Guidelines for Erection and commissioning of DVR.

1. The documents viz. Schematic drawing, Test report and O & M Manual, concerned with the project should be available at the site. 2. Locate the place where the cubicles have to be erected with due consideration for cable entry, movement of personnel around the panel, Ventilation etc. Check for vibration, dust ingression, oil & moisture. Ensure that they do not become a source of problem. (Refer OGA drawing). 3. After opening the packing, check the panels for transit damages, Module non-availability, Cubicle mounted components etc. In case of discrepancy prepare a report indicating the M.O.No., Packing list no. / Despatch advice no., Component details (Refer component list in schematic diagram). 4. The following cabling is to be checked with reference to schematic drawing. Any other additional input / Aux. contacts has to be wired to suit project requirement a. Inter-connection between Regulation, Field Flashing, Field breaker, Thyristor and Excitation transformer cubicle. b. Connections from Generator relay panel, Generator circuit breaker control box, Turbine control panel, Generator control desk and Generator PT / CT. c. Power connections from Excitation transformer LV to Thyristor Panel, Field breaker panel to Generator slip rings, Excitation transformer HV to Generator Bus duct. d. AC / DC Power supply for Field breaker control, field flashing, regulation, Measuring and control supply. 5. Ensure proper glanding of the power and control cables. The cables should be properly identified with cable tags, cross-reference ferrules and should be terminated with proper lugs. For Gen. PT/CT connections Ring type lugs should be used and for other terminations it is preferred to use ring / fork type lugs. Check the tightness of all Connections / Terminations and firmness of plug-in connectors in the rear side of the Racks (System cable connectors). 6. Ensure Earthing has been provided for all the panels. Zero volt and Screen has to separately earthed with independent cables. In case it is not possible to provide separate earth for the above it is advised that two separate cables to be laid from the same earth pit. For Cubicle earthing GI strip and for Zero volt / Screen earthing, multi-strand copper cable of size approx. 70 sq. mm to be used. Refer OGA drawing for suggested earthing procedures. 7. Pulse cables should be laid separately in the cable tray without any other cable crossing over. Ensure that the pulse cables are tied together in the cable tray and kept isolated. 8. The IR value of the Power and Control cables has to be noted down (> 200M.ohms). 9. Rack out all the modules and confirm the Modules link settings, Serial nos. are as per the test report.

10. Prior to Charging the Panels with power supply, check the Fuses and MCB settings as per the test report. Isolate the load side and charge the circuit stage by stage as shown in the schematic diagram. Confirm that there are no abnormalities after switching ON the Power supply. 11. Press Acknowledge and Reset Push button in the control panel and clear the Fault / alarm persisting if any. 12. Plug in the modules in the following order (suggested) and ensure proper housing of the modules in the rack. Switch ON the designated MCB and record the input and output power supply values. a. b. c. d. e. f. Manual channel Auto channel PLC / Monitoring Channel DC / DC Convertors (Regulation supply) AC-DC/DC Convertors (Thyristor Pulse supply) Control & Measuring supply (if any).

13. Power supply. (For range of values & tolerances refer test report) 13.1 DC Station supply extended to TB nos. __FS, __FS & __FS, __FS (in FS cubicle): _FS - _ FS:_____ V DC; _ FS - _ FS: _____ V DC

13.2 Station Auxiliary Supply at TB Nos. __FS, __FS, __FS & __FS (in FS cubicle). a) T04 : Input Voltage : 3, 415 V AC Output Voltage: 3, 165 / 90 V AC Check Phase sequence. b) T05 : Input Voltage : Output Voltage: 13.3 Power Supply Modules: a. Auto Channel Power Supply (MCB - F60) Location AA37 DC Input Voltage DC Output Voltage 220 / 110 V + 24 V + 15 V - 15 V + 5V : : : : : 1, 240 V AC: 1, 220 V AC: : : V AC, 3 V AC, 3

V AC V AC Actual Values

b.

Manual Channel Power Supply (MCB - F61) Location AA01 DC Input Voltage DC Output Voltage 220 / 110 V + 24 V + 15 V - 15 V + 5V : : : : :

Actual Values

c.

PLC Power Supply (MCB - F54) Location AB01 DC Input Voltage DC Output Voltage 220 / 110 V + 24 V + 15 V - 15 V + 5V : : : : :

d.

Control Circuit Power Supply (MCB-F71) Location AG01 DC Input Voltage DC Output Voltage 220 / 110 V 48 V : :

e.

Trip Circuit Power Supply (MCB-F72) Location AG10 DC Input Voltage DC Output Voltage 220 / 110 V 48 V : :

f.

Pulse Final Stage Power Supply (MCB-F52.1) Location AH01 DC Input Voltage 220 / 110 V : DC Output Voltage + 48 V : +10V at N1/5 - N1/3 :

g.

Pulse Final Stage Power Supply (MCB-F52.2) Location AH18 DC Input Voltage 220 / 110 V : DC Output Voltage 48 V : +10V at N1/5 - N1/3 :

h.

Pulse Final Stage Power Supply (MCB-F52.3) Location AJ10 DC Input Voltage 220 / 110 V : DC Output Voltage + 48 V : +10V at N1/5 - N1/3 :

i.

Pulse Final Stage Power Supply (MCB-F52.4) Location AJ18 DC Input Voltage 220 / 110 V : DC Output Voltage + 48 V : at N1/5 - N1/3 :

14. Protection and Indication logic checked as per schematic and found OK. The alarms (Annunciation Modules AB61 & AB65) were checked by simulation and found OK. 15. Actual Value Simulation 15.1 Generator Voltage Simulation Generator PT ratio : kV / 110 V Rated Voltage : 110 V Feed AC Voltage 110V, 3, at TBR __, __, & __ Value recorded at (i) (ii) TBR __-__ : V; __ - __ : Check Phase sequence. DE010/U01 1 - 2 : Vac ; X 250 - X 251 X 251 - X 252 X 252 - X 250 V ; __ - __ : V

2-3 : Vac ; 3 - 1 : : ________ V AC : ________ V AC : ________ V AC

Vac

(iii)

AA53 UR - 0V : ____Vac ; US - 0V : _____V ac; UT - 0V : _____Vac UG -0V : _____Vdc; U1 - 0V : _____Vdc; U2 - 0V : _____Vdc.

15.2 Generator Current Simulation Generator CT Ratio : ______ A / __ A Gen. Rated Current : ______ Amps. Rated CT Secondary Current : ______ Amps. Fed Rated (CT Secondary) current at TBR _, __, __ & __ (Current injected : _____ Amps. Approx.)
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Value recorded at i. DE010/U01 X 257 - X 258 : _______ Vac X 258 - X 259 : _______ Vac X 259 - X 257 : _______ Vac ii. AA53 IR - 0V : _______ Vac; IS - 0V : _______ Vac; IT - 0V : _______ Vac IG - 0V : _______ Vdc 15.3 Field Current Actual Value Simulation: Field current CT Ratio Rated field current CT secondary current : ______ A/1 A. : _______Amps. : _______ Amps.

Fed Rated (CT Secondary) current at TBR __, __, & __ (Current injected : _____ Amps. Approx.) Value measured at i) AA 65 ii) AA 29 iii) AA 53 If - 0V : If - 0V : If - 0V : ______ V dc ______ V dc ______ V dc

15.4 Over Current Relay Testing (K7) Excitation transformer HV CT Ratio Rated Primary Current Secondary current (In) Over-current delayed setting Time setting for Delay Over-current Instantaneous setting : : : : : : ___ A/1A _____ Amps. ____ Amps 1.35 x In 6.0 Sec. 3 x In

Simulate the above currents and check the operation of Relay & Alarm Annunciation. Relay to be calibrated for the above settings. In case intermediate current transformer is used, the values have to be set accordingly.

16. Light Load Test: Input voltage *** Load connected : : _____V, 3, AC, 50 Hz _____W ( Heater / Lamp load)

*** Approx. Exc. Transformer Secondary Voltage. Set switch S-865/1 in ON position in Manual channel UN 0663 and Field flashing ON relay to be removed during the test. Light load test to be done with individual thyristor bridges and all bridges in service. UC (AA29/ UC -OV) _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc Output Voltage (V DC) _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc _____ Vdc

Check pulse sequence, shape, amplitude, width & Thyristor conduction for individual bridges. 17. Excitation Transformer to be charged for Dry-out & Fault protection Checks of the Generator. Connect the Field breaker trip contact and HV breaker trip contact so as to ensure the tripping of both Field breaker and HV breaker in case of any faults during testing. AC Voltages - Values measured at Sl. Transformer Input Voltage Output Voltage No Device Ref. R - Y Y - B B - R r - y y - b B - r 01 Excn. Trfmr KV** KV ** KV ** 02 T01 03 T02 04 T03 05 06 T05 (1ph) 07 DE010/U01 08 DE020/U01 09 AA29 10 AA65 ** From Panel meter. 17.1 Short Circuit Characteristics
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Gen. Current Amps AC

Field Voltage Volts DC

Field Current Amps DC

DE010/U01(Vac) X257 X258 X259 X265 X265 X265

AA53 (Vac) IRIS IT 0V 0V 0V

AA53 Ig- 0v Vdc

AA65 If-0v Vdc

AA29 If-0V Vdc

17.2

Open Circuit Characteristics

Uc Con Volt Field Voltage Volts DC Field Current Amps DC DE010 /U01(Vac) X250 X251 X252 X251 X252 X250 AA53 (Vac) UR - US 0V 0V UT 0V AA53 Ug-0v Vdc AA65 If-0v Vdc AA29 If-0V Vdc

Gen./PT* Voltage KV/VAC

* PT Voltage to be measured at DE010/U01 - 1,2 & 3 After the Dry-out is completed the modifications done prior to starting of the test has to be restored.

18.

Commissioning activities a. Voltage Build up in Manual Channel - DC Field Flashing (If applicable) Manual channel Min. set to ______ KV of Generator Voltage Check Follow-up & Channel changeover and observe smooth changeover. De-excite the Machine - FB Off. b. Voltage Build up in Auto Channel - AC Field Flashing (If applicable) Check Range of Auto Channel - Min.:9.9kv to Max.:12.1KV Check channel change over & follow-up control De-excite the Machine - Excitation off. c. Voltage Build up in Auto Channel - AC / DC Field Flashing. Check Micro terminal Display for the Parameter of UG, Uc, If1 & 2, with Actual value. d. Conduct Step test without Machine synchronised for + / - 10% & + / - 5% of Generator Voltage (Recording has to be done). e. Check remote operations from control desk.

f. Check DVR for unit auto operation prior to synchronisation and after synchronisation. Record the following values : Parameter UN0663 AA29:Ur-Us-Ut UN0663 AA29:If UN0663 AA29:Uc UN0661-AA53:Ur-Us-Ut UN0663 AA29:If UN0663 AA29:Ug, Ig UN0663 AA29:U1, U2 UN0663-AA65:Ur-Us-Ut UN0663 AA29:If UN0663 AA29:Uc PT Voltage RY-YB-BR Field voltage Field current (mV drop & currrent) Excn. Trafo. Sec. Volts RY-YB-BR MV drop across fuses 1-3-5-4-6-2 : Thy-1 MV drop across fuses 1-3-5-4-6-2 : Thy-2 MV drop across fuses 1-3-5-4-6-2 : Thy-3 MV drop across fuses 1-3-5-4-6-2 : Thy-4 At No-Load At P= ,Q= , Cos phi =

Procedure For Limiter Commissioning & Response Checking

1. Carry out the calibration of Generator terminal voltage. Calibration to be carried out as follows. a. Excite the generator & build up rated terminal voltage in manual channel. Ensure that the AVR PT voltage is 110Vac at Regulation Terminals. b. Adjust/ Calibrate machine terminal voltages as per factory test report. I.e. Ur=Us=Ut= 4.37 V AC & Ug= 7.0 V DC on interrupt Generator module (UN0661) of Auto channel. 2. Set auto channel PID parameters and carry out Step test (+10% and 10%). a. For +10% step, change Uref(F270) from 100 % to 110 % & check the response. b. For +10% step, change Uref(F270) from 100 % to 110 % & check the response. Note:- For correct adjustments of PID parameters , during step test the controlled variable Ug settles with one over shoot & one under shoot. The over shoot should be within 8 - 10% of the adjusted reference value. 3. After successful completion of Step test & calibration of Generator terminal voltage, proceed further with limiters commissioning. 4. Field Current Maximum Limiter a. In order to ensure that the value displayed in the micro-terminal for Ifac is correct, measure the milli-volt drop across the FB Shunt & compute the same for rated value in terms of percentage. This computed value should match the value displayed in microterminal for Ifac. In case the values are different then calibration for Ifac has to be done. b. With Generator Terminal voltage at rated value (Uref= 100 %), Note down all the parameters of DVR as per table. c. Gradually increase terminal voltage by varying the reference value from local panel to a higher value i.e. in Micro-terminal Uref= 105%. d. With Generator Terminal voltage at 105% of rated value ( Uref= 105 %) , Note down all the parameters of DVR as per following table. e. Bring back the terminal voltage to rated value i.e. Uref=100%. f. Note down Field current variation from the above reading at 100 & 105 %. In order to check the intervention/operation of limiter, field current value shall be adjusted within the above two values recorded. g. After adjusting limiter value (F400) to new value, give step input to Generator voltage from 100 % to 105 %. h. Check operation / intervention of Field current maximum limiter. i. With the help of dual channel recorder record the limiter intervention. Also check the operation of output relay at digital output Module. j. With limiter in operated condition, note down all the parameters as per table. k. Restore the limiter values to original as per factory test report or as per site requirement.

Parameter U reference Uref Generator Voltage Ugen Field Current Ifac

Before operation of Limiter

After operation of Limiter

Remarks Recording of Limiter response is Enclosed.

Generator Current Igac Power P Control Voltage Uc Reactive Power Q Parameters to be recorded from micro terminal.

5.

Inductive Stator Current Limiter: a. Check and ensure that the value in micro-terminal for Igac and the generator current meter reading in the control desk display the same value. b. With Generator Terminal voltage at rated value ( Uref= 100 %) , Note down all the parameters of DVR as per table. c. Gradually increase terminal voltage by varying the reference value from Micro-terminal. I.e adjust ref. Value Uref= 105%. d. With Generator Terminal voltage at 105% of rated value (Uref= 105 %), Note down all the parameters of DVR as per following table. e. Bring back the terminal voltage to rated value i.e. Uref=100%. f. Note down Generator stator current variation zone hence obtained from reading at 100 & 105 %. In order to check the intervention/operation of limiter, Inductive stator current value shall be adjusted within the above two values recorded. g. After adjusting limiter value (F430) to new value, give step input to Generator voltage from 100 % to 105 %. h. Check operation / intervention of Inductive stator current limiter. i. With the help of dual channel recorder record the intervention. Also check the operation of output relay at digital output Module. j. With limiter in operated condition, note down all the parameters as per table. l. Restore the limiter values to original as per factory test report or as per site requirement.
Parameter Before operation of Limiter After operation of Limiter Remarks Recording of Limiter Response is enclosed.

U reference Uref Generator Voltage Ugen Field Current Ifac Generator Current Igac Control Voltage Uc Power P Reactive Power Q Power Factor Cos

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6.

Capacitive Stator Current Limiter

a. With Generator Terminal voltage at rated value ( Uref= 100 %) , Note down all the parameters of DVR as per table. b. Gradually reduce terminal voltage by varying the reference value from Micro-terminal. I.e adjust ref. Value Uref= 90%.( Voltages shall be varied as per system conditions) c. With Generator Terminal voltage at 105% of rated value ( Uref= 90 %) , Note down all the parameters of DVR as per following table. d. Bring back the terminal voltage to rated value i.e. Uref=100%. e. Note down Generator stator current variation zone hence obtained from reading at 100 & 90 %. Hence to check the intervention/operation of limiter, capacitive stator current value shall be adjusted within this zone. f. After adjusting limiter value (F460) to new value, give step input to Generator voltage from 100 % to 90 %. g. Check operation / intervention of Capacitive stator current limiter. h. With the help of dual channel recorder record the intervention. Also check the operation of output relay at digital output card. i. At limiter operated condition, note down all the parameters as per table. j. Restore the limiter values to original as per factory test report.
Parameter U Reference Uref Generator Voltage Ugen Field Current Ifac Generator Current Igac Control Voltage Uc Power P Reactive Power Q Power Factor Cos Before operation of Limiter After operation of Limiter Remarks Recording of Limiter response is enclosed.

7. Load Angle Limiter a. The value of Xq & Xe has to be entered in DVR. Xq (C4A4) = Xe (C4A6) = Procedure for Calculations of Xe & Xd 1. Please refer calculations details for " External Network Reactance Xe P.U." Xe= (change in vol. Ug/ Ugn) / (change in MVAR/ S) Where,
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Ug = Generator terminal Voltage Ugn= rated generator terminal voltage. S= Rated MVA capacity of generator. For reference, the data of BPCL DVR is enclosed. Take machine to inductive zone and note down readings as.( all measurements are taken from microterminal)

Power factor= 0.95 Lag; Ug= 110.00 V AC ( PT volts) Reactive power Q = 17.0 %( 7 MVAR lag ) Delta act.( Dact) = 43.2 deg. Take machine to capacitive zone and note down readings as.( all measurements are taken from microterminal )

power factor= 0.95 Lead; Ug= 99.8 V AC; Reactive power Q = 16.1 %(- 6.3 MVAR lead ) Delta act.( Dact) = 68.9 deg.

Calculations Change in Ug/ Ugn = (U lag - U lead)/ Ugn = (110 - 99.8) / 110 = 7- ( - 6.3) Xe = 13.3 = 0.093 Change in MVAR = (MVAR lag - MVAR lead) = (change in vol. Ug/ Ugn) / (change in MVAR/ S) = 0.093/ ( 13.3/ 42.362) = 0.093/ 0.323 = 0.28

2 a.

b. c. d. e.

Xd and Xe Values. For this, refer to the DVR factory test report document, page titled " synchronous machine data & specification of excitation equipment". This sheet gives details about machine synchronous reactance (direct axis unsaturated / quadrature axis). In case the Quadrature axis reactance is not mentioned then the value as given for direct axis unsaturated in the generator data sheet or DVR test report for e.g. 192.26% (1.92 p.u.) then this value of Xd can be assumed. With Generator Terminal voltage at rated value ( Uref= 100 %) , Note down all the parameters of DVR as per following table. Gradually reduce terminal voltage by varying the reference value from Micro-terminal. I.e adjust ref. Value Uref= 90%.( Voltages shall be varied as per system conditions) With Generator Terminal voltage at 105% of rated value ( Uref= 90 %) , Note down all the parameters of DVR as per table. Bring back the terminal voltage to rated value i.e. Uref=100%.

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f. Note down Generator stator current variation zone hence obtained from reading at 100 & 90 %. Hence to check the intervention/operation of limiter, capacitive stator current value shall be adjusted within this zone. g. After adjusting limiter value (F4A0) to new value, reduce terminal voltage gradually from 100 % to 90 %. h. Check operation / intervention of load angle limiter at set value. i. With the help of dual channel recorder record the intervention. Also check the operation of output relay at digital output card. j. At limiter operated condition, note down all the parameters as per table. k. Restore the limiter values to original as per factory test report.
Parameter U reference Uref Generator Voltage Ugen Field Current Ifac Generator Current Igac Control Voltage Uc Power P Reactive Power Q Power Factor Cos Before operation of Limiter After operation of Limiter Remarks Recording of limiter response is enclosed

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