Unit-4 Annual overhaul Report

Areas Covered:

Generator and Auxiliary Systems.

11KV/3.3KV/415V Switchgear relay protection.

GRP

Excitation System

Equipment testing

Following jobs were carried out during Unit- 4 Bi-AOH 2018

Generator and Auxiliary Systems:

• Generator terminal bushing inspection before purging clearance.
• H2 filling valves NB8 replacement in filling rack.
• N2 relief valve servicing.
• CO2 flash evaporator servicing.
• Exciter filters cleaning and air sealing.
• H2 gas driers servicing, painting, testing and leak test.
• Seal oil parameters adjustment and tuning.
• Primary water main winding and bushing flow adjustment.
• Generator exciter cleaning, brushes replacement, filters cleaning.
• Generator bushings inspection.
• Primary water conical filters cleaning.
• Seal oil pump change over checking with C&I and operation
• P.W coolers changeover by operation.
• P.W tank level transducer calibration by C&I.
• P.W resin replacement by Chemistry.
• Sealing of exciter unit air gapes.
• Lighting checking of exciter unit.
• Checking and cleaning of stroboscopes.

Excitation system:
• DAVR transducers Calibration.
• DAVR redundant network for DPU checking.
• DAVR DPU Backup taken.
• Excitation system DAVR cleaning, tightness, cards settings checking,
• Addresses checking, voltage and current injection and light load test.
• DAVR load limiters checking.
• DAVR Alarm and SOE checking.
Venkatesw Digitally signed by
Venkateswara Rao B

ara Rao B Date: 2019.01.29

10:36:36 +05'30'
• DAVR no load step response checking done.

GRP:
• Testing & Calibration of GRP relays.
• CT/ PT Tightness testing at GRP.
• CT Resistance measurement and IR measurement of Generator CTs.
• IR Value checking of field cables.
• GRP logic, SOE & Alarm checking.
• SCC and OCC Testing.
• PT Primary injection.
• Offline stability checking before barring gear.
• 400KV Main and Tie breaker closing and tripping from UCB.
• C&I Load transducers and Load shedding relay calibration and testing.
• Auto synchroniser calibration and testing done.

Transformer Testing Details:

Transformers Testing- 20 Nos.:

• GT- 3Nos (Normal testing, Tan Delta measurement & SFRA).

• C1 & C2 measurement of GT bushing – 3 Nos.
• ST-1 (Normal testing, Tan Delta measurement & SFRA).
• C1 & C2 measurement of ST-1 bushing – 3 Nos.
• UT- 1Nos (Normal testing, Tan Delta measurement & SFRA).
• C1 & C2 measurement of UT-1 bushing – 3 Nos.
• UAT-2 Nos. (Normal testing)
• Dry type transformers – 4 Nos.
• ESP Transformers – 5 No.
• VFD Transformer – 4 Nos. (Normal testing).
• Neutral Earth Resistance Measurement – 20 No.

HT and LV Switchgear:

• 11KV, 3.3KV and 415V switchgear Numerical relays testing.

• Scada System checking.
• Fast change over and slow changeover checking.
• Ensuring under voltage tripping of all HT Breakers.
• Breaker trip checking from relay operation. Venkatesw Digitally signed by
Venkateswara Rao B

• SCADA System checking. ara Rao B Date: 2019.01.29

10:37:03 +05'30'
New Jobs carried out during unit-4 overhaul:
• Modification of local / remote switch for changeover from local to remote.
• GT more than 2 cooler fail relay was commissioned.
• SPS signal for automatic load reduction to 400MW in case of GT More than 1 cooler fail
provided that generator load is more than 400MW.
• Excitation system limiter settings have been revised for enabling the generator to go up to
maximum allowed leading capability.

Pre-synchronization & synchronization:

• Generator SCC test & proving of protections.

• Generator OCC tests.

TOTAL COST OF OVERHAULING FOR GEN & PROTECTION IN

UNIT-4:

Total overhauling cost:

1. Manpower deployment cost: Rs.1,68,000/-

2. New items consumed (Numerical relays of ABB Make): Rs 5,16,000/-.

TOTAL COST: Rs 6,84,000/-

Venkates Digitally signed

by Venkateswara
wara Rao Rao B
Date: 2019.01.29
B 10:37:14 +05'30'
UNIT # 4 GENERATOR SCC OCC DATE:05/10/2014
page:1 / 7

UNIT # 4 GENERATOR SCC

Exe. Exe
Pannel
Ig% Uc (Vdc) If % Voltage current Gen If
KAmp
(VDC) (A)

1 1.5 -8.56 0.2 0.04 0.3 123 1.83

2 9.6 1.17 4.5 2.29 4.2 1311 131

3 32.8 1.59 18.5 12 17 5003 650

4 62.8 2.1 37.9 24.68 34.5 9978 1364

5 92.6 2.66 55.8 38.4 51.6 15121 2053

6 60.7 2.089 35.3 24.53 33.4 9618 1322

7 31.7 1.55 17.5 12.17 17.4 4928 633.25

10

11

12

13

14

15

16

17

18

19

Venkatesw Digitally signed by

Venkateswara Rao B
ara Rao B Date: 2019.01.29
10:37:27 +05'30'

Page 1 of 7
UNIT # 4 GENERATOR SCC OCC DATE:05/10/2014
page:2 / 7

CURRENT SHARING (in A)

BRIDGE-1

1 2 3 4 5 6

6 5.74 4.1 5.31 5.35 5.14

BRIDGE-2

1 2 3 4 5 6

5 5.61 6.03 6.18 6.24 6.23

Current Common

1 2 3 4 5 6

12.22 13.24 15 12.31 11.51 9.4

VOLTAGE DROP ACROSS FUSES (in mvolt dc)

BRIDGE-1

1 2 3 4 5 6

16.4 15.1 11.1 14.3 13.76 12.93

BRIDGE-2

1 2 3 4 5 6

12.75 14.4 19.21 17.33 16.9 17.33

Digitally signed by
Venkatesw Venkateswara
B
Rao

ara Rao B Date: 2019.01.29

10:37:38 +05'30'

Page 2 of 7
UNIT # 4 GENERATOR SCC OCC DATE:05/10/2014
page:3 / 7

UNIT # 4 GENERATOR OCC

Exe Exe Pannel
Ug% Uc If % Gen If
voltage current KV
1 4.4 0.01 1 0 0.5 0.93 9.16

2 23.3 1.18 5 2.71 4.8 4.74 130.9

3 47.4 1.38 11.2 7.91 10.9 9.92 373

4 72.8 1.62 20.4 13.3 18.7 15.42 707

5 99.9 1.9 30 20.21 30.7 20.98 1072

6 67.8 1.52 16.1 10.52 18.4 13.87 576

7 52 1.38 12.2 8.8 14.3 10.67 407

8 26.6 1.19 6.2 3 8.4 5.5 157

Venkate Digitally signed by

swara Venkateswara Rao B

Date: 2019.01.29
10:37:50 +05'30'
Rao B

Page 3 of 7
UNIT # 4 GENERATOR SCC OCC DATE:05/10/2014
page:4 / 7

DATE: 16.09.2018

GEN SCC

16000
14000
12000
Panel KA Gen

10000
8000
6000
4000
2000
0
0 10 20 30 40 50 60

If%

Ig & Q-AXIS

2500

2000
Rotor fld current

1500

1000

500

0
0 2000 4000 6000 8000 10000 12000 14000 1600
Ig (Panel KA)

Digitally signed by
Venkatesw Venkateswara Rao B
ara Rao B Date: 2019.01.29
10:38:02 +05'30'

Page 4 of 7
UNIT # 4 GENERATOR SCC OCC DATE:05/10/2014
page:6 / 7

GEN OCC

35

30

25

20
Ug%

15

10

0
0 20 40 60 80 100 120
If%

Venkateswa Digitally signed by

Venkateswara Rao B

ra Rao B Date: 2019.01.29

10:38:31 +05'30'

Page 6 of 7