UN 5000 User’s manual

Chapter 6
Commissioning

Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-1

Contents:
6 Commissioning......................................................................................................................................... 6-4

6.1 General ......................................................................................................................................................... 6-4

6.2 Safety conditions .......................................................................................................................................... 6-4
6.2.1 Consequences of non-compliance 6-6
6.2.2 Requirements for the personnel carrying out the work 6-6

6.3 Instructions in the event of emergencies ...................................................................................................... 6-7

6.3.1 Behaviour in case of fire: 6-7
6.3.2 First aid measures for electrical installations: 6-7

6.4 Prerequisites for commissioning................................................................................................................... 6-8

6.5 Commissioning procedure ............................................................................................................................ 6-8
6.6 Commissioning activity ................................................................................................................................. 6-9
6.6.1 Preliminary tests 6-9
6.6.2 No-load tests 6-10
6.6.3 Tests under load 6-11
6.6.4 Concluding work: 6-12

6.7 Commissioning report................................................................................................................................. 6-13

Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-2

 Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-3

6 Commissioning

6.1 General
This document contains the information required for the commissioning of an excitation
system of the type UNITROL5000.
Please read this manual carefully before you start work on commissioning. This document
contains:
• Information on safety and servicing
• Advice on safe and correct commissioning
This manual is primarily aimed at commissioning personnel. This personnel should possess
both deep electrical engineering as well as good basic technical knowledge. Commissioning
may only be carried out by personnel specially trained in the UNITROL5000. This training is
carried out periodically by ABB Industrie AG.

6.2 Safety conditions

Danger Extreme care is required when carrying out work inside the
Electricity control cabinets.

Danger Serious injury can result from contact with live parts of the
Electricity system. Personnel may not enter the cabinets without the
necessary specialised knowledge and without protective
measures being taken. All live parts in the regulator cabinet
(+1ER) with a potential over 50V are protected against
accidental contact.

Danger The components in the converter cabinet (+2EG) (heat

Electricity sinks, busbars etc.), which are connected with the
secondary side of the excitation transformer or with the
rotor represent an extremely dangerous electrical potential.
For this reason, these parts are protected against
accidental contact by means of a plexiglas cover. If
servicing work needs to be carried out inside these
cabinets, these covers must be removed. Extreme care is
required when carrying out any work inside these cabinets.

Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-4

 Danger Since the secondary voltage of the excitation transformer
Electricity and the rotor field voltage are fed into the excitation
cabinets, there is a danger that enormous short-circuit
currents can occur in the cabinets in the event of faults.

Danger In the de-excitation field (+3EE), the magnetic field switch

Electricity and the de-excitation equipment are connected directly with
the rotor. Dangerous potential must therefore be expected
at any time. The de-excitation field is protected against
accidental entry by means of two bars. If these barriers are
removed, it should be remembered that high voltages and
extremely high short circuits can occur.

The excitation system must be operated in a protected environment. Access is only

permitted to authorised personnel.

Note Please note that the following environmental conditions

must always be fulfilled for safe operation of the excitation
system:
• Ambient air temperature +5oC...+40oC
• Relative atmospheric humidity 5%...85%
• Air quality free of particles
(e.g. carbon, iron,
sand,....)
• Protection class for cabinets IP21

Note Warning signs are affixed to all cabinet doors to warn of the
operating voltages present in the control cabinets (over 50
volts), but above all to warn of the voltages which occur in
the power section (over 1000 volts possible) and the
enormously high short-circuit currents. These signs are
intended to point out that the doors may not be opened
during operation.

Danger The excitation system can affect the function of heart

pacemakers. It must be ensured that corresponding safety
notices are positioned at a distance of at least 6 m from the
excitation system.

Danger The cabinets +2EG (converter) and +3EE (de-excitation)

Electricity contain exposed busbars which can be under high currents
or voltages.

Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-5

 Danger Never remove protective fixtures before the voltage has
Electricity been disconnected from all touchable electrical parts and
these have been earthed.
Work may only be carried out on the electrical installation if
the touchable live parts have been switched off and earthed
on all sides. If this is not possible, the following special
measures should be taken.
- The working area must be fitted with a safety barrier
(fencing) and a yellow warning sign reading "Caution:
high voltage – deadly danger".
- Countermeasures must be taken (e.g. lock switching
function through use of key-switches) to prevent
installations which have been switched off from being
switched on accidentally through control errors or by
third parties.

National and works-specific safety regulations must be strictly complied with.

6.2.1 Consequences of non-compliance

• If safety regulations are not complied with, serious injury and material damage can result.
• If the required commissioning work is not carried out, or is only partially carried out,
damage can occur which leads to high repair costs. In particular, soiling and deposits of
dust on converters leads to a high risk of voltage spark-over, which can cause serious
damage.

6.2.2 Requirements for the personnel carrying out the work

• Commissioning personnel must be familiar with the "functional description " and the
"user‘s manual " for this excitation system
• They must be familiar with this document
• They must be familiar with the control elements , operating and alarm displays of the
excitation system, both on the excitation equipment itself (local operation) and in the
control room (remote operation etc., see user‘s manual)
• They must be familiar with the operating, commissioning , maintenance and repair
procedures
• They must have been instructed on the power supply concept for the excitation system
and on emergency shutdown measures and be able to shut off the voltage to the
installation in an emergency
• They must be familiar with accident-prevention measures at their workplace and must
have been trained in first aid and fire-fighting measures.
• They must have attended the training courses on UNITROL5000 offered by ABB
Industrie AG.

Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-6

6.3 Instructions in the event of emergencies

6.3.1 Behaviour in case of fire:

Note All personnel must be aware of the locations and operation of

the fire extinguishers and know where the emergency exits are
located.

Fire extinguishers are filled with halon, carbon dioxide (CO2) or foam.
CO2 fire extinguishers are intended to be used to fight fires in electrical installations and
may not be pointed at persons.
Foam extinguishers are intended to be used to fight fires in utility objects. They may not be
used to fight electrical fires. They may be used on persons.

In the event of fire in the installation:

First switch off the excitation, locally or from the control room, or if necessary using the
emergency shutdown mechanism (see user‘s manual). Then switch off all power supplies to
the installation.
Only use CO2 fire extinguishers to fight fires in cabinets which are under voltage, do not
use foam or water !

6.3.2 First aid measures for electrical installations:

1. First switch off the excitation, locally or from the control room, or if
necessary using the emergency shutdown mechanism (see user‘s
manual). Then switch off all power supplies to the installation.

2. Free the victim from their endangered situation and lay them flat.
Perform first aid in accordance with training and taking into account the
rules applying to electrical installations. Call for assistance.

Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-7

6.4 Prerequisites for commissioning
Preparations by customer must have been completed, e.g.:
• All cables and wires leading to the excitation cabinets have been laid, connected and
tested (terminated in accordance with schematic). Including voltage transformer, current
transformer and protective circuits.
• AC and DC power supplies are present and ready to be switched on.
• If generator tests and primary tests are planned: temporary power supply for the
excitation transformer prepared and ready to be switched on.
• Other components such as protection, substation/cables, turbine regulator, turbine,
generator and auxiliary equipment should be ready for commissioning in the next few
days.
• Safety barriers must have been prepared.

General:
• Travel
• Meetings
• Equip workplace (table, chair, lighting)
• Make changes if necessary

6.5 Commissioning procedure

Condition Purpose Time

required
Shutdown Wiring work completed Check power supply 5 days
work measuring transformer wiring
control by control system,
No-load Nominal rotational speed Check settings in manual mode 1,5 days
tests measuring transformer inputs
settings in automatic mode
Tests Generator can be used Check settings in manual mode 3 days
under load through entire power- settings in automatic mode
chart network can take limiters
power stabilisation
Concluding Writing report for the installation 0,5 days
work

The times stated refer to the actual time required for trials/tests. The work can only be
completed in the stated time if the installation is only available for the exciter tests and the
network does not impose any restrictions.

Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-8

6.6 Commissioning activity
Record Activities marked with this symbol are to be recorded in form of a report.

6.6.1 Preliminary tests

Note Machine at standstill

Depending on their importance, the following tests are to be carried out on both channels
(CH I, CH II):
• Visual check for transport damage, correct erection.
• Compare terminal connections with schematic (correct connection, cross section,
earthing, check screws).
• Basic settings on equipment.
• Visual check of high-voltage circuits, de-excitation circuits, dielectric resistances.
• External AC, DC supplies, rotating field, polarity, step-by-step connection of protective
circuit breakers & checking of individual pieces of equipment, fans etc. and their function.
• Loading of software and parameter list, ARCnet communication.
• Consider and set parameters, calculate RTM and PSS.
• Interface – digital inputs and outputs, incl. alarms.
• Interface – analogue inputs and outputs.
• Control – field circuit breaker, field flashing, control circuits etc., operation from local
panel.
• Trip circuits – protection, generator circuit breaker (input and output), separately for CH I
& CH II.
• Check control commands from control room, Synchrotact, fieldbus etc.
• Program internal measuring transformer if required.
• External voltage and current transformer circuits, transformation ratio (possibly already
dealt with by customer).
• Check pulse channels.
• Request field resistance from customer or measure.

• Either Low-load test of final control elements

(e.g. temporary external power supply to control elements
3x380VAC), characteristic Uf = f(Uc) at temporary resistive load
(approx. 2kW, 100Ω);
Calibrate Uf, check polarity of field voltage.

Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-9

 • Or (if requested) organise an external power supply for the
excitation transformer in preparation for the primary testing of
the generator and short-circuit and no-load characteristics;
Check the necessary locking functions.
Characteristic Uf = f(Uc) at temporary resistive load
(approx. …kW, 100Ω);
Calibrate Uf, check polarity of field voltage.
• In manual mode, apply minimum current to field circuit (machine is at standstill or,
preferably, turning slowly),
Set Preset to 0%, optimise regulator in manual mode;
Calibrate Ifdc, Ifac, de-excitation and field circuit breaker trip.
• Any other preparations required for generator short-circuit and no-load
characteristics tests, locking functions.
• field flashing on the field, size of current, polarity.
• Superimposed regulator (Q; cosϕ; Joint Control). Check analogue inputs, setpoint
values.
• Agree with customer on setting of limiter characteristics and monitoring functions on
the basis of the power chart.

Note Generator short-circuit and no-load characteristic / primary

test:.
Are all current transformer circuits closed?
Check the voltage and current transformer circuits,
calibrate Ig, Ug, Ifdc, Ifac.

6.6.2 No-load tests

Note To run these tests, the machine must be available at
nominal rotational speed (not synchronized) during several
hours.

Depending on their importance, the following tests are to be carried out on both
channels (CH I, CH II):

6.6.2.1 Manual mode

• field flashing with blocked final control elements, check rotating field on excitation
transformer.
• Filed flashing in manual mode, shunt as well as de-excitation and tripping of field
circuit breaker.
• Optimise manual mode, adjust setpoint range.
• Calibrate Ugen, Usyn, Uf, Ifdc, Ifac, primary and/or secondary circuits of excitation
transformer in SW and check scaling in panel.

Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-10

6.6.2.2 Switch over to automatic mode
• Automatic mode filed flashing, de-excitation and soft-start, static or compounding.
• Optimise setting of automatic mode regulator, adjust setpoint range.
• Channel switchover CH I <=> CH II and A <=> M,
tracking control.
• Current flow monitoring, current distribution.
• Monitoring functions, tripped by overvoltage protection for example.
• Ground leak relay.
• Rotor temperature measurement.
• V/Hz limiter and V/Hz protection
(rotational speed reduced as far as possible).
• Various measurements, partially fill in the report.

Synchronising:
Initial synchronising with voltage regulator in manual mode.

6.6.3 Tests under load

6.6.3.1 Low-load P < 0.1pu

Note Tripping by the excitation is possible during the following tests

• Stator current measurement, internal P- and Q-measurement.

• Xe measurement, statics / compensation.
• Setpoint jump on network, manual and automatic mode, osc.
• Calibrate Ig and If at highest possible current.
• Load shut-off overexcited (Q = +0.4pu) and underexcited Q = -0.4pu)
automatic & manual mode
(together with load shut-offs for turbine/turbine regulator).
• Optimise Ifmin limiter
Set setpoint (P = approx. 0pu; Q = approx. -0.4pu).
• Optimise Q(P) limiter,
Set setpoints, (P = approx. 0 pu; Q = approx. -0.4 ... -0.2pu).
• Optimise If(P) limiter in manual mode,
Set setpoints (P = approx. 0 pu; Q = approx. -0.4 ... -0.2pu).

Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-11

6.6.3.2 Tests under load P > 0.25pu

Note Tripping by the excitation is possible during the following tests

• Check machine actual values at highest possible actual values.

• Optimise exciter current limiter, set setpoint
(P > 0.7pu, Q = approx. +0.4pu).
• Optimise stator current limiter, overexcited and underexcited, set setpoints (P =
0.8pu; Q = approx. +0.4pu or -0.4pu).
• Continuation Q(P) optimise limiter, set setpoint,
(P = 0.25, 0.5, 0.75, possibly 1.0pu; Q = approx. -0.4 ... -0.2pu).
• Continuation If(P) optimise limiter in manual mode,
Set setpoints (P = approx. 0.5, 1.0pu; Q = approx. -0.4 ... -0.2pu).
• Slip stabilisation (option), optimise settings
(P = 0.4, 0.8pu; Q = +0.4, -0.4pu).
• Check at approx. nominal load: rotor temperature measurement.
• Check ground fault relay.
• Check current flow monitoring.
• Check converter cooling (fans); heating in the cabinets.
• Check current distribution.
• Superimposed regulator (option), stability, setpoint range.
• Various measurements, partially fill in record.

6.6.4 Concluding work:

• Save current parameters and software.
• Set reserve units and check function.
• Fit covers and doors.
• Prepare report.

Remarks:
The approximate times stated above apply under the following conditions:
• Preparations prior to commissioning (see above) were carried out by customer.
• During the stated times, the machine is fully available to the AVR commissioning
engineer, i.e. no other tests such as generator, protection or turbine tests may be
carried out.
• No waiting times arise.
• Normal network conditions;
i.e. the generator can be operated within the entire power chart range and can be
switched from one power chart range to the other within minutes.
Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-12

6.7 Commissioning report

The commissioning report is enclosed in this section. This report is an independent

document which records all setting values and measurements which were made
during commissioning.

Document number Lang. Rev. ind. Sheet

ABB Industrie AG 3BHS114940/E80 en 6-13