STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 SHEET 1 OF 15 NTPC REF NO: SIM/ 1/ TS/ 1 /112 PLANT

AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT LIST OF CONTENTS 1. PLANT DETAILS 2. TESTING OBJECTIVES 3. TESTING PROPOSALS 4. SERVICES REQUIRED 5. SAFETY PRECAUTIONS 6. EMERGENCY PROCEDURES 7. STATE OF THE PLANT 8. COMMISSIONING PROCEDURE 9. COMPLETION OF CRITERIA 10. APPENDICES

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 SHEET 2 OF 15 NTPC REF NO: SIM/ 1/ TS/ 1 / 112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT

1.0 PLANT DETAILS This system consists of: i. ii. iii. Battery Bank Battery Charger - Main and Standby DC Distribution board. The battery is installed in the battery room in the HT switchgear room. This provides a 220 V DC supply to the relay and control circuits in the Generator. Generator transformer and Unit transformer protection and control panels, 11KV and 3.3 KV HT switchgear and 4.5 V LT switchgears Unit and station service boards and aux. Control panels. Battery Cells - Data Sheet Guaranteed AH Capacity at 10 Hrs.discharge Rate 1 Volt / Cell at 27 C Designation Recommended range of floating/trickle Charging voltage Recommended range of boost charging Voltage Trickle charging current Boost charging current 1.53 -- 1.67 V/Cell 1 to 2 MA /AH 198 A 1.4 -- 1.42 V/Cell 990 AH KPH 990 P

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 SHEET 3 OF 15 NTPC REF NO: SIM/ 1/ TS/ 1/112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT Open circuit voltage of cell when completely Discharged at 27 C at 5 hrs discharge rage Dimension (mm) Amount of specific gravity or electrolyte Per cell required for first filling at 27 C Specific gravity of cell when fully charged Max. electrolyte temp. that cell can withstand Continuously Net dry cell weight With electrolyte Cell container material No of cells / Bank Charger - I & II Input Voltage Output Voltage Float Voltage Boost Voltage Rectifier current limit Battery current limit Auto charge over current Voltage variation 0 - 100 % load variation at a time). 415 V+- 10% 220 V DC 236 V DC 287.3 V DC 400 A 198 A 40 A +-1% 50 C 45 Kg 68 Kg Polypropylene 169 18 Lit / cell, 1.19 +- 0.01 1.19+- 0.01 1.0 V 522 L x 192 W x 405 H

Steady state output voltage Regulation (For +- 10% I/P

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

SHEET 4 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1 / 112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT

2.0 TESTING OBJECTIVES: 2.1 To ensure that all the relevant checklists have been completed for the battery, battery charger and distribution boards. 2.2 To complete the connections between the battery / battery charger and the distribution boards. 2.3 To make the distribution board live at 220 V DC in a safe and orderly manner. 2.4 To carry tests and checks to ensure that all the components on the borads are operating satisfactorily including cables to all the remote points in the 400 KV substation and control room.

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 NTPC REF NO: SIM/ 1/ TS/ 1 /112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT

SHEET 5 OF 15

3.0 3.1 live. 3.2 3.3 3.4

TESTING PROPOSALS: AC distribution board for 3 phase AC input supply to chargers will be made Each module will be checked individually. Each outgoing supply will be tested up to the fuses at the remote end. Battery E/F will be simulated for both the poles and E/F relay sensitivity will be checked.

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 NTPC REF NO: SIM/ 1/ TS/ 1 /112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 SERVICES REQUIRED: 415 V, 3 Phases, 50 Hz supply. Adequate running water. Suitable voltmeter, ammeter, thermometer and hydrometer. Variable resistance or water load for discharging the battery. Electrolyte for cells as per IS-266 Pure battery grade distilled water. Funnel, jugs, cleaning brush, wire brush etc. Variable resistance box of 15 to 150 K Ohms 1 No. 500 VDC megger. 1 No. oscilloscope, preferably dual beam or dual trace. 1 No. AVO meter or multimeter 0 - 1000 V DC 1 No. phase rotation indicator.

SHEET 6 OF 15

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 SHEET 7 OF 15 NTPC REF NO: SIM/ 1/ TS/ 1 / 112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT 5.0 SAFETY PRECAUTIONS: The following equipment will be available at all times: 5.1 5.2 5.3 5.4 5.5 5.6 5.7 PLANT: 5.8 5.9 5.10 Acid proof ashphault flooring battery room. Fire extinguishers installed. " NO SMOKING AND 'NAKED FLAME' notices should be displayed. Eye wash bottle Safety goggles. Rubber gloves Insulated spanners and tools 5% to 10% ammonia or soda solution. Exhaust fan near ceiling. Acid proof aprons.

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 SHEET 8 OF 15 NTPC REF NO: SIM/ 1/ TS/ 1 / 112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT 6.0 6.1 6.2 applied. 6.3 All the persons working on battery shall wear, acid proof aprons. EMERGENCY PROCEDURE: First aid charts for acid injuires and electrical shock will be displayed. In case of any accident involving acid burns neutralizing solution must be

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 SHEET 9 OF 15 NTPC REF NO: SIM/ 1/ TS/ 1 / 112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT 7.0 7.1 i. ii. 7.2 7.3 7.4 STATE OF THE PLANT: Check list for the following plant item completed. Battery charger DC distribution board. All outgoing cabling work completed up to remote end panels. All outgoing feeders from DC distribution board switched off. Safety clearance certificates signed and returned by all parties.

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 SHEET 10 OF 15 NTPC REF NO: SIM/ 1/ TS/ 1 / 112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT 8.0 1. 8.1 COMMISSIONING PROCEDURE: TESTING OF BATTERY CHARGERS: The insulation value shall be checked with 500 V DC Megger. During this test, all low voltage circuits & Relays etc, shall be kept shorted. 8.2 The panel shall be switched on at no load. For this, first make input switch Q1 ON & check the voltages at all phases indicated by lamps VD1, VD2 & VD# & voltmeter by selector switch VS1. Now the voltage is connected to the primary of the Main transformer which steps the voltage down as required for the specific DC output Voltage & isolates AC Input line from Battery circuits. The transformer's secondary is connected to the Full wave rectifier assembly. The bridge is standard three phase full wave half controlled silicon bridge. The voltage control is accomplished by the application of a positive pulse to the gate terminals of the SCR at the desired time. Before the pulse is applied , the SCR is open and no current flows in the circuit. As soon as SCR is fired, it operates as a standard silicon rectifier until the forward current is reduced to almost zero. 8.3 8.4 8.5 Check the no load output voltage at the output terminals. Ensure the output voltage is steady without any trouble for 15 minutes. Check for annunciation interlocks etc.

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 NTPC REF NO: SIM/ 1/ TS/ 1 / 112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT 8.6 8.7 8.8

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If load is available, the equipment shall be loaded progreesively upto rated value Check for voltage regulation, free from oscillation, ripple etc. Check for dropping characteristics at higher loads. Run the equipment for 2 hours and observe of stability and check for local heating. When unit is loaded the ripple voltage level (peak to peak) may be observed on a CRO. This will be within limits. Incase, it is more than specified , then it means firing is disturbed.

II 8.9

FIRST CHARGING OF BATTERY: DC Voltage needed for battery charging will be 2 times the no of cells in battery bank. The initial charging will take approximately 16 to 24 hours since the batteries are already charged and sent as maintenance free ones.

8.10 8.11

It is of utmost importance that the terminal of the battery is connected to +ve load of charging source. So polarity should be ascertained. Check thoroughly to ensure cells are connected in series and all fastenings and connections are tight. The test polarity of the charging leads and correct the +ve terminal to that of charger.

8.12 8.13 8.14 8.15

Commence charging not later than 24 hours after connecting all battery cells. Give the first portion of charge at a rate of 100 Amps for 10 Hours Discharge it using Water resistance or halogen lamps at a rate of completion of charge observed. for hours. Give the second charging at the rate of approximately 20 Amps till the signs of

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500- 112 SHEET 12 OF 15 NTPC REF NO: SIM/ 1/ TS/ 1/ 112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT 8.16 8.17 8.18 8.19 Select any one cell (except the end cell or regulating cell) as pilot cell out of every rack as given in the layout of the battery bank. Voltage and specific gravity reading from pilot cells will indicate the state of charging of the whole battery system. All cell terminals & connections are to be applied with pertroleum jelly. No adjustment should be made which will disturb charging. When all the cells have been greasinyg freely and when voltage and specific gravity of pilot cell has been constant over 3 successive hour readings, the cells can be deemed to be fully charged and the charging may be terminated. Then wipe down outside of all cells and clean the floor. 8.20 Put the battery system on trickle charging when charging completes.

CAUTION : DONT TOUCH BATTERY TERMINALS WHEN CLEANING OUTSIDE AND BATTERY AREA. USE PROPER GLOVES AND OTHER SAFETY MATERIALS. 8.21 III 8.22 8.23 8.24 8.25 The trickle charge should be adjusted to give optimum battery voltage of 1.53 - 1.67 volts per cell. ENERGISING OF DISTRIBUTION BOARD: Take final I.R. value of the board Ensure that all outgoing circuits are locked in OFF position. Ensure that all safety procedures have been observed. Check that polarities of D.C switch board battery charger and battery are matching.

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 SHEET 13 OF 15 NTPC REF NO: SIM/ 1/ TS/ 1/ 112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT 8.26 8.27 8.28 8.29 8.30 Close the incomer switch of board to charge it. Measure D.C Voltage at the Input. Observe D.C board for any abnormality. If board condition is satisfactory, check that all remote end fuses of outgoing circuits are removed. Switch ON outgoing feeders one by one. Record the following for each circuit. i.) ii.) IV 8.31 8.32 8.33 8.34 8.35 8.36 8.37 8.38 Polarity at both ends of circuit Voltage at both ends of circuit.

EARTHFAULT RELAY ON LOAD TEST: To carry out on load test for the Battery E/F relay, connect variable resistance box of the range of 15 to 150 K Ohms between +ve pole of the board and earth Keep selectivity setting plug of E/F relay at 3 ms setting. Cut out resistance slowly to simulate an E/F and observe the current in milli ammeter when the relay operates. Record resistance and current in mA Carry out this test on each available setting on relay. While doing test observe and record the direction of deflection in the ammeter. Check whether it confirms the pole on which the fault is simulated. Repeat 8.32 to 8.37 on -ve pole of the board The test is satisfactory if the operation of the relay confirms with the setting

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 SHEET 14 OF 15 NTPC REF NO: SIM/ 1/ TS/ 1 / 112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT 9.COMPLETION CRITERIA: 220 V DC System for main plant is ready and All measurements and remote indication points are recorded and kept along with this Schedule.

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112 SHEET 15 OF 15 NTPC REF NO: SIM/ 1/ TS/ 1/ 112 PLANT AREA: ELECTRICAL SYSTEM TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT 10.APPENDICES DRAWINGS: LAY OUT OF BATTERY ARRANGEMENT SCHEMATIC DIAGRAM OF BATTERY CHARGERS SCHEMATIC DIAGRAM OF DC DISTRIBUTION BOARD.

220 V DC SYSTEM FOR MAIN PLANT