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SCC

GENERATOR
STATOR
AVR CONTROL
CURRENT(A) VOLTAGE(Uc)
1000
2000
4000
6000
8000
10000
12000
14000
16000
19407

OCC
GENERATOR
STATOR
VOLTAGE
AVR CONTROL
(KV)
VOLTAGE(Uc)
0
1
2
4
6
8
10
12
14
16
18
20
21

DATE:
EXCITER FIELD
EXCITER FIELD CURRENT(mv)
VOLTAGE(V)
[60mv=200A)

GENERATOR FIELD
CURRENT(A) Q
Axis coil volt
(0-40V=0-8000A)

DATE:
EXCITER FIELD
EXCITER FIELD CURRENT(mv)
VOLTAGE(V)
[60mv=200A)

GENERATOR FIELD
CURRENT(A) Q
Axis coil volt
(040V=0-8000A)

Remarks

Remarks

500 MW GENERATOR TESTING PROCEDURE FOR FIRST SYNCHRONIZATION

OBJECTIVE:
TO CARRY OUT GENERATOR SHORT CIRCUIT TEST,CURRENT OPERATED RELAYS DYANAMIC
TESTING,OPEN CIRCUIT TEST,VOLTAGE OPERATED RELAYS DYNAMIC TESTING,SYNCHRONIZATION
CIRCUIT CHECK,PROTECTION TRIP OF GENRATOR CIRCUIT BREAKER AND SYNCHRONIZATION
PREPARATIONS:
1 The following measurement circuits are to made through for monitoring and taking readings
A)
Generator voltage- RY,YB,BR
B)
Generator current- R,Y,B
C)
Excitation Voltage
D)
Excitation Current
E)
Generator field current(Q-AXIS coil voltage)
F)
Active power
G)
Reactive Power
H)
Power factor
I)
Energy meter
2 Synchronising cirucits and protection circuits are also to be kept ready alongwith recommended
settings set in the protection relays
3 Testing/measuring equipments to measure PMG voltage(3 Ph AC),Main Exciter(DC) and PMG's Phase
sequence and frequency in AVR are to be kept ready
4 Winding resistance for PMG&ME are to be measured to check the healthiness of PMG&ME

PREPARED BY:RMS

SHEET 3 OF 12

500 MW GENERATOR TESTING PROCEDURE FOR FIRST SYNCHRONIZATION

5 No trip should persist from GRP&turbine panel and in DAVR


6 Gen PTs are to be ensured racked in and bust duct is pressurised with air
7 21 KV R,Y,B terminals of Generator at 8.5 mtrs must be shorted with the shorting bar provided.
8 Mechanical system readiness
a)
Stator water cooling system is to be kept on line.Online conductivity monitoring made ready
b)
Rotor cooling is to be confirmed by parameters of H2 temp
c)
Generator slot,stator core,tooth temps are to be monitored in control room
d)
Rotor earthfault circuit to be tested and kept online
e)
Fire protection system of GT must be kept online
9 Following modifications are to be carried out for testing and to be normalized before synchronization
a)
Excitaion system on manual internal mode
b)
Auto channels to be kept in blocked condition
c)
Field breaker closing from ATRS to be inhibited
d)
Auto sync circuit output to be isolated from GCB closing circuit
CJJ10 X09 -18
X09 -19
e)
Generator Trip to turbine trip to be isolated
GRP3 TB1-63,64
TB1-65,66
TB1-67,68
f)
LBB links are to be kept out to avoid 400 kV HVCB TRIP
GRP-3 TB2-9,10(MAIN CB)
TB2-11,12(TIE CB)
g)
186A1/286A1,186C/286C trip from GR1,2 to be kept out to avoid 400 kV HVCB TRIP
GR1 L1,L2,L5,L6,K1,K2,K5,K6
GR2 L1,L2,L5,L6,K1,K2,K5,K6
g)
h)

Interlock between switchyard and Field circuit breaker are to be isolated if required
GT Trf,Overall differential&Gen diff protection to be kept in service

10 AT standstill condition,test rotor earthfault and 100% stator earthfault circuit with 20 Hz Gen
a) earth the main exciter star point slip ring terminal at main exciter
b) earth the NGT 1.1 terminal at NGT

11 a) AT 3000 RPM,measure PMG VOLTAGE,Frequency and Phase sequence.


Terminals
Voltage
RY
YB
BR
b)
Measure the spill currents in relay panel,AVR,load Transducer and T&AVT panel

ROTOR EARTH FAULT SIMULATION


100% STATOR EARTH FAULT SIMULATION

Frequency

Phase Sequence

SHORT CIRCUIT TEST


a)
AT 3000 RPM,If spill currents are successfully measured in all terminals as per spill current
measurement sheet,Close FB and raise Excitation for SCC test
b)
Raise gen current up to 1000 amps and check the Gen differentail protection
protection by shorting CT secondary.
e)
Raise current for Check the field fialure,Dead machine relays and impedance relays.
f)
Bypass/block the Dead machine protection,field failure and impedance protection.
Sl No

Protection

Gen diffl(87G-GR1)

Methodology
SHORT ANY PHASE TO NEUTRAL
GRP-1 : N.SIDE - TB1-1,2,3,4
PH.SIDE - TB1 - 6,7,8,9

Relays
operation

operated I Value

Remarks

186A2/286A2

Iset= 0.1 In
(In=5 A)

186A2/286A2

Iset= 0.1 In
(In=5 A)

1
Gen diffl(87G-GR2)

SHORT ANY PHASE TO NEUTRAL


GRP-3 : N.SIDE - TB1-1,2,3,4
PH.SIDE - TB1 - 6,7,8,9

Dead machine protection (GR1)

Raise the current to the set value

186A1/286A1

Iset= 0.09 In
(In=5 A)
sec

Dead machine protection (GR2)

Raise the current to the set value

186A1/286A1

Iset= 0.09 In
(In=5 A)
t=1 sec

PREPARED BY:RMS

SHEET 4 OF 12

t=1

500 MW GENERATOR TESTING PROCEDURE FOR FIRST SYNCHRONIZATION

I2th.set= 0.07 In
186C/286C
Negative Phase sequence(46G1)

(In=5 A)

I2th.k=6.3

Interchange R,Y Currents and raise the


current to the set value
GRP-1 : N.SIDE - TB1-1,2,3,4

I2th.set= 0.07 In
186A1/286A1

(In=5 A)

I2th.k=6.3

t=1

sec
3

I2th.set= 0.07 In
186C/286C

Negative Phase sequence(46G2)

(In=5 A)

I2th.k=6.3

Interchange R,Y Currents and raise the


current to the set value
GRP-3 : N.SIDE - TB1-1,2,3,4

I2th.set= 0.07 In
186A1/286A1

(In=5 A)

I2th.k=6.3

t=1

sec

Overcurrent (51G1)

reduce the set value to 100% and raise


the current to the set value.

ALARM

Iset= 1.1 In
(In=5 A)
sec

t=2

ALARM

Iset= 1.1 In
(In=5 A)
sec

t=2

4
Overcurrent (51G2)

reduce the set value to 100% and raise


the current to the set value.

50 LBB (GR1)

Remove field CB trip.operate


186A2/186D.Raise the current to the set
value.

186A1/286A1

Iset= 0.05 In
(In=5 A)
t=0.3 sec

50 LBB (GR2)

Remove field CB trip.operate


186A2/186D.Raise the current to the set
value.

186A1/286A1

Iset= 0.05 In
(In=5 A)
t=0.3 sec

g)

Raise the current in steps and Take readings as given in SCC table.

h)

Note the spill current in all differential protection and shaft voltage and Temperatures of GEN and GT

PREPARED BY:RMS

SHEET 5 OF 12

500 MW GENERATOR TESTING PROCEDURE FOR FIRST SYNCHRONIZATION


OPEN CIRCUIT TEST
a)

After SCC& 21 kV shorting normalization

b)

Measure the spill voltage in all PT circuits.

c)

Create 1 phase earth fult at SPVT cubicle. Check the 95% Stator earth fualt protection and
Interturn fault protection.

d)

e)

Remove the the 1 phase earthing at SPVT cubicle


Normalise all the protection and settings. Close feid breaker and slow raise the Gen voltage in step
as per table up to 100 % voltage.
Find SCR(Gen field current at Rated voltage/Generator field current at Rated current)

f)

Check PT voltages at all circuits and measure Gen Shaft voltage.

g)

Note down the Temperatures of Generator and GT for winding,core and air
Protections during OCC

Sl No

Protection

Methodology

Relays
operation

operated V. Value

Remarks

95% Stator E/F - GR1

Earthing at SPVT cubicle and slowly raise the


voltage to the set value.
GRP- 186A2/286A2
3 : TB1-29,31

Vn set=11 V
t=0.2 sec

95% Stator E/F - GR2

Earthing at SPVT cubicle and slowly raise the


voltage to the set value.
GRP-3 : TB1-29,31

186A2/286A2

Vn set=11 V
t=0.2 sec

ALARM

V>1 = 115.5 V
2 sec

Over Voltage - 59G1

Reduce the set value and raise the voltage to


the set value
GRP-1 : TB1-24,25,26,27

186A2/286A2

V>2 =154 V
t= 0 sec

2
Over Voltage - 59G2

Under frequency - 81G1UF

Reduce the set value and raise the voltage to


the set value
GRP-1 : TB1-41,42,43,44

186A2/286A2

V>1 = 121 V
6 sec

t=

186A2/286A2

V>2 = 154 V
0 sec

t=

ALARM

F<1 = 48.5 HZ t=2.5


sec

186C/286C

F<2 = 47.5 HZ t=2.0


sec

ALARM

F<1 = 48.5 HZ t=2.5


sec

186C/286C

F<2 = 47.5 HZ t=2.0


sec

Reduce the turbine speed to the set value

7
Under frequency - 81G2UF

t=

Reduce the turbine speed to the set value

Over frequency - 81G1OF

Reduce the set value and raise the turbine


speed to the set value

ALARM

F>1 = 51.5 HZ t=2.0


sec

Over frequency - 81G2OF

Reduce the set value and raise the turbine


speed to the set value

ALARM

F>1 = 51.5 HZ t=2.0


sec

ALARM

V/F =1.05 vn/fn


t= 20 sec

Over fluxing - 99G1

Reduce the set value and raise the


voltage/reduce the turbine speed

186A2/286A2

7
ALARM
Over fluxing - 99G2

low forward power(37G1)

Reduce the set value and raise the


voltage/reduce the turbine speed

build up 21 KV and close GCB

1)V/F =1.06 vn/fn


TMS=0.4 sec
2)V/F=1.4vn/fn
t=1 sec
V/F =1.05 vn/fn
t= 20 sec

186A2/286A2

1)V/F =1.06 vn/fn


TMS=0.4 sec
2)V/F=1.4vn/fn
t=1 sec

186A2/286A2

P<1=5W
T= 10 SEC
(WITH GCB
CLOSE)

186A2/286A2

P<1=5W
T= 10 SEC
(WITH GCB
CLOSE)

8
low forward power(37G2)

build up 21 KV and close GCB

AVR CHECKING
PREPARED BY:RMS

SHEET 6 OF 12

500 MW GENERATOR TESTING PROCEDURE FOR FIRST SYNCHRONIZATION

De excite the machine and normalise the Manual chanel internal mode.
Reduce the over voltage protection to 105 % and Excite mahine through manual channel.
Check the change circuit of auto channel after cheking the matching circuit.
Check the Auto channel flashing after PID tuning
check the manual channel and auto chennel from ECP.
Check the V/Hz limiter.
Normalise all protections and the settings.
Synchronization circuit check
Normalise the turbine interlocks.
CFA01
TBK-23,24(R&N)
TBK-27,28(R&N)

21 KV VT-2 PT SUPPLY:
21 KV VT-4 PT SUPPLY:
SKE 11 CHECK SYNC RELAY SETTINGS

Phase angle difference


Percentage Voltage difference
Percentage Slip

10
4%
0.22

Time Setting

0.5

ECP
CHECK SYNC SWITCH SELECTION FOR GCB MAN SYNC
CFA01
ECP
TBK-5 (INC)
1TBC-40
TBK-6 (RUN)
1TBC-41
TBK-7 (COMM)
1TBC-42
AT 12'0 CLOCK POSITION,
VOLTAGE BETWEEN 1TBC-40&1TBC-41 OF ECP SHALL BE ZERO AND CHECK SYNC PERM AVAILABLE
PHASE SEQUENCE OF GENERATOR PT SIGNALS:FORWARD
SYNCHRONIZATION
1 Excite the machine and develop 21KV voltage at Generator terminals.
2 Adjust the voltage & speed from ECP and get synchronising 12'O clock position using Voltage Raise\Lower PBs & Speed Raise\ Lower PBs.
3 Close GCB at 12'O clock position.
MASTER TRIP RELAY OPERATIONS ( 186 - GROUP 1 AND 286 - GROUP 2)
1 A1 - All trips ( Turbine, 21KV GCB, Field Breaker Trips, Main & Middle Breaker trips)
2 A2 - Only Turbine, 21KV GCB, Field Breaker Trips
3 C - Only Switch Yard Breakers Trips( Main & Middle Breakers)
4 D - Only 21KV GCB & Field Breaker Trips

PREPARED BY:RMS

SHEET 7 OF 12

SPILL CURRENT MEASUREMENT


SL NO CT NO

CT-2 (0.2S)

RATIO

PANEL TERMINALS READINGS(mA) PURPOSE


CJJ10
X05 -1
3
LOAD
5
MEASUREMENT
22000/5 A
16
GRP-1

CT-3(PS)

22000/5 A

GRP-3
3

CT-4(PS)

22000/5 A

CT-5(PS)

22000/5 A

CT-6(PS)

22000/5 A

GRP-1

GRP-3

CJJ10

CT-7(0.2S)

GRP-2

T&AVT

CT-8(0.2S)

TB1-1
2
3
4

GROUP-2
PROTECTION

TB1-6
7
8
9
TB1-6
7
8
9
X05-17
19
21
26

GROUP-1
PROTECTION

GROUP-2 PROTECTION

LOAD
MEASUREMENT

TY-50
54
58
60

DVR CH-1

TB1-40
41
42
43

ENERGY METER

TBE-07
10
13
5

METERING

X05-27
29
31
36

LOAD
MEASUREMENT

TY-62
66
70
72

DVR-CH2

22000/5 A
CJJ10

DVR

M/S.APGENCO

GROUP-1
PROTECTION

22000/5 A
DVR

TB1- 1
2
3
4

REMARKS

M/S. BHEL

SL NO CT NO

CT-2 (0.2S)

CT-3(PS)

CT-4(PS)

CT-5(PS)

CURRENTS @ 1000 A,19407 AMPS


RATIO
PANEL TERMINALS @ 1000 A
CJJ10

X05 -1
3
5
16

GRP-1

TB1- 1
2
3
4

GRP-3

TB1-1
2
3
4

GRP-1

TB1-6
7
8
9
TB1-6
7
8
9

22000/5 A

22000/5 A

22000/5 A

22000/5 A

GRP-3
5

CT-6(PS)

CT-7(0.2S)

CT-8(0.2S)

M/S.APGENCO

22000/5 A

CJJ10

X05-17
19
21
26

DVR

TY-50
54
58
60

GRP-2

TB1-40
41
42
43

T&AVT

TBE-07
10
13
5

CJJ10

X05-27
29
31
36

DVR

TY-62
66
70
72

@ 5000 A

@ 10000 A

@15000 A

@19407 A

22000/5 A

22000/5 A

M/S. BHEL

PURPOSE

REMARKS

LOAD
MEASUREMENT

GROUP-1
PROTECTION

GROUP-2
PROTECTION

GROUP-1
PROTECTION

GROUP-2 PROTECTION

LOAD
MEASUREMENT

DVR CH-1

ENERGY METER

METERING

LOAD
MEASUREMENT

DVR-CH2

M/S.APGENCO

M/S. BHEL

SL NO VT NO

RATIO

PANEL

GRP -1

VT-1(0.2/3P)

21000/110V

CJJ - 10

AVR

GRP -1

VT-2(0.2/3P)

21000/110V

AVR

T & AVT

CJJ - 10

GRP - 1

VT-3(0.2)

21000/110V CJJ - 10

10

T & AVT

11

GRP - 1
VT-4(0.2/3P)

12

21000/110V
T & AVT

TERMINALS

TB1-24
25
26
27
X03 - 1
4
7
10
TY - 46
47
48
TB1 - 41
42
43
44
TY - 41
42
43
TBK - 23
24
X03 - 11
13
15
TB2 - 1
2
3
4
X03 - 18
20
22
TBE - 1
2
3
4
TB2 - 22
23
24
25
TBK - 27
28

SPILL

@ 2KV

@ 5KV

@ 10KV

@ 12KV

@ 15KV

@ 21KV

PURPOSE

GR-1 RELAY

FREQUENCY & LOAD


TRANSDUCER,LOAD
SHEDDING

AUTO CH - 1

GR - 2 RELAY

AUTO CH - 2

SYNCHRONISING
LOAD
TRANSDUCER

METERING

LOAD
TRANSDUCER

METERING

SYNCHRONISING,
59 NGT

SYNCHRONISING

REMARKS