Site Test and Commissioning Plan

Site Test and Commissioning Plan

Client LARAIB ENERGY LTD. Prep. 24.04.2012 CQG Filename NBE-000-07-001_R0

Project NEW BONG ESCAPE Chk. 30.04.20122011 06 16

XYG Zubler Index / Date Filedate 2012-05-09

Project Nº Appr. 06.05.2012 HCN-PM 0 2012-05-06 Page 1 of 19

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Internal Nº DOC Nº NBE-000-07-001

0 For approval 06.05.2012 CQG XYG HCN-PM

Index Modification Date Prepared Checked Approved







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Table of content

1. INTRODUCTION....................................................................................................................3

2. QUALIFICATION OF ASSIGNED PERSONNEL ..................................................................3

3. SITE TEST AND COMMISSIONING PLAN...........................................................................4

3.1. Dry Test ................................................................................................................................................ 4 3.2. Flooding/Wet Test ............................................................................................................................. 14






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1. INTRODUCTION

The guideline contains essential information about the pre-commissioning and commissioning of NBE project. This document is not exhaustive and has to be adapted by all involved parties. It is not a regu-lation where the sequence is fixed. All steps have to be reviewed and checked before execution. The guideline can not cover all precautions, safety instructions and operating instructions of hydro-power plants. It contains only the most important information which has to be taken into account and can not compensate technical competence of commissioning personnel. Details and results of the commissioning will not be mentioned in this document.

2. QUALIFICATION OF ASSIGNED PERSONNEL

The commissioning of the machine / plant has to be executed by qualified, reliable and authorized personnel only. Qualified personnel are persons, who were authorized due to their education, experi-ence as well as knowledge of relevant standards and regulations, rules for the prevention of accidents and operating conditions to perform the necessary works and to recognize and avoid possible dan-gers.



Plant NEW BONG ESCAPE Chk. 30.04.201220

11-06-16 XYG Zubler Index / Date Filedate 2012-05-09


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Internal Nº DOC Nº

NBE-000-07-001

3. SITE TEST AND COMMISSIONING PLAN

3.1. Dry Test

Item Task name Reference international standard

1 Turbine and governor system Turbine

Inspect shaft seal water circuit Inspect air pressure pipes & Inspect instrumentation for standstill sealing Inspect pipes and instrumentation for leakage water pipe Turbine Guide Bearing: Inspect instrumentation Standstill seal / Maintenance seal

1.1

Operating of the Wicket gate Governor system

High Pressure Unit (HPU) cleanliness HPU oil filling and pressure building HPU signals check HPU function test Governor actuator test Electrical governor signals check

1.2

Governor system test

IEC 60308

2 Mechanical auxiliary system Compressed air system

Inspect pipes and Installation (cleanliness, earth connection) Check direction of rotation of compressor Check sensors and signals

2.1

Check proper function of equipment High pressure hydraulic oil system

Inspect pipes and Installation (cleanliness, earth connection) Check direction of rotation of pumps Check sensors and signals

2.2

Check proper function of equipment






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Item Task name Reference international standard Drainage and dewatering system

Inspect pipes and Installation (cleanliness, earth connection) Check direction of rotation of pumps Check sensors and signals

2.3

Check proper function of equipment Guide bearing lubrication system

Inspect pipes Inspect instrumentation Check direction of rotation

2.4

Check of signals and adjustments

3 Generator system Stator winding

DC resistance measurement Insulation resistance test

3.1

High voltage test Rotor winding

DC resistance measurement Insulation resistance test

3.2

High voltage test Cooling water system

Inspect pipes and Installation (cleanliness, earth connection) Check sensors and signals

3.3

Check proper function of cooling equipment Braking system

Inspect pipes and Installation (cleanliness, earth connection) Check limit switches and signals

3.4

Operation test Electrical braking system

Visual inspection 3.5

Operation test






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4 Electrical power system Power transformer

Visual inspection

Measurement of voltage ratio for all tapings and check of vector group(phase displacement)

Measurement of winding resistance

Dielectric strength test of transformer oil

Functional tests on tap changers Measurement of principal winding insulation resistance Functional tests on all control, protection, supervision equipment

4.1

Signal Checks

IEC 60076

4.2 Control system Local Control Unit 1- 4 (LCU1- 4)

Visual check Wiring check in the cubicles Digital inputs and outputs test, analog inputs test, analog outputs test Start/Stop Sequencing test

Trip test

4.2.1

Communication test Local Control Unit 5 (LCU5)

Visual check Wiring check in the cubicles Digital inputs and outputs test, analog inputs test, analog outputs test Function test

4.2.2

Communication test Local Control Unit 5 (LCU6)

Visual check

Wiring check in the cubicles Digital inputs and outputs test, analog inputs test, analog outputs test

4.2.3

Interlocking test

IEC 62270 IEC 60870






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Item Task name Reference international standard Synchronization test

Communication test

Communication interface to NPCC (LCU7) Visual check Wiring check in the cubicles Time synchronization test

4.2.4

Communication test

4.3 Protection system 132kV line protection

Visual check Wiring check in the protection cubicle Digital inputs and outputs test Function test

4.3.1

Trip test 132kV busbar protection

Visual check Wiring check in the protection cubicle Digital inputs and outputs test Function test Trip test

Generator/main transformer protection

Visual check Wiring check in the protection cubicle Digital inputs and outputs test Function test

4.3.2

Trip test

IEC 60255

Excitation system Visual check Insulation check of the primary part

4.4

Inputs and outputs test

IEEE 421






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Item Task name Reference international standard Function test Check of PT and CT Circuits

Excitation transformer Visual inspection of the assembly Functional check of auxiliary circuit Measurement of the resistance of main circuit Measurement of insulation resistance of primary parts

4.5

Signal checks

IEC 60076

Medium voltage switchgear Visual inspection of the assembly s Operation test of the switching devices Functional check of auxiliary circuit Verification of polarity and ratio of CT, PT Measurement of contact resistance Measurement of insulation resistance of primary parts

Calibration checks of meters

4.6

Signal Checks

IEC 62271-100, 102, IEC 60439

Neutral grounding cubicle Visual inspection of the assembly Measurement of insulation resistance of primary parts

4.7

Measurement of voltage ratio Station service transformer

Visual inspection of the assembly Functional check of auxiliary circuit Measurement of the resistance of main circuit Measurement of insulation resistance of primary parts

4.8

Signal checks

IEC 60076

400V system distribution Visual inspection of the assembly s Operation test of the switching devices

4.9

Functional check of auxiliary circuit






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Item Task name Reference international standard Measurement of insulation resistance of main circuit Signal Checks Check of correct phase sequence

220VDC switchgear

Visual inspection of the assembly Check of polarity of 220V DC incoming voltage from 220V battery charger Operation test of the switching devices

4.10

Signal checks

UPS/DC system batteries Visual inspection of the assembly

4.11

Operation test of the fuse box

Cables Insulation resistance test for power cable

4.12

Withstand voltage test (only for MV cable) IEC 60502

132kV Gas insulated switchgear Visual inspection Measurement of the resistance of the main circuit Check of SF6 dew point Measurement of circuit breaker open/closing time Operation test Dielectric tests on the main circuits

4.13

Signal checks Indoor and outdoor lighting system (Panels)

Visual inspection of the assembly Measurement of insulation resistance of main circuit Operation test of the switching devices Functional check of auxiliary circuit Functional check of indoor lighting system Functional check of outdoor lighting system

4.14

Signal checks 4.15 Emergency diesel generator






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Item Task name Reference international standard Visual inspection Check of cabling Adjustment of CB settings Start up of diesel no load test run Checking temperature of cooling system Signal checks

Fire detection equipment Visual inspection Triggering of each fire alarm detector (locally) Signal check at the fire alarm control panel

4.16

Signal checks with control system

Water spray system (for generator transformer) Visual inspection Deluge valve test at the transformer

Signal check at the fire alarm control panel

4.17

Signal checks with control system

Elevator

Visual inspection (examination and clearing) Adjustment of the safety gear Test run and adjustment Adjustment and determine the coefficient of equilibrium of the elevator Adjustment of stop leveling of the elevator Adjust acceleration and deceleration of the elevator Adjust and examine landing doors Check of electrical switches Adjustment and examine the tension of the hoist rope for traction Electrical isolation resistance and grounding

4.18

Isolation resistance test

4.19 Line interconnection






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Item Task name Reference international standard Inspection of erected towers/tightening Inspection of strung conductor / hardware / shield wire Inspection of new strung portion of transmission Line

5 Outdoor switchyard equipment Coupling filter

Visual inspection Check the connection with the HF cable Functional test

5.1

Operation test

Line trap Visual inspection Functional test

5.2

Operation test

CVT Visual inspection Insulation resistance test Polarity check

5.3

voltage ratio test

IEC 60044-1, -2

HV Surge arrestor Visual inspection Insulation resistance test

5.4

DC reference voltage

IEC 60099

6 Telecom equipment Telecommunications-PLC

Visual inspection Function test Operation test Signal checks with telephone system & remote control system & protection system

6.1

Verification of the voice and data transfer with NPCC, Kharian and Mangla control centers 6.2 Access control system






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Item Task name Reference international standard Visual inspection Function test Signal checks

CCTV Visual inspection Function test

6.3

Signal checks Telecommunications - direct wire telephone

Visual inspection Function test

6.4

Signal checks Telecommunications - omnibus telephony


6.5

Signal checks PAS Components


6.6

Signal checks Telecommunications - telephone

Visual inspection Function test Signal checks

6.7

Verification of the voice transfer with PTCL Kharian and Mangla control centers

7 Stoplog and stoplog crane Stoplogs

Dimension check for the second embedded parts Operational test with gantry crane

7.1

Inspection for the sealing of stoplogs Crane 7.2

Inspection for traveling mechanism






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Item Task name Reference international standard Inspection for drive transmitting Inspection for crane frame Gear box oil level inspection Electrical circuit inspection Electrical control inspection Resistor inspection Insulation resistance inspection Motor inspection Position switch inspection No-load test Static load test Dynamic load test Gear box, bearing, driver shaft coupling and rotating parts inspection Noise inspection Rope drum, pulleys, pins and drive sprockets inspection Rope anchorage inspection






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3.2. Flooding/Wet Test


1 Dead water test 1.1 General conditions

Before proceeding with the tests as described in this section, all tests and adjustments as described in Dry Tests, must be completed and all conditions must be fulfilled.

1.2 Filling the tailrace water ways: Generator brakes applied Bearing oil system / high pressure pumps ready for operation Guide vanes locked in closed position (servomotor locked) Filling up the tail water through filling valve Check for any leakage Pull out the stop logs (draft tube gates) Close drainage/filling valves again

1.3

Filling the inlet water ways: Guide vanes locked in closed position (servomotor locked) Generator brakes applied Bearing oil system / high pressure pumps ready for operation Guide vanes locked in closed position (servomotor locked) Open Valves and fill up inlet water ways before guide vane Check for any leakage

2 No load test 2.1 First roll on

Before initial start up of the unit, all partners involved in this commissioning, must be aware of the actual condition of their system and must agree to continue with the program

Their commissioning personal must be placed around the unit for visual and acoustical supervision The turbine opening / closing for the first roll on shall be manually controlled Mechanical brakes must be disengaged Maintenance seal released

2.2 General procedure: Start up the unit by using the step by step automatic mode or manually up to turbine governor start sig-

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Item Task name Reference international standard Open the wicket gates until the unit starts to rotate Immediately close the wicket gates. It is advisable, that the speed does not exceed say 10 % of the

nominal speed During runout, check the unit for abnormal noise, scraping or other phenomenon on the bearings, the

shaft, the runner, etc. Check standstill. If nothing abnormal is detected, the unit may be restarted up to nominal speed step by step

2.3 Recordings during first roll on It is important, to carry out the following checks and recordings during the first step of operation:

Observation and recording of bearing temperatures Observation of oil flow to the bearings Vibration measurement

2.4 Balancing of generator - rotor If required, balancing of the unit

2.5 No load bearing heat run The unit is kept under manual control, 100 % speed, until the bearing temperatures are stabilized. Approxi-mately 4-8h. The stabilized temperature should not exceed the guarantee values. If any temperature is higher than the guar-antee values, or increases quickly, the unit shall be stopped immediately and the cause investigated and cor-rected.

2.6 Overspeed Test Run unit manually up to over speed limits Check operation of mechanical over speed devices Readjust mechanical over speed device if necessary. Record speed signal Check run out time until complete standstill will be reached

Important: During these tests it is important to observe the unit for excessive vibrations noise or scrapping. After over speed tests, check all links, pipes etc. for proper fastening

2.7 Governor test Governor automatically start and stop test No-load speed step tests: make a sudden change of speed setpoint, check and adjust the speed con-

troller PID parameters






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Item Task name Reference international standard No-load stability test

2.8 Start / Stop and breaking curves Record of automatic start curve Record unit run out curves until complete standstill is reached (100% - 0% speed), once without brakes

applied and once with brakes automatically applied.

2.9 Short circuit tests After mechanical run is finished the short circuit will be followed.

Current symmetry(Protection) Short circuit saturation characteristics 3-phase (Generator) 3-phases short circuit test on aux. transformer terminals (Protection) 3-phasea short circuit test on HV side of main transformer (Protection)

IEC 60034-4

2.10 Open circuit tests Open circuit saturation characteristics (Generator) Voltage symmetry (Generator) Phase sequence (Generator) Voltage wave form (Generator) Shaft voltage (Generator) Vibration (Generator)

IEC 60034-4

2.11 Increase voltage test with main transformer Energizing of main transformer with generator in steps until nominal voltage Voltage symmetry Vibration and noise check of main transformer Check of synchronizing equipment Check of phase rotation at two sides of synchronizing CB

2.12 Excitation tests Calibration of generator voltage Check initial excitation Rotor current regulator tests Voltage regulator tests Field discharge tests Change over tests

2.13 Energizing of main transformer Energizing of main transformer from grid






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3 Load test 3.1 General conditions

Before proceeding with the tests as described in this section, all tests and adjustments as described in no-load test section must be completed and all conditions be fulfilled.

3.2 Plant conditions To be fulfilled before starting the wet tests with load:

All related systems must be fully tested and ready for load test Generator and Excitation must be ready for synchronizing tests Governor must be ready for synchronizing tests Start / Stop automatic must be ready for synchronizing All related auxiliaries ready and available Recording and data acquisition equipments installed and ready

3.3 First synchronization Run unit up to 100% speed (excited) in automatic mode Synchronize unit with grid (synchronize in automatic mode) Go up to base load Check adjustments and power measurement Normal shut down

3.4 ESD, Emergency shut down test at 25% load: Run unit up to 100% speed Synchronize unit with grid Load up unit step by step until 25% load ESD by push button Verify closing time of the servomotors, speed rise and pressure rise. Readjust the corresponding orifice if necessary

3.5 QSD, Quick shut down test at 25% load: Run unit up to 100% speed Synchronize unit with grid Load up unit step by step until 25% load Vibration checks and recordings Initiated a QSD e.g. by simulating an over temperature of the guide bearing No over speed must occur during this test

3.6 Rejection test at 25% load






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Item Task name Reference international standard Run unit up to 100% speed Synchronize unit with grid Load unit step by step until 25% load Readings of turbine, generator, excitation and protection values Open CB Verify closing time of the servomotors Verify speed rise, pressure rise and voltage rise during load rejection

3.7 Rejection test at 50% load: Run unit up to 100% speed Synchronize unit with grid Load unit step by step until 50% load Readings of turbine, generator, excitation and protection values Open CB Verify closing time of the servomotor Verify speed rise, pressure rise and voltage rise during load rejection

3.8 Rejection test at 75% load: Run unit up to 100% speed Synchronize unit with grid Load unit step by step until 75% load Vibration checks and recordings Readings of generator, excitation and protection values Open CB Verify closing time of the servomotor. Readjust the corresponding diaphragm if necessary Verify speed rise, pressure rise and voltage rise during load rejection

3.9 Rejection test at 100% load: Run unit up to 100% speed Synchronize unit with grid Load unit step by step until 100% load Vibration checks and recordings Readings of turbine, generator, excitation and protection values Open CB Verify closing time of the servomotor. Readjust the corresponding orifice if necessary Verify speed rise, pressure rise and voltage rise during load rejection






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Item Task name Reference international standard 3.10 Mechanical quick shut down test at 100% load:

Run unit up to 100% speed Synchronize unit with grid Load unit step by step until 100% load Initiated a QSD by simulating e.g. thrust bearing temp. too high

3.11 Turbine/Governor WG Servomotor capacity test Control mode function test and adjustment for e.g. Power control POC and opening control OPC. Test to determine the optimum correlation between wicket gate and runner blade position Vibration checks and recordings Readings of turbine

3.12 Generator Record Data during All Tests (Vibration, MW, etc…) Perform Shaft Voltage Measurement Perform Noise Measurement Perform Vibration Signature Tests

3.13 Excitation / Protection Excitation:

Stator current limiter test Under excitation limiter test Field current limiter test

Protection: Protection readings Differential protection direction check Re-check all protection function by DRS indication

3.14 Heat run Start Unit in automatic synchronizing, increase load to destined value and record unit temperatures until stabi-lized. The stabilized temperatures shall not exceed the guaranteed values. If any temperature is exceeding the guar-antee values or increases too quickly, the unit shall be stopped and the cause investigated and corrected.

IEC 60034-4

3.15 Unit reliability run tests 3.16 Performance tests IEC 60041

Documents

Site Test and Commissioning Plan