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1-48-01To,
WBS ElementNo: CE/0664-SH

Doc No:EDN48-0664-02

.
CE/0664-SH6-48-01

Date.01.04.2010

TESTPROTOCOL
CPP
6 X 1 5 0 M WA D I T Y A A L U M I N I U M
HINDALCO

1.

ProjectName

2.

VoltageRegulator(DAVR)
/ Product : DigitalAutomatic
Equipment

3.

Rating

: 6 X 1 5 0M W

4.

Client

5.

OtherRequirements,if
any

LTD.
INDUSTRIES
HINDALCO

By:
Prepared

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on thisdocumentis the propertyof BHELlt mustnot

The information
COPYRIGHTAND CONFIDENTIAL:
to the interestof the company.
in any way detrimental
be useddirectlyor indirectly

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REVISIONHISTORYSHEETFOR PROJECTSPECIFIC
TEST PROTOCOL

NATUREOF
CHANGE
06.01
.2010

REASONS

Firstlssue

01.04.2010 Secondlssue

Loqo Included

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N.THOMAS

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be useddirectlyor indirectly
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TEST PROTOCOL
CONTENTS
1.

SCOPE.

2.

REFERENCE
DOCUMENTS.

3.

TESTSAT WORKS.

4.

TESTSAT SITE.

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1.0 scoPE
Fo||owingtestsareconductedonDVRatBHEL-EDNworksandatS|TE.Refer
IEEE421.2(1990)
standards:
TESTSATWORKS.
i)
TESTSAT SlrE.
ii)
2.0

REFERENCEDOCUMENTS
diagram
Schematic
a)
b)
c)

OGAdiagram
Test instruction

3.1

TESTS AT WORKS
COMPONENTLAYOUTAND ASSEMBLYTEST
is a
mountedin the cubiclew'r't Componentlistwhich
Checkingof components
drawing.
partof schematic

3.2

W]RINGCHECK

3.0

continuitytestlsdonefortheinternalcabinetwiring.Thisison|yanintern
the Panel'
donebeforeenergizing
3,3

3.4

H.V.& IR TESTS
tests)
resistance
(Highvoltageand Insulation
respectto
circuitgroupswith_
-etc.
Thistest determinesthe insulationstrengthof voltage
which have alreadybeen
the panel eartn.Ril electronicmodulei, devices
testing,priorto svstemtesting,are isolatedfrom this
subjectedto HV test
"tFca
before an? after appiyingHV' -This.'isan-internal test'
test. lR to Oe measured
th" p;""1s ior'intLrnal functional tests on each
performed O"tor",
functional
will be given to customerduring inspectionof
set. HV test report"i-"igili"g
tests.
FUNCTIONALTESTS

3.4.1 Power SuPPIYcheck :

and for a variationof
Checkingof DC powersupplyoutputfor rated inputvoltage
of ratedvoltagefor each of the PowersuPPlYmodules
+1To/o
and - 15o/o

mustnot
on thisdocumentis the propertyof BHELlt
The information
copyRlGHT AND CONFIDENTIAL:
beusedoirecttyffiydetrimenta|totheinterestofthecompany'

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3.4.2 Logic sequencecheck :

checkingof the followinglogicsequenceby simulationwherevernecessaryas
per schematic.
a)

ExciterFieldBreakerON/OFF

b)

ExcitationON/OFF

c)

Channelchangeovercontrolfor each of the channelsfrom every

Intentional
otherchannel,

d)

Raise/ Lowercontrolof each of the channels.

Signalingand monitoringcircuit/ contactsfor externalconnections.For each
simulatethe faultand checkthe indicationon DAVR
of tne tauttindications,
paneland the contactsfor externalconnections.

e)

Protectivechangeover
Auto -1 to Auto - 2 on Auto -1 failure
Auto -2to Auto - 1 on Auto -2failure
Auto -1 to Manual- 1 on Auto - 1 functionfailurewhen Auto-2has
alreadyfailed.
failurewhen auto-1has
Auto -2to Manual-2 onAuto- 2-function
alreadyfailed.

3.4.3 Signal flow check:

v

a) Actual values setting

i) Settingof actualvaluesby injectionof inputsensingvoltageand current'
b) Checking and setting of gate control circuit for the channels
Followingchecksare performedwith unloadedthyristorbridge
i) Checkingof pulsesat thyristordevices
of pulsesat the thyristorbridge.
ii) Synchronisation
iii) Blockingand releaseof pulses.
c) Auto Channel Settings/ checks
i) Rangeof auto set pointreference.
ii) Checkingof pulsefinalstageamplifier.
d) ManualChannelsettings/ checks
i) Rangeof Thyristorbridgeoutputvoltagein Manualchannels.
ii) Checkingof pulsefinalstageamplifier.
on thisdocumentis the propertyof BHELlt mustnot
The information
copyRlGHT AND CONFIDENTIAL:
to the interestof the company.
in any way detrimental
or indirectly
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e) Follow-up control
i) Checking of automaticfollow-up circuit. Stand-by channel shall follow the
channelin service.
3.4.4 Light load characteristic:
a) Lightloadtest on eachthyristorbridgefor channelswith resistiveload at
PMG frequency.
b) Tabulationof inputcontrolvoltageVs Thyristorbridgeoutputvoltage.Check
if the characteristics
are linear.
c) Checkingof bridgecapabilityto meet ceilingvoltagerequirement.
3.4.5 Checking of complete AVR operation at PMG frequency
With rated PMG Voltage at rated PMG frequencyas input to AVR and a resistive
load connectedto Thyristorbridgeoutputs,check the stabilityof controlof each of
the in builtManualchannelsby issuingRAISE/LOWERcommandsthroughpush
buttons.
A brief changeoverto Auto channelcan be made after ensuringchannelbalance.
HoweverRaise/ Lowercommands,if issuedwill make excitationreach its extreme
limits.
Note: lf there is a main supplyvariationin testingstation,there will be variationin
thyristorbridgeoutputalso.
3.4.6 Checkingof Auxiliarycontrol functions.
a) Load angle limiter (Underexcitation limiter)
i) By phaserotationof lR, lY & lB with respecttoUR, UY & UB simulateoperation
of Generatorin leadingreactivepowerzone.
ii) Adjust Uref and Uact so that Regulatoroutputhas not reachedmaximumlimit.
Note down actual value of load angle achieved.Switch OFF all other limiters.
SwitchON Loadanglelimiter.
iii) Reducethe load anglereferenceto a valuebelowthe actualvalueachieved.
iv) Observeinfluenceof limiteron regulatorto increaseexcitation.
v) Checkindication.
vi) Normalizeloadanglereferencevalue.

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b) Stator current capacitiveLimiter (Under excitation limiter)

i) By phaserotationof tR, lY & lB with respecttoUR, UY & UB simulateoperation
of Generatorin leadingreactivepowerzone.
ii) SwitchOFF all limiters& PSS.SwitchON Statorcurrentcapacitivelimiter.
iii) AdjustGeneratorcurrentactualvalue,between80 to 100%.AdjustUrefand U
actualso that Regulatoroutputhas not reachedmaximumlimit.
iv) Reducereferencevalue of statorcurrentlimiterand Observeinfluenceof limiter
on regulatorto increaseexcitation.
v) Checkindication.
vi) RestoreStatorcurrentcapacitivelimiterreferencevalue.
c) Rotor current limiter (Over -ExcitationLimiter)
i) SwitchOFF all limiters& PSS.SwitchON Rotorcurrentlimiter.
ii) AdjustUref and Uact so that Regulatoroutputis well withinthe currentratingof
loadingrheostat.
iii) Reducereferenceof Rotorcurrentlimiter
iv) Observeinfluenceof limiteron regulatorto decreaseexcitationafter a delay.
v) Checkindication.
vi) Restorereferencevalue of Rotorcurrentlimiter.
d) Stator current Inductive limiter (Over -ExcitationLimiter)
i) By phaserotationof lR, lY & lB with respectto UR, UY & UB simulateoperation
of Generatorin laggingreactivepowerzone.
ii) SwitchOFF all limiters& PSS.SwitchON StatorcurrentInductivelimiter.
iii) AdjustUrefand U actualso that Regulatoroutputis well withinthe currentrating
of loadingrheostat.Temporarilyreducereferencevalueof Statorcurrentlimiter.
iv) Observeinfluenceof limiteron regulatorto decreaseexcitationaftera delay.
v) Checkindication.
vi) NormalizeStatorcurrentreferencesetting

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e) YlHzLimiter(Overfluxinglimiter)
i) checkactualvalueof w signarvortage& Frequency.
ii) switchoFF all limiters& PSS.switchoN v/F timiter
iii) AdjustUrefandUactsuchthatExcitation
is notat itsminimumvalue
iv) Reducethe V/F reference
valuelowerthanActualV/F ratio.
v) Observeinfluence
of limiteron regulator
to decreaseexcitation
aftera delay.
vi) Checkindication.
vii)Normalize
V/F reference
setting.
3.4.7 checkingof Panellllumination
and Heatercircuit
Checkthe operationof panelillumination
circuitby operatingdoor limitswitches
usingdoor.
Checkthe operationof heatercircuit.

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The information
on thisdocumentis the propertyof BHELlt mustnot
be useddirectlyor indirectly
in any way detrimental
to the interestof the company.

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TESTSAT SITE:
The list of tests that need to be conductedon excitationequipment,at site and the
purpose has been listed in this document.For details,CommissioningProtocol
groupshallbe referredto.
documentof Erection/ Commissioning

4.1

PRECOMMISSIONING
:

4.1.1 Checkingof components& wiring :

a) Checkingof componentsmountedin the cubicleswith respectto componentlist,
whichis a part of schematicdrawing.
b) Checkingof interpanelCableterminations.
4.1.2 Open loop tests:
a) Checkingfor controlof ExcitationSystemfrom REMOTEcommands.
Indicationsat
Indications/Meter
b) Ensuringproperfunctioningof Status/Alarms/Fault
REMOTE.
c) Functioning
of protectionlogics.
4.1.3 Checking and setting of actual values & parameters:
a) Checkingand settingof Actualvalues.
b) Checking and setting of parametersfor Gate Control circuit, Regulatorsand
Limitersas per systemrequirements.
c) Ensuringsmoothcontroland healthinessof ThyristorConverters.
4.1.4 Light load test:
V-.

a) Light load test on ThyristorBridgefor each channel,with resistiveload, at PMG

frequency.
b) Tabulationof inputcontrolvoltageVs ThyristorBridgeoutputvoltage.Check if the
characteristics
are linear.
c) Checkingof bridgecapabilityto meet ceilingvoltagerequirement.
4.2

COMMISSIONING
TESTS:

4 . 2 . 1 C h e c k i n go f v o l t a g eb u i l d - u pi n M a n u a lc h a n n e l1 & 2 .
4.2.2 Follow up control
i) Checkingof automaticfollow-upcircuit. Stand-bychannel shall follow the
channelis in service.Changeover from one channelto otherchannelshallbe
smoothundersteadystateconditions.

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4.2.3 Step test on Auto channel 1 and 2

Afterchangingoverfrom Manualto Auto mode,checkingof Auto channeltransient
responseduringclosedloopoperationby recordingthe generatorvoltageresponse
value.The purposeof thetest is to
to a 10%stepchangein Autochannelreference
tune the PID regulatorfor optimumresponse.(Thistest shall be conductedafter
voltage-build
up in Manualmodeandthe machinenotsynchronized.)
4.2.4 Voltagebuilds up in eachof the Auto channels.

(-

4.2.5 Stabilityof control during Loadingof Generator.

4.2.6 Checkingof stabilityof System/ Regulatorbehaviorwith machineconnected
to grid / machineconnectedto other machinesof the plant'
Reactivedropto be compensatedif foundnecessaryas per systemrequirement.
4.2.7 Commissioningof limiters:
of limitersoperation
Recording
the responseof the followinglimitersand indication
at REMOTEat 60%loador above.
1. Rotorcurrentlimiter(Over-Excitation
Limiter)
Limiter)
2. StatorcurrentInductive
limiter(Over-Excitation
3. YlHz Limiter(Overfluxinglimiter)
4. Loadanglelimiter(Underexcitation
limiter)
limiter)
5. Statorcurrentcapacitive
Limiter(Underexcitation
4.2.8 Load throw off test:
Recording
transientresponseof AUTOchannelduringpartialI full loadthrowoff to

3-'

confirmmaximumpossibleover voltage.
4.2.9 Power System Stabilizer

the damping
steptestandobserving
Checkinn
tn" operation
of PSSby conducting
or
above.
in activepoweroscillations
withandwithoutPSSat60%load

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