EDN 4&1050-02

ELECTRONICS DIVISION
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Doc No: EDN 48-1050-02 WBS Element No: CE/I050-SH3-48-01 &

Date:18.09.2014 cE/1050-sH4-48-01

1 . Project Name IB THERMAL POWER STATION, UNIT -3 & 4

2. Equipment / Product DTGITAL AUTOMATIC VOLTAGE REGULATOR

3. Rating 2X660MW

4. Customer M/S OPGCL

5. BHEL DRG.NO. : EN-DG-1050-145-1003

6. Other Requirements, if
any

Prepared By: Approved By:

e.AAV"v+-
€-*n-^-*y:y
R.RAJKUi'AR SATHYANARAYANA

Fi
,v,

COPYRIGHT AND CONFIDENTIAL: The information on this document is the property of BHEL lt must not
be used directly or indirectly in any way detrimental to the interest ofthe company.

I
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TEST PROTOCOL

NATURE OF REASONS PREPARED APPROVED

REV DATE
NO. CHANGE BY BY

First lssue R.RAJKUMAR SATHYANARAYANA

00 10.04.2014
18.O9.2014 Second lssue Customer R.RAJKUMAR SATHYANARAYANA
01
Comments
Letter No:
OPGC/BTGiO3
39t17-06-2014

APPROVED: SATHYANARAYANA
S oJ-f.n a^ --e,,- a-ya''-ea

PREPARED: ISSUED: DATE:

?.t4ttr,+--
R.RAJKUMAR CE/GCE 18.09.2014

is the property of BHEL lt must not

copyRlcHT AND CONFIDENTTAL: The information on this document
the company.
ffiy detrimentalto the interest of
 EDN 48-1050-02
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TEST PROTOCOL

CONTENTS
1. SCOPE.

2. REFERENCE DOCUMENTS.

3. TESTS AT WORKS.  
      DEVELOPMENT CONSULTANTS
  PRIVATE LIMITED
Reviewed for general conformance with Contract
drawings and specifications.

4. TESTS AT SITE. ACTION :

1 Approved
1

4 Disapproved.

Approved except as
For information/reference
2 noted. Forward final 5
only.
drawing.
Approved except as Information category with
3 noted. Resubmission 6 comments. Resubmission
required. required.

Approval of Contract documents by the Consultant shall

not relieve the Seller of his responsibility for any errors
and fulfilment of Contract requirements.

Digitally signed by Shouvik Patari

DN: cn=Shouvik Patari, o=DCPL,
ou=DCPL,
email=shouvikp@in.dclgroup.co
m, c=IN
Date: 2014.10.10 11:06:03 +05'30'

COPYRIGHT AND CONFIDENTIAL: The information on this document is the property of BHEL It must not
be used directly or indirectly in any way detrimental to the interest of the company.
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1.0 SCOPE
Following tests are conducted on DAVR at BHEL-EDN works and at SITE.
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 circuits and contacts for external connections.
f) Protective changeover
 Channel-1 to Channel-2 on Channel-1 failure
 Channel-2 to Channel-1 on Channel-2 failure
 Channel-1 to Channel-3 on Channel-1 failure when Channel-2 has
already failed.
 Channel-2 to Channel-3 on Channel-2 failure when Channel-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.
e) Follow-up control
i) Checking of automatic follow-up circuit. Stand-by channel shall follow the channel
in service.

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f) Under excitation limiter (Load angle and stator current capacitive limiter)
a) Checking of actual value & setting of reference value.
b) Influence of limiter on regulator.
c) Checking of indication.
g) Over Excitation Limiter (Rotor current and stator current inductive limiter)
a) Checking of actual value & setting of reference value.
b) Checking of indication
c) Influence of limiter on regulator.
h) V/Hz Limiter
a) Checking of actual value & setting of reference value.
b) Checking of indication
c) Influence of limiter on regulator
3.4.4 Light load characteristic:
a) Light load test on each thyristor bridge for channels with resistive load at
PMG frequency.
b) Checking of DC output.

3.4.5 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.
3.4.6 Checking of transducers.
3.4.7 Current sharing Test
This test is conducted to check the sharing of load current among the thyristor
bridges. This test is not performed separately in case Heat Run test is conducted.
However current sharing data is recorded during Heat Run Test.
3.5 Type test
3.5.1 Heat Run Test (only on one set of equipment):
110% of rated exciter field current is passed continuously through the thyristor
bridge and exciter field breaker with cubicle doors closed. The temperature rise is
monitored till the same stabilises. Exciter Field current will be increased to ceiling
condition for 10Secs during above test.
The test is continued disabling one of the bridge to check the capability of bridges for
(N-1) operation.

COPYRIGHT AND CONFIDENTIAL: The information on this document is the property of BHEL It must not
be used directly or indirectly in any way detrimental to the interest of the company.
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4 TESTS AT SITE:
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) Checking of DC output.
4.2 COMMISSIONING TESTS:
4.2.1 Checking of voltage build-up in Manual channel.
4.2.2 Follow up control
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.
4.2.3 Step test on Auto channel 1 and 2
After changing over from Manual to Auto channel, 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 channel and the machine not synchronized.)
4.2.4 Voltage builds up in each of the Auto channels.
4.2.5 Commissioning of limiters:
Recording the response of the following limiters and indication of limiters operation
at REMOTE at 60% load or above.
COPYRIGHT AND CONFIDENTIAL: The information on this document is the property of BHEL It must not
be used directly or indirectly in any way detrimental to the interest of the company.
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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)
4.2.6 Load throw off test:
Recording transient response of AUTO channel during partial / full load throw off to
confirm maximum possible over voltage.
4.2.7 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.

4.2.8 Accuracy test

Keep the Auto channel reference at 100% and record the generator terminal voltage
at No load to rated load. Generator terminal voltage and the reference value should
be match.

4.2.9 Response ratio test

This test is a part of step test. During step test exciter field voltage will be measured
and response ratio will be calculated as follows.
Ratio = (Ceiling Exciter field voltage – Rated exciter field voltage) / (0.5secs * Rated
exciter field voltage)

4.2.10 Impulse input response test

This test is a part of step test. During this test a 5% step change will be made in Auto
channel reference value and generator voltage response will be recorded.

4.2.11 Current sharing

Current sharing test will be demonstrated under loaded condition.

COPYRIGHT AND CONFIDENTIAL: The information on this document is the property of BHEL It must not
be used directly or indirectly in any way detrimental to the interest of the company.