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Doc No: EN-DG-304 -145-1021 WBS Element No: CE/0604-SH 1-48-01

Date: 03.10.2010 cE/0604-sH248-01

TEST PROTOCOL

1. Project Name : GOINDWAL SAHIB THERMAL POWER STATION

\e 2. Equipment / Product : Digital Automatic Voltage Regulator(DAVR)

3. Rating . 2X270 MW STG

4. Client GVK POWER LIMITED

5. Consultant TCE Consulting Engineers Ltd.

6. Other Requircments,if
any

\e

Approved By:

t ^
lo, ll,lo
RUKMANI.R

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PROJECT SPECIFIC
TEST PROTOCOL

NATURE OF
CHANGE

3.1Q.2010 First lssue

APPROVED: Rul<mani R

' lo
PREPARED: ISSUED: DATE :

SURESH CE/GHCE 03.10.2010

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be used directly or indirectly in anv way det:'imental to lhe interest of the company.
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TEST PROTOCOL

CONTENTS
1. SCOPE.

2. REFERENCE DOCUMENTS.

3. TESTS AT WORKS.

4. TESTS AT SITE.

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1.0 SCOPE
Following tests are conducted on DVR at BHEL-EDN works and at SITE. Reference
standards: IEEE 421.2 (1990)
i) TESTS AT WORKS.
ii) TESTS AT SITE.
2.0 REFERENCE DOCUMENTS
a) Schematic diagram
b) OGA diagram
c) Test instruction
3.0 TESTS AT WORKS
3.1 COMPONENT LAYOUT AND ASSEMBLY TEST
Checking of components mounted in the cubicle w.r.t. Component list which is a
part of schematic drawing.
3.2 WIRING CHECK
Continuity test is done for the internal cabinet wiring. This is only an internal test
done before energizing the panel.
3.3 H.V. & IR TESTS
(High voltage and Insulation resistance tests)
This test determines the insulation strength of voltage circuit groups with respect to
the panel earth. All electronic modules, devices etc. which have already been
subjected to HV test at PCB testing, prior to system testing, are isolated from this
test. IR to be measured before and after applying HV. This is an internal test,
performed before, energizing the panels for internal functional tests on each
set. HV test report will be given to customer during inspection of functional
tests.

3.4 FUNCTIONAL TESTS

3.4.1 Power Supply check :
Checking of DC power supply output for rated input voltage and for a variation of
+10% and - 15% of rated voltage for each of the power supply modules
.

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3.4.2 Logic sequence check :

Checking of the following logic sequence by simulation wherever necessary as
per schematic.
a) Exciter Field Breaker ON/OFF
b) Excitation ON/OFF
c) Intentional Channel changeover control for each of the channels from every
other channel.
d) Raise / Lower control of each of the channels.
e) Signaling and monitoring circuit / contacts for external connections. For each
of the fault indications, simulate the fault and check the indication on DAVR
panel and the contacts for external connections.
f) Protective changeover
Auto –1 to Auto – 2 on Auto –1 failure
Auto –2 to Auto – 1 on Auto –2 failure
Auto –1 to Manual – 1 on Auto – 1 function failure when Auto-2 has
already failed.
Auto – 2 to Manual – 2 on Auto – 2-function failure when auto-1 has
already failed.

3.4.3 Signal flow check:

a) Actual values setting

i) Setting of actual values by injection of input sensing voltage and current.
b) Checking and setting of gate control circuit for the channels
Following checks are performed with unloaded thyristor bridge
i) Checking of pulses at thyristor devices
ii) Synchronisation of pulses at the thyristor bridge.
iii) Blocking and release of pulses.
c) Auto Channel Settings / checks
i) Range of auto set point reference.
ii) Checking of pulse final stage amplifier.
d) Manual Channel settings / checks
i) Range of Thyristor bridge output voltage in Manual channels.
ii) Checking of pulse final stage amplifier.
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e) Follow-up control
i) Checking of automatic follow-up circuit. Stand-by channel shall follow the
channel in service.
3.4.4 Light load characteristic:

a) Light load test on each thyristor bridge for channels with resistive load at
PMG frequency.
b) Tabulation of input control voltage Vs Thyristor bridge output voltage. Check
if the characteristics are linear.
c) Checking of bridge capability to meet ceiling voltage requirement.

3.4.5 Checking of complete AVR operation at PMG frequency

With rated PMG Voltage at rated PMG frequency as input to AVR and a resistive
load connected to Thyristor bridge outputs, check the stability of control of each of
the in built Manual channels by issuing RAISE /LOWER commands through push
buttons.

A brief changeover to Auto channel can be made after ensuring channel balance.
However Raise / Lower commands, if issued will make excitation reach its extreme
limits.
Note : If there is a main supply variation in testing station, there will be variation in
thyristor bridge output also.

3.4.6 Checking of Auxiliary control functions.

a) Load angle limiter (Under excitation limiter)

i) By phase rotation of IR, IY & IB with respect to UR, UY & UB simulate operation
of Generator in leading reactive power zone.
ii) Adjust Uref and Uact so that Regulator output has not reached maximum limit.
Note down actual value of load angle achieved. Switch OFF all other limiters.
Switch ON Load angle limiter.
iii) Reduce the load angle reference to a value below the actual value achieved.
iv) Observe influence of limiter on regulator to increase excitation.
v) Check indication.
vi) Normalize load angle reference value.

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b) Stator current capacitive Limiter (Under excitation limiter)

i) By phase rotation of IR, IY & IB with respect to UR, UY & UB simulate operation
of Generator in leading reactive power zone.
ii) Switch OFF all limiters & PSS. Switch ON Stator current capacitive limiter.
iii) Adjust Generator current actual value, between 80 to 100%. Adjust Uref and U
actual so that Regulator output has not reached maximum limit.
iv) Reduce reference value of stator current limiter and Observe influence of limiter
on regulator to increase excitation.
v) Check indication.
vi) Restore Stator current capacitive limiter reference value.

c) Rotor current limiter (Over -Excitation Limiter)

i) Switch OFF all limiters & PSS. Switch ON Rotor current limiter.
ii) Adjust Uref and Uact so that Regulator output is well within the current rating of
loading rheostat.
iii) Reduce reference of Rotor current limiter
iv) Observe influence of limiter on regulator to decrease excitation after a delay.
v) Check indication.
vi) Restore reference value of Rotor current limiter.

d) Stator current Inductive limiter (Over -Excitation Limiter)

i) By phase rotation of IR, IY & IB with respect to UR, UY & UB simulate operation
of Generator in lagging reactive power zone.
ii) Switch OFF all limiters & PSS. Switch ON Stator current Inductive limiter.
iii) Adjust Uref and U actual so that Regulator output is well within the current rating
of loading rheostat. Temporarily reduce reference value of Stator current limiter.
iv) Observe influence of limiter on regulator to decrease excitation after a delay.
v) Check indication.
vi) Normalize Stator current reference setting

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e) V/Hz Limiter (Over fluxing limiter)

i) Check actual value of VT signal voltage & Frequency.
ii) Switch OFF all limiters & PSS. Switch ON V/F limiter
iii) Adjust Uref and Uact such that Excitation is not at its minimum value
iv) Reduce the V/F reference value lower than Actual V/F ratio.
v) Observe influence of limiter on regulator to decrease excitation after a delay.
vi) Check indication.
vii) Normalize V/F reference setting.

3.4.7 Checking of Panel Illumination and Heater Circuit

Check the operation of panel illumination circuit by operating door limit switches
using door.

Check the operation of heater circuit.

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4 TESTS AT SITE:
The list of tests that need to be conducted on excitation equipment, at site and the
purpose has been listed in this document. For details, Commissioning Protocol
document of Erection / Commissioning group shall be referred to.
4.1 PRECOMMISSIONING :
4.1.1 Checking of components & wiring :
a) Checking of components mounted in the cubicles with respect to component list,
which is a part of schematic drawing.
b) Checking of inter panel Cable terminations.
4.1.2 Open loop tests:
a) Checking for control of Excitation System from REMOTE commands.
b) Ensuring proper functioning of Status/Alarms/Fault Indications/Meter Indications at
REMOTE.
c) Functioning of protection logics.
4.1.3 Checking and setting of actual values & parameters:
a) Checking and setting of Actual values.
b) Checking and setting of parameters for Gate Control circuit, Regulators and
Limiters as per system requirements.
c) Ensuring smooth control and healthiness of Thyristor Converters.
4.1.4 Light load test:
a) Light load test on Thyristor Bridge for each channel, with resistive load, at PMG
frequency.
b) Tabulation of input control voltage Vs Thyristor Bridge output voltage. Check if the
characteristics are linear.
c) Checking of bridge capability to meet ceiling voltage requirement.
4.2 COMMISSIONING TESTS:
4.2.1 Checking of voltage build-up in Manual channel 1 & 2.
4.2.2 Follow up control
i) Checking of automatic follow-up circuit. Stand-by channel shall follow the
channel is in service. Change over from one channel to other channel shall be
smooth under steady state conditions.

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4.2.3 Step test on Auto channel 1 and 2

After changing over from Manual to Auto mode, checking of Auto channel transient
response during closed loop operation by recording the generator voltage response
to a 10% step change in Auto channel reference value. The purpose of the test is to
tune the PID regulator for optimum response. (This test shall be conducted after
voltage-build up in Manual mode and the machine not synchronized.)
4.2.4 Voltage builds up in each of the Auto channels.
4.2.5 Stability of control during Loading of Generator.
4.2.6 Checking of stability of System / Regulator behavior with machine connected
to grid / machine connected to other machines of the plant.
Reactive drop to be compensated if found necessary as per system requirement.
4.2.7 Commissioning of limiters:
Recording the response of the following limiters and indication of limiters operation
at REMOTE at 60% load or above.
1. Rotor current limiter (Over -Excitation Limiter)
2. Stator current Inductive limiter (Over -Excitation Limiter)
3. V/Hz Limiter (Over fluxing limiter)
4. Load angle limiter (Under excitation limiter)
5. Stator current capacitive Limiter (Under excitation limiter)
4.2.8 Load throw off test:
Recording transient response of AUTO channel during partial / full load throw off to
confirm maximum possible over voltage.
4.2.9 Power System Stabilizer

Checking the operation of PSS by conducting step test and observing the damping
in active power oscillations with and without PSS at 60% load or above.

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