disclosure to the contractors. The contractors should operate strictly in accordance with the
maintenance file package.
9.4.3 Post assessment for foreign contracted projects should be strengthened to evaluate work
performances of the contractors.
9.5 Safety management of foreign contracted projects.
9.5.1 Safety technical agreements should be provided for foreign contracted projects to identify
responsibilities of the contract parties and implement the system of joint supervision and acceptance by
both parties.
9.5.2 Before access to the production site, construction teams of the contractors should be subject to
education on safety knowledge conducted by safety supervision departments of power plants and be
qualified after exams.
9.5.3 Personnel for special operations including cranemen, electric welders and scaffolders, etc.
undertaking site operations and personnel for calibration of measuring instrumentation from the
contractors should hold corresponding qualification certificates. Tools and instruments in use should
comply with the relevant safety and technical provisions and be enclosed with qualified calibration
certificates.
9.6 The contractors should strictly abide by the relevant rules and regulations of power plants.
10 Management for the whole process of maintenance for power

generating equipments
10.1 Concept of management for the whole process of maintenance
The management for the whole process of maintenance means that all management items, files and
personnel, etc. in formulation of maintenance plan, procurement of materials, spare parts and
accessories, compilation of technical files, construction, cold (static) state acceptance, hot (dynamic)
state acceptance and maintenance summary are under control so as to achieve anticipated
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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
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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.
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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.
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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
Name of parts Standard items Special items

1. Drums (1) Maintain manhole doors, check and clean (1) Replace, improve or
internal corrosion and scaling of drums; maintain large amount of
(2) Check internal weld joints and steam-water steam-water separators;
separators; (2) Disassemble over 50%
(3) Measure inclination and bending of drums; insulating layers;
(4) Check and clean internal devices including (3) Repair welding, patching
connecting pipes of water level indicators, pipe and opening of drums.
joints of pressure meters, chemical dosing pipes,
blowdown pipes and emergency drain pipes, etc.;
(5) Check and clean supports and hangers, top
corrugated plate cases and perforated plates, etc.,
verify water level indicators;
(6) Remove steam-water separators; clean and
repair some parts.
2. Water cooled (1) Clean coke button and ash deposition on outer (1) Replace headers;
wall pipes and walls of pipes, and check weld joints and fins; (2) Replace over 50% water
headers (2) Check abrasion, expanded thickness, cooled wall pipes;
deformation, damage, sweep of gases and (3) Pickle water cooled wall
high-temperature corrosion of outer walls of pipes; pipes.
measure thickness of water cooled walls, and
replace a few pipes;
(3) Check supports and hangers, expansion gap
of pull hooks;
(4) Regulate tightening force of supports and
hangers of headers;
(5) Check, repair and calibrate pipes, pipe banks
and pipe clamps, etc.;
(6) Open header handholes or cut off glands;
check and clean corrosion and scaling, and clean
inner deposits;
(7) Cut off pipes for sampling.
3. Superheaters, (1) Clean soot formation of outer wall of pipes (1) Replace over 5% pipes or
reheaters and (2) Check abrasion, expanded thickness, bending, handle a large amount of weld
headers corrosion, deformation of the pipes; measure wall joints;
thickness and creeping expansion; (2) Patch or replace headers;
(3) Check and repair pipe supports and hangers, (3) Replace over 25% pipe
pipe straps and abrasion-proof devices, etc.; supports and clamps;
(5) Check and regulate supports and hangers of (4) Expand over10% heating
headers; surface;
(5) Open handholes or cut off glands; check (5) Pickle superheaters and
corrosion and clean scaling; reheaters.
(6) Measure creeping expansion of steam header
pipe segments at the temperature of more than
450℃, check welded junction of header pipe seats;
(7) Cut off pipes for sampling;
(8) Replace a few pipes;
(9) Calibrate pipe banks;
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DL / T 838 一 2003
(10) Check elbows of steam conduits at the exit

and weld joints of steam headers.
4. Economizers (1) Sweep ash deposition on outer walls of pipes; (1) Handle a large amount of
and headers (2) Check pipe abrasion, deformation and defective welded junction of
corrosion, etc.; replace unqualified pipes and coil pipes or replace over 5%
elbows; pipes;
(3) Maintain supports and hangers, pipe clamps (2) Pickle economizers;
and abrasion-proof devices; (3) Replace complete
(4) Check and regulate supports and hangers of economizers;
headers; (4) Replace headers;
(5) Open handholes, check corrosion and scaling, (5) Increase or decrease over
clean inside; 10% heating surface of
(6) Calibrate pipe banks; economizers.
(7) Measure creeping expansion of pipes.
5. Desuperheaters (1) Check and repair hybrid desuperheater (1) Replace desuperheater
headers and inlet pipes, replace nozzles if cores;
necessary; (2) Replace desuperheater
(2) Check core pulling of indirect-contact heaters or inner sleeves.
desuperheaters or replace desuperheater pipes;
(3) Check and repair supports and hangers.
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DL / T 838 一 2003
Table A.1 (continued)

6. Combustion (1) Clean coking around combustors and repair (1) Replace over 30%
equipments insulated burning zones; combustors;
(2) Maintain combustors, replace nozzles; check and (2) Replace over 60% air
weld up bellows; dampers;
(3) Check and replace combustor adjusting (3) Replace over 20%
mechanisms; primary air pipelines and
(4) Check and regulate air dampers; elbows.
(5) Synchronous swing test of combustors;
(6) Measure circles of contact of combustors and test
dynamic field;
(7) Check firing equipments and tertiary air nozzles;
(8) Check or replace shade separators;
(9) Maintain or replace a small amount of primary air
pipelines and elbows, maintain air dampers.
7. Steam and (1) Check and regulate pipe expansion indicators; (1) Replace main steam
water pipeline (2) Check high-temperature and high-pressure main pipes, reheated steam
system steam pipes, reheated steam pipes, welded junction of pipes, main water supply
water supply pipes; measure wall thickness of elbows; pipe segments, tee joints
(3) Measure creeping expansion of high-temperature and elbows, replace a
and high-pressure steam pipelines; large amount of other
pipes;
(4) Check appearance of high-pressure main steam
pipe flanges, screws and thermometer sockets; (3) Replace
high-pressure
(5) Check and regulate supports and hangers; power-driven main steam
(6) Check flow measuring devices; valves or water supply
(7) Check and handle high-temperature and doors and safety valves;
high-pressure flanges and bolts; (3) Cut and replace
(8) Check wall thickness and weld joints of tee joints high-temperature and
and elbows of blowdown pipes, drain pipes and cooling high-pressure pipeline
water pipes, etc.; monitoring segments.
(9) Maintain safety valves, water level measuring
devices, water level alarms and valves;
(10) Maintain all common steam-water valves;
(11) Maintain transmission of power-driven
steam-water valves;
(12) Replace valve padding and verify its flexibility;
(13) Safety valve verification and setting test;
(14) Maintain mufflers and pipelines.
8. Air preheaters (1) Remove all ash deposition and clogging of air (1) Check and calibrate
preheaters; case plates or rotors of
(2) Check and replace part of corrosive and abrasive rotary preheaters;
pipes and heat transfer elements; replace part of (2) Replace whole set of
anti-corrosion sleeves; abrasion-proof sleeves;
(3) Check, repair and regulate sealing devices, (3) Replace over 10%
transmissions, central support bearings and heat pipes of tubular
transfer elements, etc. of rotary preheaters, check preheaters;
rotors and sector plates, and measure flutter and wow (4) Replace over 20%
of rotors; heat transfer elements of
(4) Check and repair inlet and outlet baffles and rotary preheaters;
expansion joints; (5) Turn over or replace
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DL / T 838 一 2003

(5) Check and repair cooling water system and rotor shrouds of rotary
lubricating oil system; preheaters;
(6) Check and repair soot blowers and fire-fighting (6) Replace upper and
system; lower bearings of rotary
(7) Check and repair air heaters; preheaters.
(8) Air leak test.
9. Coal and (1) Check coal feeders, pulverized coal feeders and (1) Replace overall belts
pulverized coal pulverized coal conveyors; or chains of coal feeders;
feed system (2) Repair or replace the abrasion of coal feedpipes, (2) Replace over 20%
pulverized coal pipeline throats, elbows and expansion pulverized coal pipelines;
joints, etc.; (3) Repair raw coal
(3) Clean and check pulverized coal bunkers; check bunkers and pulverized
measuring devices of pulverized coal level, moisture coal bunkers with much
absorption pipes, clappers and belts, etc.; workload;
(4) Maintain explosion doors, air doors, scrapers, (4) Replace chains of
chains and transmissions, etc.; pulverized coal conveyors
(5) Clean and check fire-fighting system; (steel wire ropes)
(6) Check air-pulverized coal mixers;
(7) Check and repair weld joints of raw coal hoppers
and frames.
10. Coal mills and (1) Eliminate air leakage, powder leakage, oil leakage (1) Check and repair
coal pulverizing of coal mill and coal pulverizing system and repair foundations;
system shield, check and repair air dampers, baffles, (2) Repair sphere and
lubricating system and oil system, etc. rungsten-gold of sliding 批注 [T1]: 查不到，保留原文，请客
(2) Maintain fine pulverized coal separators, coarse bearings or replace 户确认。
pulverized-coal separators and wood separators, etc. damaged rolling bearings;
(3) Check pulverized coal bunkers, air and pulverized (3) Replace big gears of
coal pipes, powder level devices and fire-extinguishing ball mill or turn over big
facilities, check and replace explosion doors, etc. gears, replace the whole
(4) Ball mills: set of lining bushings,
1) Maintain big and small gears, couplings and their large bearings or gears of
driving and anti-dust devices; reduction gearboxes;
2) Check barrels and weld joints, maintain steel (4) Replace drive worm
bushings, lining plates and bolts, etc., select and gears, , bevel gears or
supplement steel balls; main shafts of medium
speed mills;
3) Maintain lubricating system, spiral pipes of inlet and
outlet hoppers, cooling system and other wear parts; (5) Replace cases or all
liner plates of high-speed
4) Check bearing, oil pump station and bolts of all parts, hammer coal mills or
etc. fan-type coal mills;
5) Check gearbox devices; (6) Replace or improve
6) Check hollow shafts and end caps, etc. fine pulverized coal
(5) Medium speed coal mills: separators or coarse
1) Check coal mills, replace worn grinding rings, pulverized coal
millstones, grinding bowls, lining plates, grinding separators.
rollers, roller shells, etc and maintain transmissions;
2) Maintain drain valves of pebble coal, air rings and
sealing devices of main shafts;
3) Regulate loading devices and calibrate the center;
4) Check and clean lubricating system and cooling
system, maintain hydraulic system;
5) Check and repair canned motors, check inlet and
15
DL / T 838 一 2003

outlet baffles and primary air chambers, calibrate liner
plates of air chambers, and replace scrapers.
(6) High-speed hammer and fan-type coal mills;
1) Repair weld or replace worn parts such as hammers,
hammer levers, liner plates and impellers, etc.
2) Maintain bearings and cooling devices, main shaft
seals and cooling devices;
3) Maintain expansion joints;
4) Calibrate the center.
11. Various fans (1) Check and repair worn cases, lining plates, blades, (1) Replace the whole set
(induced draft fans, impellers and protecting jackets of bearings; of fan blades, lining plates
forced draft fans, (2) Maintain inlet and outlet baffles, blades and or impellers and cases;
dust exhaust fans, transmissions; (2) Re-pour Tungsten of
primary air fans (3) Maintain rotors, bearings, bearing boxes and sliding bearings.
and seal fans, etc.) cooling devices;
(4) Check and repair lubricating oil systems, check fans
and oil stations of motors, etc.;
(5) Check and repair hydraulic couplers or frequency
converters;
(6) Check and regulate driving devices;
(7) Calibrate balance of fan impellers.
12. Fuel system (1) Maintain oil guns, fuel atomized nozzles and Clean oil tanks
connecting devices of oil pipes;
(2) Maintain intake regulating baffles;
(3) Clean oil pipes and strainers;
(4) Maintain fuel dampers and oil inlet return valves;
(5) Maintain fuel pumps and heating devices;
(6) Check and repair fuel quick-break valves, oil
outlets and solenoid valves, etc;
(7) Check and calibrate oil level indicating devices;
(8) Check jumper wires and grounding devices of oil
pipeline.
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DL / T 838 一 2003

13. Dust collectors (1) Clear internal dust deposition, eliminate air (1) Repair flues and dust
leakage. collectors;
(2) Water film dust collectors: (2) Replace large area
1) Maintain nozzles, water supply systems and perform of tiles;
water film test; (3) Readjust space
2) Repair tiles, water screens, clappers and ash between anode and
discharge pipes. cathode of electrostatic
(3) Electrostatic precipitators: precipitators;
1) Check and repair anode plates, cathode lines and (4) Replaced over 20%
frames, etc.; cathode lines;
2) Check and repair cathode and anode rapping (5) Replaced over 10%
devices and space between anode and cathode, etc. anode plates.
3) Check and repair transmissions, heating devices and
clappers, etc.;
4) Check abrasion of flow equalizing plates and
spoilers, etc. or replace a small amount;
5) Check ash conveying hoppers, tracing heat and
mixing devices;
6) Check leakproofness of cases and remove air
leakage;
7) Check high-pressure generators, distribution
devices, control systems, cables and insulators.
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;
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DL / T 838 一 2003

(3) Check and clean coolers and cooling water
system.
16. Ancillary (1) Maintain motors and switches; (1) Replace power or
electric (2) Check and verify relevant electric instruments, control cables in large
equipments control circuits, protection equipments, automatic amount;
devices and signal devices; (2) Replace HV motor
(3) Maintain distribution devices, cables, lighting windings.
equipments and communication system;
(4) Preventive test
17. Others (1) Perform hydrostatic test for the whole boiler, check (1) Super hydrostatic test
leakproofness of pressure-bearing parts; of boilers;
(2) Test air leakage of boilers; (2) Maintain chimneys;
(3) Maintain soot blowers of boilers; (3) Chemical cleaning.
(4) Check and repair ash and slag systems and
devices;
(5) Check expansion indicators;
(6) Check dosing and sampling devices;
(7) Check and repair flues;
(8) Check air duct systems;
(9) Check and repair high/low-pressure drainage
systems and devices, verify their safety doors;
(10) Check and repair blowdown systems;
(11) Check in accordance with the provisions of metal,
chemical supervision and monitoring of boilers and
pressure vessels;
(12) Test boiler efficiency.
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DL / T 838 一 2003
Table A.2 Table of reference items in A class maintenance for steam turbines
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
(2) Check speed governors, emergency test of unit speed regulating

governors and springs, perform characteristic test if system.
necessary;
(3) Check steam distribution mechanisms;
(4) Perform conventional test and adjustment of
static characteristics, valve leakproofness and
flexibility of emergency governors of speed
regulating system.
7. Oil systems (1) Clean and check speed regulating oil system, (1) Replace cores of oil
lubricating oil system and equipment components, coolers;
measure clearance and dimensions of relevant (2) Replace lubricating oil or
components, repair and replace parts if necessary, fire resistant oil;
perform hydrostatic test for oil coolers; (3) Sweep all oil pipelines;
(2) Clean and check sealing oil system and its (4) Replace sealing pads and
equipment components, repair and replace parts if inner oil baffles;
necessary;
(5) Replace servo valves, etc.
(3) Clean and check fire resistant oil system and
its equipment components, conduct performance
test of servo valves;
(4) Check and repair sealing pads, measure and
adjust clearance;
(5) Circularly filter turbine oil and fire resistant oil;
(6) Clean jacking oil system and strainers.
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DL / T 838 一 2003
Table A.2 (Continued)

8. Steam-water (1) Check and repair main steam valves, bypass (1) Replace above DN
pipeline system valves, extraction valves, extraction check valves, 200high-pressure valves;
governing valves and safety valves; (2) Replace main steam
(2) Check and repair pipelines and valves of high pipes, feedwater pipes and
and low-pressure bypass system; their tee joints and elbows;
(3)Check and repair air dampers, water strainers, (3) Replace high ,middle and
desuperheaters and pressure reducers; low-pressure pipelines in a
(4) Measure creeping expansion of main steam large amount;
pipes; (4) Adjust and replace
(5) Check and adjust supports and hangers and supports and hangers of main
expansion indicators of pipelines; steam pipelines operating for
(6) Repair and adjust driving devices of valves; more than 200,000h.
(7) Check and repair high and low-pressure drain
flash tanks and drain valves, etc.
9. Condensers (1) Wash condensers, analyze and check (1) Replace over 20%
condenser pipes according to the requirements, condensers;
replace a small amount of damaged condenser (2) Pickle condensers.
pipes if necessary;
(2) Check and repair accessories including
condenser water level indicators and water level
regulators, etc.;
(3) Perform anti-corrosion of condenser water
boxes;
(4) Check expansion joints at throat of
condensers;
(5) Check vacuum system and remove leakage;
(6) Check leakage of condenser by watering;
(7) Check and repair secondary strainers and
rubber ball washing devices.
10. Air extractors (1) Maintain main and auxiliary air extractors and (1) Replace vacuum pump
and vacuum coolers, and perform hydrostatic test; rotors;
pumps (2) Clean and maintain vacuum pumps, water-jet (2) Replace air extractors.
pumps and ejector coolers.
11. Regenerative (1) Check and repair steam extraction (1) Replace over 10% heat
system regenerative system; exchange pipes;
(2) Check and repair accessories of regenerative (2) Improve heater drainage
system equipments; system.
(3) Perform measurement for thickness of heater
barrels, hydrophobic elbows and flaw detection of
weld joints;
(4) Perform hydrostatic test of heaters to eliminate
leakage.
12. Water pumps (1) Check and repair condensate pumps, drain (1) Replace pump impeller
pumps, feedwater pumps, boost pumps and other shafts and bearings;
pumps, replace impellers and guide vanes if (3) Replace blades of steam
necessary; feed pump turbines;
(2) Check, repair or replace pump inlet and outlet (3) Perform dynamic balance
valves, check valves, inlet strainers and lubricating test of steam feed pump
oil pumps; turbines.
(3) Check steam feed pump turbines, accelerating
21
DL / T 838 一 2003
boxes of power feed pumps and hydraulic

couplers;
(4) Clean and check lubricating oil system;
(5) Pump set coupling centering.
13. Deaerators (1) Check and repair deaerators and accessories, (1) Deaerator over-pressure
perform hydrostatic test, verify safety valves; test;
(2) Check and repair deaerating head water (2) Transform deaerating
distribution devices. heads;
(3) Handle a large amount of
weld joints;
(4) Replace deaerator
paddings.
14. Circulating (1) Check and repair circulating water pumps and (1) Replace impellers and
water system outlet butterfly valves; bearings;
(2) Check and clean circulating water pipelines (2) Perform large-area
and maintain valves; anti-corrosion of circulating
(3) Check and repair primary strainers; water pipelines;
(4) Check and replace a small amount of water (3) Replace circulating water
tower paddings, water distribution devices and pipelines and valves;
dehydrator; (4) Replace a large amount of
(5) Dredging for cooling tower pools. water power paddings, water
distribution devices and
dehydrators.
(5) Perform anti-corrosion of
water power barrels and
columns.
15. Ancillary (1) Maintain motors and switches; (1) Replace a large amount of
electrical (2) Check and verify relevant electric instruments, power cables or control
equipments control circuits, protection devices, automatic cables;
devices and signal devices; (2) Replace HV motor
(3) Maintain distribution devices, cables, lighting windings.
equipments and communication systems;
(4) Perform preventive test.
16. Others (1) Check in accordance with the provisions of
metal, chemical supervision and monitoring of
boilers and pressure vessels;
(2) Test steam turbine efficiency.
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DL / T 838 一 2003
Table A.3 Table of reference items in A class maintenance for turbine generators
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
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DL / T 838 一 2003
switches and circuits;

(6) Check and clean ventilation devices and
coolers;
(7) Verify automatic excitation regulation devices,
carry out performance test of excitation system.
5. Others (1) Check oil pipeline flanges and insulation Replace distribution devices,
components of exciter bearing pedestals, and cables, relays or instruments in
replace if necessary; large amount
(2) Check, sweep and repair distribution devices,
busbars and cables of generators;
(3) Check and verify monitoring instruments, relay
protection devices, control signal devices and
on-line monitoring devices;
(4) Perform electric preventive test;
(5) Paint generator cases;
(6) Check and sweep fire extinguishing devices.
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DL / T 838 一 2003
Table A.4 Table of reference items in A class maintenance for control systems of thermal power
plants

1. External (1) Check and measure pipelines and valves；
inspection of (2) Check thermal detecting elements (such as
thermal temperature measuring sleeves)；
equipments
(3) Check plugging of bottom cable holes of thermal
plates (platforms), verify the equipment marks.
2.Thermal (1) Check and verify various transducers； (1 )Replace meters or
instrumentation (2) Verify various instruments, temperature measuring important measuring
components and their compensation devices; components in large
amount;
(3) Check and verify branch components, verify
instrument system in complete set. (2 ) Replace gauge pipes
in large amount
3.Thermal (1) Check and verify thermal automation system and Replace important
automation system its devices and components, perform static simulation measuring equipments
test, check and verify actuators; and actuators;
(2) Perform dynamic adjustment and disturbance test.
4.Thermal (1) Adjust primary and secondary components, Replace important
protection and actuators and control circuits; measuring devices and
interlocking system (2) Check and adjust protection settings, switch actuators
pickup values, check and test equipments and
components such as solenoid valves, baffles and
motors; etc.;
(3) Perform logic function test on protection and
sequential control system and interlocking system
5. Distributed (1) Clean, check or test system hardware and (1) Replace important
control system peripheral equipments, replace if necessary; measuring devices and
(DCS) (2) Check power supply devices, perform power actuators;
supply switchover test; (2) Modify software
(3) Check and test grounding system; configuration, settings and
(4) Check system software backup, set up backup control circuits, upgrade
files; software version
(5) Check and test data acquisition and
communication networks;
(6) Check control modules and HMI devices;
(7) Test functions of sequence of event (SOE)
devices;
(8) Check screen operating keyboards and feedback
signals;
(9 ) Check and test functions of display, recall, alarm,
printing, recording, operation guide, etc.;
(10) Check input/output (I/O) card channels and
configuration software;
(11) Perform switchover test for redundant function of
controller.
6. Coordinated (1) Check and verify transducers and primary (1 ) Replace important
Control System components; measuring devices and
(2) Maintain valves of actuators, perform actuators;；
characteristic test; (2) Modify software
(3) Check status indication, perform functional test; configuration, settings and
control circuits, upgrade,
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DL / T 838 一 2003
(4) Verify servo amplifiers; software version.

(5) Perform setting (load) disturbance test;
(6) Check oxygen measuring devices, demarcate
oxidization drilling heads, replace if necessary;
(7) Check control system configuration, parameter
setting, verify operation relation, perform static
simulation test, dynamic test and load swing test;
(8) Check electrical/pneumatic converters, actuators
and frequency changers
(9) Test cable insulation.
7.Furnace (1) Check grounding system of input power supply; (1) Replace important
Safeguard (2) Check and verify solenoid valves, baffles, measuring devices and
Supervisory transducers and thermocouples; actuators;
System (3) Check and verify pressure switches and sampling (2) Modify software
tubes, temperature switches, flow switches, flame configuration, settings and
monitoring system equipments, perform oil leak test; control circuits, upgrade,
(4) Check and modify software; software version.
(5) Check management control circuits of
combustors, verify commissioning of sequence control
of combustors;
(6) Check I/O commissioning;
(7) Perform action test of boiler purge, oil guns and
firing guns, simulation test of main fuel trip (MFT)
function;
(8) FSSS system simulation test.
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DL / T 838 一 2003

8. Data acquisition (1) Verify on-site components and primary (1) Replace important
system (DAS) components of external signals and check input measuring equipments and
signals; actuators;
(2) Perform hardware test and state inspection; (2) Modify software
(3) Check range and unit configuration, settings,
(4) Verify errors in the measured points control circuit, upgrade
software version.
9..Digital (1) Check and verify peripheral equipments such as (1) Replace important
electro-hydraulic primary components and transducers, etc. measuring equipments and
control system (2) Check and test system hardware and software: actuators;
(DEH) of steam (3) Check and test I/O signals and range of (2) Modify software
turbine parameters; configuration, settings,
(4) Check action of actuators; control circuit, upgrade
software version.
(5) Perform complete cold state commissioning of
system;
(6) Perform hot state optimization of system
10.Digital micro (1) Check and verify peripheral equipments such as (1) Replace important
electro-hydraulic primary components and transducers, etc. measuring equipments and
system (MEH) of (2) Check and test system hardware and software: actuators;
feedwater pump (3) Check and test I/O signals and range of (2) Modify software
parameters; configuration, settings,
(4) Check action of actuators; control circuit, upgrade
software version.
(5) Perform complete cold state commissioning of
system;
(6) Perform hot state optimization of system
11. Sequential (1) Verify and install measurement components and (1) Replace important
control system relays; measuring equipments and
(SCS) (2) Verify and test cards, set parameters; actuators;
(3) Verify I/O signals, logical functions and protection (2) Modify software
functions; configuration, settings,
(4) Check and test action of actuators; control circuit, upgrade
software version.
(5) Perform debugging of branch circuits and related
protection tests;
(6) Perform joint debugging of system
program-controlled functions
12. Turbine (1) Check and verify probes, front-end devices and (1) Replace important
supervisory sensors; measuring equipments and
instrumentation (2) Verify secondary instruments and all actuators;
(TSI) components; (2) Modify software
(3) Check indicating values and perform setting configuration, settings,
verification, complete system debugging and function control circuit, upgrade
confirmation; software version.
(4) Check input power supply and grounding system
13. Bypass (1) Verify and install transducers and primary (1) Replace important
automatic components; measuring equipments and
regulating system (2) Check action of regulating valves and perform actuators;
and LV/HV bypass characteristic test; (2) Modify software
pressure and (3) Static simulation test, system linkage test and configuration, settings,
temperature control circuit, upgrade
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DL / T 838 一 2003

automatic function confirmation; software version.
regulating system (4) Hot state adjustment test
14. Peripheral (1) Check and test primary components, switches
control systems and secondary doors;
(chemical water, (2) Check and repair control cards, cabinets and
coal handling, warning devices;
wastewater, ash (3) Sweep and check power supply devices, test
handling, slag cables;
removal and
condensate (4) Perform system function debugging
treatment)
15. Emergency trip (1) Verify primary components, confirm sampling (1) Replace important
system (ETS) points; measuring equipments and
(2) Perform protection tests and setting confirmation; actuators;
(3) Test logical functions; (2) Modify software
(4) Test check systems configuration, settings,
control circuit, upgrade
software version.
16. (1) Check and test switch contacts and relays; (1) Replace important
Boiler-turbine-gen (2) Test action of equipments; measuring equipments and
erator major (3) Test sequence of operation of equipments. actuators;
interlocking system (2) Modify software
configuration, settings,
control circuit, upgrade
software version.
17. Cables (1) Check, sweep and repair cable ducts and trays
(2) Check laying of various cables, check wiring,
marks and insulation;
(3) Check seal and fire protection of cables;
(4) Check grounding of cables;
(5) Check and test cable fire alarm and monitoring
devices
18. Others (1) Check and repair flame and drum water level
monitors;
(2) Check and repair signal and alarm systems;
(3) Check and repair base regulators;
(4) Check and repair power supply and instrument
heat tracing systems;
(5) Test insulation of components and cables;
(6) Check grounding systems
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DL / T 838 一 2003
Table A.5 Table of reference items in A class maintenance for wet flue gas desulfurization
devices

1. Booster fan (1) Check fasteners, connectors and accessories; Replace all fan blades
(2) Check and repair moving and stationary parts,
and replace moving blades if necessary;
(3) Clean and check lubricating and hydraulic oil
systems and equipments;
(4) Maintain inlet and outlet baffles, blades and
transmissions;
(5) Check and adjust driving devices;
(6) Check and repair main bearings;
(7) Check and clean surge probes
2. Gas-gas heat (1) Check and clean rotor hoisting equipments; Replace over 20% heat
exchanger (GGH) (2) Check and clean driving systems and exchanger components
transmission parts;
(3) Check shaft seal system and adjust sealing
clearance;
(4) Check rotor support bearings and guide
bearings;
(5) Check surface heat exchanger components;
(6) Check and repair high-pressure flush water
systems and high-pressure flush water pumps;
(7) Check and maintain gas-tight systems and
gas-tight fans;
(8) Check and repair compressed air systems and
maintain compressed air fans
3. Absorption (1) Check and repair rubber lining on inner walls; (1) Repair above 100m 2
tower (2) Check and repair nozzles, rubber lining on anti-corrosion lining rubber;
brackets of water spraying layer; (2) Replace over 20%
(3) Check demisters and rubber lining on demister nozzles.
brackets;
(4) Check blenders;
(5) Check and maintain slurry efflux pumps;
(6) Check and maintain oxidation air blowers and
clean intake screens;
(7) Check and repair drain pumps;
(8) Check and clean overflows and low-level
sampling openings, check manholes.
4. Slurry circulation (1) Check anchor bolts;
pump (2) Clean and maintain intake screens;
(3) Check connecting bolts of couplings;
(4) Check and repair suction covers and wear
reinforcement plates;
(5) Check shafts and shaft sleeves, and replace
bearings if necessary;
(6) Check and repair impellers, and replace if
necessary;
(7) Replace mechanical seal and sealing elements
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DL / T 838 一 2003

5.Vacuum (1) Check and clean dehydration belts and
dehydration belt accessories；
conveyor (2) Check and repair belt adjusting air
compressors, and clean intake screens;
(3) Check and repair filter cloth cleaning pumps;
(4) Check and repair liquid ring vacuum pumps
and acid pickling liquid ring vacuum pumps;
(5) Check and clean filtrate separators and
accessories;
(6) Check, repair and debug off-tracking devices
and flush water flow control devices
6. Flue gas system (1) Check and adjust baffle regulating devices;
(2) Check and repair anticorrosive coating on
inner walls of flue;
(3) Check and repair baffle sealing fans;
(4) Check tightness of expansion joints, flanges
and manholes
7. Limestone (1) Check and clean inner walls, vulcanization
powder storage tanks and bag-type dust collectors of limestone
and transportation silos;
and slurry (2) Check, clean and repair feeders and delivery
preparation system machines of limestone powder;;
(3) Check and clean slurry tanks and slurry pore
plates, backflow pore plates and ventilation
strainers;
(4) Check and maintain vaporization fans, and
clean intake screens;
(5) Test and adjust safety relief valves of
limestone powder silos.
8. Gypsum (1) Check and clean collection boxes of circulating
dehydration and water, collecting tanks of washing water, filtering
storage system water tanks, gypsum slurry tanks, filtrate
separators and gypsum silos;
(2) Check and repair gypsum delivery filters and
unloading devices in gypsum silos;
(3) Check and repair gypsum slurry pumps and
gypsum efflux pumps;
(4) Check and repair gypsum distributors and
gypsum cyclones.
9. Emergency (1) Check and clean rubber lining on inner walls of
slurry pond and emergency slurry tanks;
slurry transport (2) Check and repair emergency slurry pumps,
and discharge emergency slurry drain pumps, blenders of
system emergency slurry drain pits and pore plates from
gypsum slurry to emergency slurry pond
10. Process water (1) Clean process water ponds;
system (2) Check pore plates of process water pipelines;
(3) Check and repair process water pumps and
pressure stabilizing valves.
11. Wastewater (1) Check and clean vessels including decanting/
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DL / T 838 一 2003
treatment system concentrating tanks, neutralization/flocculation

tanks, wastewater storage tanks, clean water
tanks, lime silos, lime digestion tanks and lime
slurry tanks, etc.;
(2) Check and maintain thick slurry return pumps,
thick slurry efflux pumps, lime slurry circulation
pumps, clean water pumps, wastewater pumps,
wastewater circulating pumps and wastewater
collecting tank efflux pumps;
(3) Check and repair wastewater cyclones;
(4) Check and repair polyelectrolyte conveyors,
flocculant dosing pumps, sulfuric acid chloride iron
dosing pumps and TMT15 dosing pumps;
(5) Check and maintain scrubber fans;
(6) Check and repair polyelectrolyte sprayers and
acid mist scrubbers;
(7) Check and repair blenders inside the system;
(8) Check and repair lime feeders and conveyors;
(9) Check and repair dust collectors of lime silos.
12. Others (1) Check and debug control systems;
(2) Check pressure stabilizing valves, safety
valves and changeover valves;
(3) Check rubber lining pipelines by sampling;
(4) Clean pits and trenches.
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Table A.6 Reference items in maintenance of hydroturbines

1. Bearings of (1) Measure bearing clearance; (1) Transform turbine guide
hydroturbines (2) Decompose, sweep and maintain sealing devices bearing structures;
and bearings; (2) Transform of turbine guide
(3) Sweep, check and recondition bearing bushings; sealing devices;
(4) Sweep and measure journals; (3) Replace bearing
(5) Maintain spherical surface of bearing bushings; bushings;
(6) Sweep oil basins, check leakage, decompose (4) Replace oil coolers
and check Pitot tubes and oil pumps;
(7) Replace spare parts such as oil block pieces and
oil rings, etc.;
(8) Sweep and check bearing boxes and oil filters,
perform hydrostatic test of oil coolers;
(9) Replace quick-wear parts of sealing devices and
expansion seals.
2. Water (1) Decompose, sweep and check drainage devices (1) Replace upper,
distributors on top cover; intermediate and lower shaft
(2) Inject lubricant to lubrication parts of water sleeves of guide blades;
distributors; (2) Replace wear plates on
* (3) Measure and adjust clearance on guide vane façade and end-face of control
end and facade (not more than 1/4 of the total); rings;
*(4) Dismount, maintain and replace bearing seals of (3) Replace top covers and
guide vane sleeves (not more than 1/4 of the total ); wear rings of bottom rings;
(5) Repair partial cavitation (abrasion) damages of (4) Improve water seals for
guide vanes; clearance on façade and
(6) Measure and adjust pressing stroke of end-face of guide vanes, for
servomotors; example change soft seal into
hard seal.
(7) Decompose and check servomotors, conduct
pressure-tight test or replace piston rings, decompose
and check locking devices and conduct action test;
* (8) Repair and grind journals of guide vanes;
* (9) Decompose, sweep and check double-arm pull
rods ，measure shaft pins and shaft sleeves and
replace wear-out parts;
*(10) Check and grind wear plates on façade and
end-face of control rings;
*(11) Repair top covers and wear rings of bottom
rings.
3. Runners and (1) Measure clearance of labyrinth rings (or the (1) Replace runner blades;
main shafts clearance between axial-flow runner blades and (2) Deal with eccentric wear
runner chambers); and crack of journals;
*(2) Check and repair cavitation, abrasion and crack (3) Replace labyrinth rings;
of runners and runner chambers (within the approved (4) Replace runner cones;
construction period: if diameter of runners is less than
3.3m, repair 0.5m², single layer; if it is more than (5) Repair runners and runner
3.3m, repair 1.5 m², single layer); chambers in large area.
(3) Check fixation of runner cones and repair
cavitated parts;
(4) Maintain sealing devices of axial-flow runner
blades；
(5) After runners are filled with oil, detect action of
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DL / T 838 一 2003
blades and measure oil leakage of sealing devices;

(6) Sweep inside of detachable sections of runner
chambers, check and replace damaged parts;
*(7) Deal with abrasion of journals;
*(8) Check and deal with decompressors of
mixed-flow runners;
*(9) Decompose and maintain axial-flow runners and
conduct pressure-tight test；
* (10) Static balance test of runners;
* (11) Conduct flaw detection of main shafts.
4. Intake pipes, (1) Check volutes and exhaust water pipes; (1) Reinforce or transform
volutes and (2) Repair cavitation on exhaust water pipes; intake penstocks;
exhaust water (3) Check intake penstocks, leakage of expansion (2) Replace exhaust water
pipes joints and stop leakage; pipe liners;
(4) Decompose, check and repair air valves, drain (3) Lift outlet trash racks,
valve of volutes and exhaust water pipes and clean, repair and conduct
technical supply valves; anticorrosion
(5) Check and clean intake trash racks underwater;
(6) Sweep and check pipelines of measurement
meters;
*(7) Replace gland packing of expansion joints of
intake penstocks;
*(8) Conduct anticorrosion of intake penstocks and
volutes;
*(9) Grout volutes and exhaust water pipes;
* (10) Repair exhaust water pipes.
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DL / T 838 一 2003

Name of
Standard items Special items
parts
5. Air (1) Decompose, sweep, deal with, test and regulate vacuum (1) Replace vacuum
supplement breaking valves; breaking valves and
devices of (2) Decompose, sweep, deal with, test and regulate suction suction vacuum
hydroturbines vacuum valves; valves;
(3) Replace parts of vacuum breaking valves and suction (2) Replace air
vacuum valves; replenishing cross
(4) Check and repair air replenishing cross heads. heads.
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
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DL / T 838 一 2003

Name of
parts
valves, ball maintenance; valves;
valves, (2) Conduct leakage test for water seal and check of (2) Transform
cylindrical leakproofness; hydraulic hoists of
valves and (3) Decompose and check main bearings and bearing shoe rapid operating gates;
rapid grinding and check shaft seals; (3) Conduct
operating anticorrosion for rapid
gates (4) Replace seal rings, rings for sealing water or bearing
bushings of ball valves; operating gates.
(5) Decompose and check servomotors, clean and replace
piston rings (or sealing elements);
(6) Repair sealing shroud rings;
(7) Decompose and check operating mechanisms and replace
parts;
(8) Decompose, check and debug oil pumps and safety valves;
(9) Decompose and check hoist oil cylinders, pull rods and
pistons of rapid operating gates;
(10) Check and test electrical control system and integral
operation setting of system;
*(11) Replace sealing shroud rings and shaft seals of butterfly
valves;
*(12) Conduct dynamic water closing test for inlet valves and
rapid operating gates;
* (13) Conduct pressure-tight test for ball valve bodies, and
replace parts such as worm wheels and worm rods, etc;
*(14) Replace sealing shroud rings of rapid operating gates;
*(15) Decompose, check and repair locking devices of
servomotors and bypass valves.
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.
10. Others Check and test on-line monitoring system of hydroturbines
Note: items without * are B class maintenance items.
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DL / T 838 一 2003
Table A.7 Reference items in maintenance for hydrogenerators

Name of
parts
1. Stators (1) Maintain stator frames and cores, check radial jacks, (1) Replace wire rods;
check and replace shear pins; (2) Overlap cores;
(2) Check stator ends and supporting structures, repair (3) Transform stator frames;
tooth supports; (4) Replace support rings.
(3) Check stator windings and slot parts;
(4) Check and repair wind shields and fire-extinguishing
devices;
(5) Perform electric preventive test;
(6) Backflush internal water cooling stator bars, and
perform flow test and hydrostatic test;
(7) Verify temperature measurement element;
* (8) Replace temperature measurement components;
* (9) Replace part of tooth supports;
* (10) Comprehensively deal with end connectors,
cushion blocks and binding wires;
* (11) Check and handle split stator joints, detect and
handle stator ovality;
* (12) Perform wire rod anti-corona treatment;
* (13) Check and handle stator slot wedges, check and
sweep ventilating ducts.
2. Rotors and (1) Measure generator air gap; (1) Transform rotors, replace
main shafts (2) Check wheel hubs, rotor arm weld joints, assembling magnetic poles;
bolts, big keys of rotor arms and ring cross keys; (2) Turn or replace slip rings.
(3) Check magnetic poles, pole keys, pole joints,
damping rings and rotor fans;
(4) Sweep rotors (including ventilating ducts);
(5) Check brake hoops and stop dogs;
(6) Check and adjust slip ring brush devices and leads;
(7) Perform electric preventive test and measure shaft
voltage and shaft current;
(8) Backflush internal water cooling rotors, and perform
flow test and hydrostatic test;
(9) Adjust unit axis (including operating oil pipes of oil
heads);
*( 10) Handle ring sinking;
*( 11)Repair big keys of rotor arms;
*( 12) Measure and adjust roundness and pole level of
rotors;
*( 13) Handle inter-turn insulation of pole windings;
*( 14) Replace part of pole windings, leads or damper
windings;
*( 15) Make dynamic balance of rotating parts;
*( 16) Handle abrasion of brake rings;
*( 17) Perform flaw detection of main shafts.
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DL / T 838 一 2003

Name of
parts
3. Bearings (1) Check rotating parts of thrust bearings, bearing seats and (1) Replace guide
oil grooves; bearing shoes and thrust
(2) Measure compressed value of elastic oil tanks; bearing shoes;
(3) Check and scrape bearing bushings, descale water (2) Replace oil coolers;
cooled bearing bushings, and perform hydrostatic test of water (3) Transform cooling
pipelines; circulation system;
(4) Measure and adjust clearance of guide bearing shoes, (4) Return to factory for
check guide bearing shoes; grinding and replace
(5) Check and handle bearing insulation; runner plates.
(6) Handle lubricating oil;
(7) Check oil coolers and perform hydrostatic test, sweep oil
pipelines and water pipeline, and perform hydrostatic test;
(8) Sweep and check high-pressure oil lifting devices;
(9) Check and handle oil mist devices;
* ( 10) Adjust thrust bearing level and perform load adjustment
of thrust bearing shoes;
*( 11) Maintain and handle thrust heads and snap rings;
* ( 12) Grind runner plates of thrust bearings.
4. Frames (1) Check and sweep frames; Strengthen or transform
*(2) Handle combined surface of frames; frames
*(3) Measure and adjust frame center and level
5. Excitation (1) Exciters: (1) Exciters:
system 1) Measure and adjust air gap; 1) Turn and coat exciter
2) Sweep and check components and leads of exciters; commutators;
3) Check and adjust brush devices, and scrape mica slots; 2) Replace exciter poles
4) Sweep and check components of excitation circuit and or armature windings;
perform electrical performance test; 3) Replace high-power
5) Check and handle slot wedges of exciters; rectifier units;
6) Measure and adjust exciter pendulum degree; 4) Transform
commutators.
7) Perform no-load and load characteristic test for exciters;
(2) Self and shunt static
*8) Reweld armature winding heads of exciters, and re-bind excitation devices:
binding wires;
1) Replace excitation
*9 ) Adjust gap between main poles and commutating poles of regulators;
exciters.
2) Replace power
(2) Self and shunt static excitation devices cabinets;
1) Sweep and check appearance of devices; 3) Replace deexcitation
2) Check and test excitation transformers, series transformers, devices;
shunt transformers, PTs and CTs; 4) Replace excitation
3) Check and test unit boards, pulse boards, power cabinets transformers.
and rectifying elements;
4) Check and verify relays and contactors, check secondary
circuit and test insulation;
5) Maintain fans;
6) Perform circuit simulation test and tests under static,
no-load and on-load conditions;
7) Characteristic test of excitation regulators;
8) Check and debug power system stabilizers (PSS);
37
DL / T 838 一 2003

Name of
parts
9) Check and repair deexcitation devices and rotor
over-voltage protection devices;
*10 ) Replace power rectifier elements.
3. Bearings (1) Check rotating parts, pedestals and oil grooves of thrust (1) Replace guide
bearings; bearing shoes and thrust
(2) Measure compressed value of elastic oil tanks; bearing shoes;
(3) Check and scrape bearing bushings, descale water (2) Replace oil coolers;
cooled bearing bushing channels and perform hydrostatic test (3) Transform cooling
of water pipelines; recirculation system;
(4) Measure and adjust clearance of guide bearing shoes, (4) Returns to factory for
check guide bearings; grinding and replace
(5) Check and handle bearing insulation; runner plates.
(6) Handle lubricating oil;
(7) Check oil coolers and perform hydrostatic test, sweep oil
pipelines and water pipelines, perform hydrostatic test;
(8) Sweep and check high pressure oil lifting devices;
(9) Check and handle oil mist devices;
* ( 10) Adjust thrust bearings level and perform load
adjustment of thrust bearing shoes;
*( 11) Maintain and handle thrust heads and snap rings;
* ( 12) Grind runner plates of thrust bearings.
4. Frames (1) Check and sweep frames; Strengthen or transform
*(2) Handle combined surface of frames; frames
*(3) Measure and adjust frame center and level.
5. Excitation (1) Exciters: (1) Exciters:
system 1) Measure and adjust air gap; 1) Turn and coat exciter
2) Sweep and check components and leads of exciters; communtators;
3) Check and adjust brush devices, and scrape mica slots; 2) Replace exciter poles
4) Sweep and check components of the excitation circuit and or armature windings;
perform electrical performance test; 3) Replace high power
5) Check and handle slot wedges of exciters; rectifier units;
6) Measure and adjust swing of exciters; 4) Transform
commentators.
7) Perform no-load and on-load characteristic tests of exciters;
(2) Self-shunt static
*8) Reweld armature winding heads of exciters, and re-bundle excitation devices:
binding wires;
1) Replace excitation
*9 ) Adjust clearance between main poles and commutating regulators;
poles of exciters.
2) Replace power
(2) Self-shunt static excitation devices cabinets;
1) Sweep and check appearance of devices; 3) Replace de-excitation
2) Check and test excitation transformers, series transformers, devices;
shunt transformers, PTs and CTs; 4) Replace excitation
3) Check and test unit boards, pulse boards, power cabinets transformers.
and rectifying elements;
4) Check and verify relays and contactors, check secondary
circuit and test insulation;
5) Maintain fans;
6) Perform circuit simulation test and tests under static,
no-load and on-load conditions;
38
DL / T 838 一 2003

Name of
parts
7) Characteristic test of excitation regulators;
8) Check and debug power system stabilizers (PSS);
9) Check and repair de-excitation devices and rotor
over-voltage protection devices;
*10 ) Replace power rectifier elements.
6. Ventilation (1) Check coolers and clean pollutants, perform anticorrosion (1) Replace coolers or
and cooling and hydrostatic tests; copper pipes;
system (2) Maintain pipe valves and perform hydrostatic test, repair (2) Transform rotor fans
insulation layers; or air scoops.
(3) Check and repair ventilation system.
7. Braking (1) Measure and adjust clearance between brake discs and (1) Replace brakes or
devices brake hoops; greatly improve structural
(2) Replace brake discs; components;
(3) Decompose and maintain brakes, and perform (2) Transform braking
pressure-tight test; system.
(4) Maintain oil, and gas pipelines and valves of braking
system, perform pressure test;
(5) Perform simulated motion test of braking system;
(6) Verify electric braking system and maintain switches;
8. (1) Measure air gap of permanent magnet generators; Replace permanent
Tachometric (2) Check and sweep permanent magnet generators, inject magnet generators
relays of oil for bearings and check transmission mechanisms;
permanent (3) Detect speed-voltage characteristics of permanent
magnet magnet generators;
generators
(4) Detect or replace tachometric relays;
*(5) Maintain rotors of permanent magnet generators;
*(6) Replace bearings of permanent magnet generators.
9. Primary (1) Check and repair generator switches, busbars, CTs, PTs
and and lightning arresters;
secondary (2) Check, verify and repair various instruments and
equipments transducers, detect original measuring points;
of generator (3) Repair, adjust and verify relay protection and automatic
system devices and components, or replace part of components;
(4) Check and test fault recorders;
(5) Maintain and test variable frequency starting devices of
pumped storage power plant;
(6) Check and repair cable fire prevention system.
10. Others (1) Test ground systems of electric equipments;
(2) Check and test insulation properties of busbars and HV
cables;
(3) Perform preventive test of electric equipments;
(4) Check and test generator on-line monitoring system;
(5) Overall commissioning test:
1) Perform water filling, no-load and on-load tests;
2) Measure vibration, swing and temperature of various parts
of the units;
3) Perform load shedding test of the units;
4) Measure and determine water leakage of guide vanes;
39
DL / T 838 一 2003

Name of
parts
5) Perform phase modulation and phase advance tests;
6) Perform tests of efficiency and water consumption rate for
the units with conditions permitted;
7) Perform over-speed test of the units;
*8) Measure electrical parameters of generators;
*9) Perform test of closing gate quickly in flowing water of test
of inlet valves.
40
DL / T 838 一 2003
Table A.8 Computer monitoring and control system of hydropower generator units
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.
41
DL / T 838 一 2003
Table A.9 Table of reference items in A class maintenance for main transformers
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
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
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
Instruction for arrangement of maintenance progress:

Note: for category of units, domestic units or imported units should be indicated; in “instruction for
arrangement of maintenance progress” field the reasons for more or less than the days of time limit for
maintenance for standard items are filled in.
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
Check safety measures and

isolation measures for operting
systems, commence
Recover systems and relieve

Power plants hold
maintenance mobilization
meeting
Scheduling department
Branch trial run

approves time for
commencement
isolation
Propose application for

maintenance for the units
to scheduling department
Maintenance ends
Technical disclosure
re-assembly
Hold primary equipment
Overall check of Issue and implement new

and quality acceptance
preparations management procedure

acceptance meeting
and files
Adjust network diagram if Review and approve

necessary maintenance management
Equipment
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
organizational measures for

maintenance management file
Compile safety, technical and

diagram,
This unit maintenance

Disaccord handling closes
Training before maintenance,
Check arrival of spare parts and

foreign
Balance labor and complete
ends
Process acceptance
and check of file package
accessories and accept
Equipment repair
network
for
summary to competent
Report unit maintenance
Summarize and archive

contracted projects
unit maintenance data

special items
file package
preparations
Compile
authority
Adjust network diagram if
for
for
extension to power grid
Propose change of costs if

change of items if necessary
Determine major schemes
Power plants determine

department if necessary
application
application
project plan, and report as

necessary Post assessment for
maintenance
Performance test and Determine
necessary
necessary
technical authentication specific

Propose
Propose
before maintenance maintenance Hot (dynamic) state

items evaluation
Power grid approves the

Performance test and
next annual maintenance
plan
Decomposition clearup of maintenance
analysis meeting data
Power plants arrange schedule
and propose the next annual Report for
recommissioning
supervision checks and
plan
tests, technical
quality
Equipment decomposition
Competent authority
approves the next annual Integral trial run
Disaccord handling
maintenance project plan

of
inspection points
Power plants propose the

verification
next annual maintenance

Cold (static) state
Various
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
5.6 On-site maintenance management

Civilized construction; placement of maintenance equipments as provisions; work site being clean and
orderly.
5.7. Preparations of maintenance
Complete maintenance construction plan; reasonable and in-place technical measures; preparation of
maintenance tools and spare parts; promptness of materials and spare parts plan, etc.
5.8 Technical management
Complete and prompt maintenance records and reports on abnormal operation.
6. Hot state evaluation for primary equipments and maintenance project assessment
(1) Evaluation for reliability after commissioning
Success rate of unit start-up; unscheduled load shedding rate; peak-shaving range and operating
flexibility; forced shutdown and MET; commissioning rate of thermocontrol, electric instruments and
automatic, protection devices; commissioning rate of analog and binary quantities of computer
monitoring systems of hydropower enterprises; commissioning rate of DAS analog and binary quantities;
equipment leakage rate; occurrence number of equipment defects and main defects.
(2) Evaluation for technical and economic indices
1. Man-hours management
Accuracy of man-hours plan; analysis of overtime and saved man-hours; rationality of allocation of all
technical types of work; rationality of allocation of grade workers and auxiliary workers; formulation of
training plan for personnel in shortage.
2. Materials management
Reasonable reserve of materials and spare parts in stock; correctness of procurement plan;
unobstructed procurement network; correctness of delivery price information.
3. Costs management
Costs settlement; analysis for reasons of over-expenditure and saving of budgets for all projects;
correctness of expenditure of costs; control of overall budget costs, etc.
4. Technical evaluation
Completion of maintenance target; correctness in selection of new equipments and new technologies;
correctness of diagnosis for equipment conditions; test evaluation for health conditions and performance
of equipments; main problems existing in equipments and technical measures in the future; selection of
borrowed and outsourcing personnel, rationality of various contract clauses, etc.
G.2 Final report on A/B classes maintenance for boilers
Power plant No._____ unit boiler _____ (Month)_____ (Day)_____ (Year)
Manufacturer_____ , type_____
Rated evaporation____ t/h, superheated steam pressure_____ MPa, superheated steam
temperature ℃
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
49
DL / T 838 一 2003
Scheduled: ____RMB 10,000 yuan, actual: ____RMB 10,000 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) Main technical indices of operation before and after maintenance

Before
Serial No. Index item Unit After maintenance
maintenance
1 Evaporation capacity t/h
Superheated steam MPa (gauge
2
pressure pressure)
Superheated steam
3 ℃
temperature
MPa (gauge
4 Reheated steam pressure
pressure)
Reheated steam
5 ℃
temperature
Feedwater temperature at
6 ℃
inlet of economizer
7 Exhaust gas temperature ℃
Excessive gas coefficient at
8
outlet of boiler
9 Flyash combustibles %
10 Ash and slag combustibles %
11 Total efficiency of boiler %
Content of sodium and
12 mg/l
silicon dioxide in steam
Temperature of primary air
13 ℃
at inlet of air preheater
Temperature of secondary
14 ℃
air at inlet of air preheater
50
DL / T 838 一 2003
Air leakage rate of air

15 %
preheater
Flue gas resistance of air
16 Pa
preheater
(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.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
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: ____RMB yuan, actual: ____RMB yuan.
(4) Operation
Operating hours from end of previous maintenance to start of this maintenance , standby hours .
Technological
items
Scheduled
number
Actual
number
51
DL / T 838 一 2003
H point W point
Scheduled
number
Actual
number
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.
2. Brief summary
52
DL / T 838 一 2003
(8) Others.
G.4 Final report on A/B classes maintenance for steam turbine generators
MVA，____kV
Power plant, No.______generator (Month)______(Day)______(Year) Manufacturer______,
model______, cooling method______, capacity______MVA, rated voltage kV
1. Overview
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)
(2) Manpower
(4) Operation
Operating hours from end of previous maintenance to start of this maintenance , standby hours______.
Technological
items
Scheduled
number
Actual
number
H point W point
Scheduled
number
Actual
number
2. Brief summary
53
DL / T 838 一 2003

(7) Brief analysis of test results [for hydrogen cooling and internal water cooling generators, hydrogen
leakage rate before and after maintenance, difference between inlet and outlet temperatures of stator
and rotor coils (max. value), difference between interlayer temperatures of stator bars, and water
conductivity, etc. should be indicated here, and outlet air temperature difference of stator bars of full
oxygen cooling generators should be also indicated. If the test cannot be carried out in accordance with
the standards of preventive test, reasons should be explained].
(8) Others.
G.5 Final report on A/B classes maintenance for hydroturbines

Power plant, No.______hydroturbine (Month)______(Day)______(Year)
Manufacturer______, type______, capacity______MW, revolution______r/min
Speed governor: manufacturer_______, type_______, oil pressure device: manufacturer_______,
type_______
1. Overview
Scheduled: perform the ____ A/B classes maintenance from (Month)______(Day)______(Year)
to______(Month)______(Day) ______(Year), in total______days.
(2) Manpower
(4) Operation
Technological
items
Scheduled
number
Actual
number

H point W point
54
DL / T 838 一 2003
Scheduled
number
Actual
number
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 %
3. Brief summary
55
DL / T 838 一 2003

(8) Others.
G.6 Final report on A/B classes maintenance for main transformers
_________Power plant No._________main transformer ______(Month)______(Day)______(Year)
Model: __________Voltage: ________Wiring group: ________
Manufacturer: ________Ex-factory No.: ________Ex-factory date: ____(Month)____(Day)____(Year)
Commissioning date of transformer: ____(Month)____(Day)____(Year)
Commissioning date of this station (plant):____(Month)____(Day)____(Year)
Date of previous A class maintenance for transformer: ____(Month)____(Day)____(Year)
HV bushings: ____type____pcs
MV bushings: ____type____pcs
LV bushings: ____type____pcs
Cooling devices: ____type____pcs
On-load tap changers: ____plant____type
Accumulative operating times:_____
No-excitation tap changers: ____plant____type
1. Overview
Scheduled: perform the ____A class maintenance from (Month)______(Day)______(Year)
(2) Manpower
(4) Operation
Technological
items
Scheduled
number
Actual
number
H point W point
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
2. Brief summary
(8) Others.
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
Scheduled: perform the ______ A/B classes maintenance from (Month)______(Day)______(Year)
(2) Manpower
(4) Operation
57
DL / T 838 一 2003
Technological
items
Scheduled
number
Actual
number
H point W point
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
2. Brief summary
(8) Others.
G.8 Final report on A/B classes maintenance for control systems of hydro-generator units
58
DL / T 838 一 2003
Hydroturbine type________capacity________; generator type________capacity________

Exciter type________capacity________; excitation transformer type________capacity________
Relay protection type________manufacturer_______commissioning date________
Fault recorder type_______manufacturer________commissioning date________
Excitation regulator type______ manufacturer______commissioning date________
Excitation power cabinet type_________ manufacturer_______commissioning date________
Deexcitation device type_________ manufacturer_______commissioning date________
Electrical speed governor type_________ manufacturer_______commissioning date_______
Mechanical speed governor type_______ manufacturer_______commissioning date________
Control unit type_________ manufacturer_______commissioning date________
Electric brake _________ manufacturer_______commissioning date________
Variable frequency starter________ manufacturer_______commissioning date________
Runout on-line monitoring system_________ manufacturer______commissioning date______
Insulation on-line monitoring system_______ manufacturer_________commissioning date______
Air gap on-line monitoring system________ manufacturer______commissioning date______
Cavitation on-line monitoring system_______ manufacturer______commissioning date_________
Efficiency on-line monitoring system_______ manufacturer______commissioning date_________
Main transformer oil chromatography on-line monitoring system_________
manufacturer______commissioning date______
Main transformer partial discharge on-line monitoring system_________
manufacturer______commissioning date______
Main transformer cooling and control system______ manufacturer_________commissioning
date_________
Main transformer self-extinguishing system_________ manufacturer________commissioning
date________
1. Manpower
Scheduled: ____workdays, actual: ____workdays.
2. Maintenance costs
Scheduled: _______RMB yuan, actual: _______RMB yuan.
3. Commissioning rate and correct action rate
Before maintenance After maintenance
content Correct Correct Remarks
Commissioning Commissioning
operating operating
rate % rate %
rate % rate %
Relay protection
Fault recorder
Excitation regulator
Electric brake device
Electrical speed
governor
Variable frequency stator
Runout on-line
monitoring
59
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.
(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.
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

DL T 838 - Standard of China Power Plant

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DL T 838 - Standard of China Power Plant

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ICS 27.

Electric Power Industry Standard of the

Guide of Maintenance for Power Plant Equipments

Issued on 2003-01-09 Implemented on 2003-06-01

Issued by the State Economic and Trade Commission

Guide of Maintenance for Power Plant Equipments

5 Basic requirements for management of maintenance

Intervals of A class Grade combinations of

7 Maintenance items and maintenance plans

8 Management for maintenance materials, spare parts and maintenance

8.2 Management for maintenance costs

10 Management for the whole process of maintenance for power

Name of parts Standard items Special items

(10) Check elbows of steam conduits at the exit

Table A.1 (continued)

Table A.1 (continued)

Table A.1 (continued)

Table A.1 (continued)

Table A.1 (continued)

(2) Check speed governors, emergency test of unit speed regulating

Table A.2 (Continued)

boxes of power feed pumps and hydraulic

switches and circuits;

Name of parts Standard items Special items

(4) Verify servo amplifiers; software version.

Table A.4 (Continued)

Table A.4 (Continued)

Name of parts Standard items Special items

Table A.5 (Continued)

treatment system concentrating tanks, neutralization/flocculation

Table A.6 Reference items in maintenance of hydroturbines

blades and measure oil leakage of sealing devices;

Table A.6 (continued)

Table A.6 (continued)

10. Others Check and test on-line monitoring system of hydroturbines

Note: items without * are B class maintenance items.

Table A.7 Reference items in maintenance for hydrogenerators

Table A.7 (Continued)

Table A.7 (Continued)

Table A.7 (Continued)

Table A.7 (Continued)

Instruction for arrangement of maintenance progress:

Check safety measures and

Recover systems and relieve

Branch trial run

Propose application for

Hold primary equipment

Overall check of Issue and implement new

preparations management procedure

Adjust network diagram if Review and approve

organizational measures for

Compile safety, technical and

This unit maintenance

Check arrival of spare parts and

accessories and accept

Summarize and archive

unit maintenance data

Propose change of costs if

Power plants determine

project plan, and report as

technical authentication specific

before maintenance maintenance Hot (dynamic) state

Power grid approves the

Scheduled: RMB 10,000 yuan, actual: RMB 10,000 yuan.

Hydroturbine typecapacity; generator typecapacity