DG Set

NTPC TESTING SCHEDULE KUDGI
O&M COMMISSIONING DEPARTMENT
STATION: NTPC-KUDGI,ST-I 3X800MW UNIT: FGD DG Set

SYSTEM: DG SET
LOCATION:
ITEM LIST OF CONTENTS

1.PLANT DETAILS
2.TESTING OBJECTIVES
3.TESTING PROPOSALS
4.SERVICES REQUIRED
5.SAFETY
6.EMERGENCY PROCEDURES
7.STATE OF PLANT
8.TEST METHOD
9.PROGRAMME
10.RESULTS
11.REINSTATEMENT & PRESERVATION
12.STAFFING RESPONSIBILITIES & COMMUNICATIONS

SYSTEM: DG SET
LOCATION:
ITEM 1.0 PLANT DETAILS

1.1 2000KVA Diesel generator set is supplied to NTPC Kudgi as an
emergency measure for extending power supply to drives connected in
unit emergency board in case unit tripping/ black out.
Supplier: M/s ISGEC
Sub Vendor: JAKSON
Engine Make: CUMMINS.
Alternator Make: STAMFORD
Brief details of engine:
Model: QSK60G4.
Speed: 1500 rpm.
Engine weight (Dry):7185kg
Radiator weight (Dry):2500kg
Engine oil capacity:280L
Radiator Coolant Capacity:242L
Coolant: Ethylene glycol (50:50 premix).
Diesel Storage Tank Capacity:990 Liters.
Brief details of Alternator:
Capacity: 2000KVA (1600KW)
Amperes:2782.4A
Frequency: 50Hz
Voltage:415V
Excitation Voltage:63
Excitation Current:3.6
Insulation Class: H
Thermal Classification: 180O C


SYSTEM: DG SET
LOCATION:
Enclosure: IP23.
Stator Winding: 312
Stator Connection: Star.


SYSTEM: DG SET
LOCATION:
ITEM 2.0 TESTING OBJECTIVE

2.0 To ensure that the erected equipment is suited for the duty it is
required to perform, meets the design and contract specifications and
is to the appropriate Indian, other relevant engineering standards or
codes of practice.

SYSTEM: DG SET
LOCATION:
ITEM 3.0 TESTING PROPOSALS

3.1 The DG set consists of Diesel engine, Alternator, Control & Relay panels
and other associated equipments. It is proposed that these will be checked
individually.
3.2
Protections & Interlocks will be checked as per the drawing.
3.3 The 24V DC supply will be made ready, by connecting the provided
batteries in series parallel combination.
3.4 DG set will be loaded as far as possible by running the equipments on the
Unit Emergency Switchgear. The performance of machine will be checked
and any sign of stress & abnormality will be noted.
ITEM 4.0 SERVICES REQUIRED


SYSTEM: DG SET
LOCATION:
4.1 220V DC Supply.
4.2 3phase 415V AC Supply.
4.3 Multi meter, clamp meter and 1KV Megger.
4.4 Relay Testing Kit.
4.5 3 Phase Variac.


SYSTEM: DG SET
LOCATION:
ITEM 5.0 SAFETY OF PLANT

5.1 SAFETY OF THE PLANT:
The Test method must be strictly adhered to at all times except in the
following circumstances:
1. In an Emergency Situation.
2. By Agreement with the working party.
3. On instruction from the Testing team leader.
SAFETY OF PERSONNEL:
5.2 All the members of Testing team and persons associated with this Testing
Schedule should be familiar with the testing procedures and the
equipments involved in testing.
5.3 There should be safe access to, and escape routes from confined areas.
The area under test should be clearly defined.
5.4 Access to the area under test should be restricted. Proper caution boards
should be displayed at the test area.
5.5 Permanent and adequate lighting facilities should be available at all times.
All handrails, stairs, guards and trench/ manhole covers should be properly
fit/ in place.
5.6 The test area should be clear of obstructions.
5.7 Safety Clearance Certificates and Safety Clearance Notifications should be
in force for the equipments to be energized.
5.8 Operating staff should be kept informed of the programmes of testing


SYSTEM: DG SET
LOCATION:
ITEM 6.0 EMERGENCY PROCEDURE

6.1 It will be the responsibility of the testing team leader to instruct all
members of the testing team what actions are to be taken in the event of
fire, accident or other major incident.
6.2 Telephone numbers of First Aid/ Ambulance Fire Station and Hospitals
should be permanently displayed near each telephone.
6.3 First Aid Charts for the treatment of electrical should be displayed at the
teat area.
6.4 In the event of any sign of abnormality, the source of supply for the
particular area/ equipment should be immediately isolated.


SYSTEM: DG SET
LOCATION:
ITEM 7.0 STATE OF PLANT

7.1 The following items and associated equipments should be erected.
Complete, accessible for testing and available for use.
A) The DG set complete with its fuel oil, lub oil and cooling system.
B) The DG control & Relay panels and associated annunciation system.

C) All power & control cables.
7.2 Erection Completion Certificates and Manufacturers Test Certificates for
the equipments to be energized should be available and inspected before the
tests are carried out.
7.3 SRCC, operation & commissioning manual for the DG set and associated
auxiliaries of DG set should be available.
7.4 The 415V Unit Emergency Switchgear with its circuit breaker and
associated equipments should have been tested OK and available for use.
7.5 Control supplies for DG control and relay panels and the annunciation panel
should be available.
7.6 The DG set starter battery (24V) should be in fully charged condition.
Remote closing and controlling of DG Set from ECD panel mounted at
7.7
control desk is in checked condition along with logic.
7.8
Completeness of DDC logic in OWS is to be to checked and made ready.
ITEM 8.0 TEST METHOD


SYSTEM: DG SET
LOCATION:
8.1.0 GENERAL CHECKS:
8.1.1 Complete the SCL of DG set.

Complete the SCL relays mounted on the DG Control Panel.
8.1.2
Complete the SCL of alternator CTs.
Check the tightness of all electrical connections of the generator including
those excitation and voltage regulating system.
8.1.3 Check for proper connection of alternator, exciter and voltage regulating
unit main & auxiliary terminal.
Check that the generator is correctly coupled and aligned with the Diesel
8.1.4
Engine. Check the tightness of coupling bolts. Also check that
8.1.5 the coupling guards are proper and in position.
Check for proper connection of the starter battery, governor motor, fuel oil
8.1.6
solenoid, engine starter and other electrical devices of the diesel engine.
8.2
Electrical Checks:
8.2.1 Ensure that safety clearance notification have been issued and are in force
for the equipment to be energized.
8.2.2 Ensure the operation of DG Incomer breaker (Test position) at Emergency
Switchboard.
8.2.3 Ensure that the DG switchgear is isolated from Unit Emergency
Switchboard and the circuit breaker of DG set off and isolated.
8.2.4 Measure the final IR of the alternator stator winding(including cables)
IR(MΩ) :
8.2.5 Measure the final IR of the Exciter stator windings. Disconnect static
electronic circuits.
IR(MΩ) :
8.2.6
Normalize all the disconnections made during the IR tests.
8.2.7 Ensure that all the access covers and terminal covers are put in position and
that their fastening bolts are tightened.
8.2.8 Ensure that the alternator VT fuses and the control circuit fuses of DG
control and relay panels including those for the annunciation system are put
on. Also ensure that the control circuit fuses of the DG Incomer are put on.
8.2.9 With the fuel supply out if(to prevent starting of the engine) carryout control
circuit functional checks from local and remote ends, to prove the operation
of starting and stopping/ tripping interlocks of the DG set and its circuit

SYSTEM: DG SET
LOCATION:
breaker(As per relevant diagram). Check both mechanical and electrical

protection interlocks. Prove the operation of all control relays and verify the
correct time delay of all timer relays.
Check that the generator space heaters are switched off when starting
8.2.10
commands are given to the DG set.
Check that proper annunciation and indications appear both at local and
8.2.11
remote ends, by simulation of all signals at their source.
ENERGISING / STARTING PROCEDURE:
8.3
Ensure Cooling system piping circuit, Oil system piping circuit and Fuel
8.3.1
system piping circuit are complete in all aspects, including drains, vents and
instrumentation connections.
Fill the Engine’s Radiator and After Cooler Radiator with Ethylene Glycol
8.3.2
coolant “Fleet Guard Compleat EG 50:50 Premixed Coolant CC2774 of
Cummins” upto the top of level indicator.
8.3.3 Slowly fill the coolant to ensure complete venting of the system.
Slowly fill the Diesel engine sump with specified Lube oil up to indicated
8.3.4
level in Dip stick.
Once oil filling is complete, carry out bump check of Lube oil system pre
8.3.5
lubricating / priming oil pump. After verifying DOR of the pump, ensure
8.3.6
that the pump develops rated pressure of 10 PSI in the lube oil pressure
indicator mounted on GSC console. Measure and record the current of pre
lubricating oil pump.
8.3.7 Fill the fuel oil tank and cross check local level indicator level with low and
high level switches indication at DCS.
8.3.8 Slowly open the fuel oil tank’s supply isolation valve and carry out flushing
of the piping by keeping open the flange at the engine end. After flushing
restore the flange and carry out leak checks and venting till fuel oil supply
solenoid valve.
8.3.9 The following alarms and protections of the Engine must be made available
on the Lamp indication of Generator Drive Control System (GCS) console
before the start of engine;
Engine warning alarms
a) Pre High Engine temperature (HET)
b) Pre Low Oil Pressure (LOP)
c) Fail to Start
d) Common warning alarm when any of the above three
alarms are active

SYSTEM: DG SET
LOCATION:
Engine shutdown alarms

a) High Engine Temperature (HET)
b) Low Oil Pressure (LOP)
c) Overspeed (OS)
d) Common shut down alarm when any of the three alarms
are active and additionally when Local or Remote
Emergency Stop input is activated
8.3.10 The pre configured / programmed limits of Engine alarms and protections in
Electronic Control Module (ECM) must be checked, verified and simulated
via “InPOWER” software interface of Cummins via Laptop. The soft
alarms & protections which require verifications are
a) Low Oil Pressure
b) High Oil Temperature
c) Low Coolant Level
d) Low Coolant Pressure
e) Low Coolant Temperature
f) High Coolant Temperature
g) High Fuel Temperature
h) High Intake Manifold temperature
i) Over speed shutdown
8.3.11 Charger connection to Battery Bank, Flywheel Dynamo connection to
Battery bank and Battery bank connection to starter motor must be made
through.
8.3.12 Pre commissioning trial of Engine must be carried out in Local mode
through GCS panel using the following sequence
a) Put the diagnostic Mode switch in ON Position
b) Rated / Idle switch must be in IDLE position
c) RUN / OFF switch must be in RUN position
d) The AVR excitation Terminal must be in isolated.
e) Release the Emergency Stop push button in GCS console
f) Keep the engine and after cooler radiator’s coolant topping cap in
open condition
f) Crank the engine through Engine START key switch
g) After Engine start, note down all engine parameters
h) Engine will now run at 750 RPM in idle mode. Run the engine in
Idle mode for 15 mins and thoroughly check the engine for leaks
and other abnormalities. Record the engine parameters.
i) Put the RUN/OFF switch in OFF condition and stop the Engine.
j) Close the engine and after cooler radiator’s coolant topping cap
after ensuring complete venting.
k) Now put the Rated / Idle switch in RATED position and RUN /
OFF switch must be in RUN position
l) Crank the engine through Engine START key switch
m) DG set will now run at 1500 RPM in RATED mode. Run the
engine in Rated mode or 15 mins and thoroughly check the engine
for leaks and other abnormalities. Record the engine parameters.
n) Stop the Engine by Emergency Push button. Verify the stopping
of Engine and Along with the flagging of COMMON SHUT
DOWN alarm.

SYSTEM: DG SET
LOCATION:
8.3.13 After completion of Alternator Protection and Interlocks checks, and

restoration of Electrical connections, the Engine can be cleared for load trial
checks after restoring AVR excitation terminals connections with Generator
Exciter Circuit (Care to be taken to ensure correct polarity while connecting
AVR terminals to alternator field. “Three Start Failure lock out protection”
of DG Set must also be ensured at the time of DG SET P&I checks.
8.3.14 Pre Commissioning Trial run of DG set is to be carried out in Local mode
through GCS panel using the following sequence
a) REMOTE / LOCAL switch should be in LOCAL position
b) All control fuses and MCBs must be in operation and all
protection relay in healthy condition.
c) The AVR excitation terminal must be connected with Generator
Excitation circuit
d) Put the diagnostic Mode switch in ON Position
e) Rated / Idle switch must be in Rated position in GCS panel
f) RUN / OFF switch must be in RUN position
f) Crank the DG set through Engine START key switch
g) After DG start – (DG will run at Rated Speed of 1500 RPM) ,
note down and check all engine parameters ( Lube oil pressure,
Coolant temperature, Speed) and alternator parameters (Voltage,
Frequency, Power & Power Factor) as per OEM guidelines.
h) For Speed Increment / Decrement operation, operate the SPEED
RAISE / LOW switch and check the RPM / FREQ meters as per
OEM guidelines.
j) For Voltage Increment / Decrement operation, operate the
VOLTAGE RAISE / LOW switch and check the VOLT meter for
Voltage regulation as per OEM guidelines.
l) Stop the DG SET by pressing Emergency Push button.
8.3.15 Pre Commissioning Trial run of DG set is to be carried out in Remote mode
through DCS using the following sequence
a) REMOTE / LOCAL switch should be in REMOTE position
b) All control fuses and MCBs must be in operation and all
protection relay in healthy condition.
c) The AVR excitation terminal must be connected with Generator
Excitation circuit
d) Put the diagnostic Mode switch in ON Position
e) Rated / Idle switch must be in Rated position in GCS panel
f) RUN / OFF switch must be in RUN position
f) Remote start command for DG Set must be given from DCS
Console in CCR. (Ensure R1 relay gets energised in GCS panel
and DG Set would take start)
g) After DG start – (DG will run at Rated Speed of 1500 RPM) ,
note down and check all engine parameters ( Lube oil pressure,
Coolant temperature, Speed) and alternator parameters (Voltage,
Frequency, Power & Power Factor) as per OEM guidelines.
h) For Speed Increment, operate the SPEED RAISE window button
in DCS console and check the RPM / FREQ meters and its feed
back in DCS window as per OEM guidelines. (Ensure R5 relay gets
energised in GCS panel and DG Set speed should increase)

SYSTEM: DG SET
LOCATION:
i) For Speed Decrement, operate the SPEED LOW window button

in DCS console and check the RPM / FREQ meters and its feed
back in DCS window as per OEM guidelines. (Ensure R6 relay gets
energised in GCS panel and DG Set speed should decrease)
j) For Voltage Increment operation, operate the VOLTAGE RAISE
window button in DCS console and check the VOLT meter for
Voltage regulation as per OEM guidelines. (Ensure R3 relay gets
energised in GCS panel and DG Set Voltage should increase)
k) For Voltage Decrement operation, operate the VOLTAGE LOW
window button in DCS console and check the VOLT meter for
Voltage regulation as per OEM guidelines. (Ensure R4 relay gets
energised in GCS panel and DG Set Voltage should decrease)
l) Stop the DG SET by giving STOP Command from DCS Console
in CCR. (Ensure R2 relay gets energised in GCS panel and DG Set
would shut down)
8.3.16 Carry out AUTO START operation of DG set by simulating UES Bus under
voltage signal. (Ensure R7 relay gets energized in GCS panel and DG set
should take start in AUTO).
8.3.17
After completion of Pre Commissioning Trial of DG set, Load trial of DG
set for 8 hrs is to be carried out at site without exceeding DG Set rating.
During the load test half hourly records of the following parameters must be
logged;
a) Ambient Temperature
b) Exhaust Temperature
c) Coolant temperature
d) Lubricating Oil pressure
e) Speed
f) Voltage, Wattage, Current output and power factor
g) Oil tank level
h) Fuel tank level its top up log and consumption rate
i)Body Temperature measurement of DG Set as per OEM
guidelines
j) Vibration measurements of DG Set as per OEM
guidelines
k) Noise level inside and Outside DG Set as per OEM
guidelines
8.3.18
Finally the DG set’s Battery bank’s capability of performing Six (6) normal
starts without recharging must be proved as a part of site commissioning
tests.
ITEM 9.0 PROGRAM


SYSTEM: DG SET
LOCATION:
9.1 The general order in which the tests are to be carried out is indicated
in the method, but a logical any systematic approach should always
be adopted.
9.2 If necessary the sequence of tests may be varied with the approval of
testing team leader.
1. Measured voltages:
Between Control Panel DG Incomer
R-Y
Y-B
B-R
2. Phasing Out between DG Incomer PT & Unit Emergency Bus PT.

I/C
R Y B R R Y
PT
Bus PT R Y B Y B B
Volt(V)
3. Voltage Raise/Lower operation: (OK/ Not OK)

4. Speed Raise / Lower operation: (OK / Not OK)
5.Lists of tests/protections carried out:
A) Protection trip of Under voltage relay
B) Protection trip of over voltage and over load
C) Interlocks of auto start up of DG
D) Differential Protection
E) Reverse Power Protection
F) Neutral Displacement Protection
G) Over Frequency Protection.
ITEM 10.0 RESULTS


SYSTEM: DG SET
LOCATION:
10.1 The results of the checks and tests which form a part of this testing
schedule will be recorded on the standard check lists and testing
procedures specified in the method or recorded directly in this
schedule as appropriate.
ITEM 11.0 REINSTATEMENT & PRESERVATION


SYSTEM: DG SET
LOCATION:
11.1 Whether the equipment detailed in the testing schedule is to remain
energized or be isolated shall be determined by the station commissioning
panel before the equipment is energized.
11.2 If the equipment is to be isolated, due regard should be taken for the
necessity to maintain the cubicle space heaters (if any) in service and to
maintain satisfactory environmental conditions for indoor type of
installations.
ITEM 12.0 STAFFING, RESPONSIBILITIES AND COMMUNICATIONS


SYSTEM: DG SET
LOCATION:
12.1 The Testing Team which has been approved by the station commissioning
panel shall consist of the following persons:
1) Testing Team Leader :

2) NTPC Commissioning Staff:
Name Department
a)
b)
c)
d)
3) Contractor / Manufacturer’s representatives:
Name Department
a)
b)
c)
d)

SYSTEM: DG SET
LOCATION:
STANDARD CHECKLIST:
1. CONTROL RELAY PANEL:
 Check for control relay panel erection and mounting alignment

 Check for Control relay panel power and control Cable laying.
 Check for the body earthing of control relay panel.
 Check for the wiring connection of control relay panel and tightness.
 Check for the labelling
 Check for priming pump operation in both mode (Auto/Manual)
 Fixing of DPS (Digital power supply) for speed and voltage raise/low
2. MASTER RELAY TRIPPING:
 Very very low fuel level.
 Winding Temperature.
 Bearing Temperature.
 Over speed from power command (Aux cord).
 High Engine Temperature from power command (Aux cord).
 Low lube oil pressure from power command (Aux cord).
 Over Frequency trip.
 Under frequency trip.
 Under voltage trip.
 Engine fault trip (shut down) From power command.
 Earth fault trip.
 Differential protection trip.
 Emergency stop trip.
3. WARNING WINDOW:
 Fuel level very low.
 Fuel level low.
 Winding Temperature.
 Bearing Temperature.
 Earth fault trip (Configured as alarm).
 Differential protection trip.
 Under/over frequency trip.
 Under voltage trip.
 Emergency stop trip.
 Low lube oil pressure from power command (Aux cord).
 Over speed from power command (Aux cord).
 High Coolant Temperature from power command (Aux cord).
 DG Fail to start.
 Priming pump trip.
 Not in auto.
4. AUXILIARY PANEL-1:
 Check for panel erection and mounting alignment.
 Check for power and control Cable laying.
 Check for the body earthing.
 Check for the wiring connection of panel and tightness.
 Check for the labeling.
 Check for interlocking of Control relay panel and Auxillary panel-1.
 Check for IR value, Inductance and winding resistance of Supply air fan 1 to 4

SYSTEM: DG SET
LOCATION:
5. AUXILIARY PANEL-2:
6. BATTERY CHARGER PANEL:
 Check DC output voltage of battery charger.
 Check for interlocking of engine and battery charger
7. ECP PANEL:
 Check for control cable laying.
 Fixing of Aux-card for speed and voltage raise/low and fault extension (LLOP,HWT,O/S,FS)
 Activation of Aux-card and customer fault input (using In power software through cummins
representative)
 Extension of additional connector installation as per customer advice.
 Check for Engine wiring connections and tightness
8. ENGINE AND ALTERNATOR:
 Check the tighness of the self-Starter and charging alternator also check the output of charging
alternator
 Check the lub oil level.
 Check the vaccum indicators.
 Checked air filter and oil filter.
 Checking of 4 nos of Batteries and connecting to self starter and check the voltage and
specific gravity.
 Check erection of Neutral extension box and the differential CT's.
 Testing of winding resistance, polarity, knee voltage and ratio test of differential CT's
conducted.
 Testing of winding resistance and IR value of alternator conducted.
 Testing for IR value, Inductance and winding resistance of Priming pump.
 Check fabrication and erection of fuel tank and fuel piping.
 Check tightness of busbar both side ( Neutral and load side).
 Check the R.T.D and B.T.D connections.
 Check for cable laying.
 Check for the body earthing of alternator.
 Check for the erection of silencer, exhaust pipe and supports.

DG Set

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NTPC TESTING SCHEDULE KUDGI

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-KUDGI,ST-I 3X800MW UNIT: FGD DG Set

ITEM LIST OF CONTENTS

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-KUDGI,ST-I 3X800MW UNIT: FGD DG Set

ITEM 1.0 PLANT DETAILS

emergency measure for extending power supply to drives connected in

unit emergency board in case unit tripping/ black out.

Supplier: M/s ISGEC

Sub Vendor: JAKSON

Engine Make: CUMMINS.

Alternator Make: STAMFORD

Brief details of engine:

Speed: 1500 rpm.

Engine weight (Dry):7185kg

Radiator weight (Dry):2500kg

Engine oil capacity:280L

Radiator Coolant Capacity:242L

Coolant: Ethylene glycol (50:50 premix).

Diesel Storage Tank Capacity:990 Liters.

Brief details of Alternator:

Capacity: 2000KVA (1600KW)

Thermal Classification: 180O C

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-KUDGI,ST-I 3X800MW UNIT: FGD DG Set

Stator Winding: 312

Stator Connection: Star.

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-KUDGI,ST-I 3X800MW UNIT: FGD DG Set

ITEM 2.0 TESTING OBJECTIVE

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-KUDGI,ST-I 3X800MW UNIT: FGD DG Set

ITEM 3.0 TESTING PROPOSALS

ITEM 4.0 SERVICES REQUIRED

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-KUDGI,ST-I 3X800MW UNIT: FGD DG Set

4.1 220V DC Supply.

4.2 3phase 415V AC Supply.

4.3 Multi meter, clamp meter and 1KV Megger.

4.4 Relay Testing Kit.

4.5 3 Phase Variac.

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-KUDGI,ST-I 3X800MW UNIT: FGD DG Set

ITEM 5.0 SAFETY OF PLANT

2. By Agreement with the working party.

3. On instruction from the Testing team leader.

Schedule should be familiar with the testing procedures and the

equipments involved in testing.

The area under test should be clearly defined.

should be displayed at the test area.

5.6 The test area should be clear of obstructions.

5.7 Safety Clearance Certificates and Safety Clearance Notifications should be

in force for the equipments to be energized.

5.8 Operating staff should be kept informed of the programmes of testing

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-KUDGI,ST-I 3X800MW UNIT: FGD DG Set

ITEM 6.0 EMERGENCY PROCEDURE

fire, accident or other major incident.

should be permanently displayed near each telephone.

particular area/ equipment should be immediately isolated.

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-KUDGI,ST-I 3X800MW UNIT: FGD DG Set