PCR V4 P4C Commissioning

Nepal Electricity Authority
Kreditanstalt für Wiederaufbau
Middle Marsyangdi Hydroelectric Project (MMHEP)
Project Completion Report

Volume 4C
- Project Commissioning Report-
Fichtner GmbH & Co. KG Statkraft Grøner ASOslo- Consulting Engineers

Stuttgart Lysaker Salzgitter GmbH, Salzgitter
FICHTNER JV
Middle Marsyangdi Hydroelectric Project
Project Completion Report - Volume 4C
Nepal Electricity Authority – NEA
Project Commissioning Report
FICHTNER JV
Fichtner JV Site Office

Lamjung District
Nepal
Phone: +977 (19) 542 509

Fax: +977 (19) 542 510
Fichtner JV Kathmandu Office

P.O. Box: 200 79
Pulchowk, Lalitpur
Kathmandu, Nepal
Phone: +977 (1) 55 36 768

Fax: +977 (1) 55 36 831
Email: fichtner@jv.wlink.com.np
mmhep_fjv_site@yahoo.de
TABLE OF CONTENTS
1 INTRODUCTION 1
2 REFERENCE DOCUMENTS 1
3 TESTS DURING ASSEMBLY AND PRE-COMMISSIONING 1
3.1 MAIN INLET VALVES 1
3.1.1 MIV Closing in Dead Water 1
3.2 TURBINES 2
3.2.1 Opening and Closing Time of Wicket Gate in Dry Condition2
3.2.2 Closing Tendency of Wicket Gate 3
3.3 TURBINE GOVERNORS 4
3.3.1 Oil Accumulator Volume Test 4
3.3.2 Governor Dead Band/Sensitivity Test (at Factory) 5
3.3.3 Governor Dead Time Test (at Factory) 6
3.4 GENERATORS 7
3.4.1 Stator Winding HV Testing 7
3.4.2 Stator Winding Insulation Resistance Measurement 7
3.4.3 Stator Winding Ohmic Resistance Measurement 8
3.4.4 Inside Diameter Stator Wound 8
3.4.5 Rotor Winding – Ohmic Resistance Measurement 9
3.4.6 Rotor Winding AC Voltage Test 9
3.4.7 Rotor Winding – Insulation Resistance Measurement 9
3.4.8 Diameter Rotor Complete 9
3.5 EXCITATION SYSTEM 10
3.6 CO2 GENERATOR FIRE EXTINGUISHING SYSTEM 10
3.7 UNIT TRANSFORMERS 10
3.7.1 Insulation Resistance 10
3.7.2 Ratio Test 11
3.7.3 Magnetizing Current Test 11
3.7.4 Short Circuit Test 11
3.7.5 Winding Resistance 12
3.8 110 BATTERIES 13
3.8.1 Power House Discharge Test 10 Hours 110 A 13
3.8.2 Headworks Discharge Test 10 Hours 54.6 A13
3.9 132 & 33 KV TRANSMISSION LINES 14
3.9.1 Measurement Insulation Resistance 132 kV Line 14
3.9.2 Measurement Insulation Resistance 33 kV Line 14
3.9.3 Attenuation Measurement OPGW 132 kV Line 15
3.9.4 Attenuation Measurement ADSS 33 kV Line 16
3.9.5 Contact Resistance Measurement of ACSR Conductor Joint at TW1 of 132 kV
Line 17
4 RUNNING TESTS 18
FICHTNER JV I
4.1 MAIN INLET VALVE 18

4.1.1 Closing under Flow18
4.2 TURBINE 20
4.2.1 Overspeed Test 20
4.2.2 Load Rejection Tests (LRT) Units 1 and 2 21
4.2.3 Emergency Shut Down (ESD) Tests23
4.2.4 Heat Run at Generator Nominal Load – Bearing and Cooling water Temperatures
24
4.2.5 Heat Run at Generator Nominal Load – Bearing Temperatures and Levels 26
4.2.6 Vibration Measurement 27
4.3 TURBINE GOVERNOR 28
4.3.1 Optimization Start-Up Curve 28
4.3.2 Optimization Speed No-Load 29
4.3.3 Optimization without Frequency Influence 30
4.3.4 Synchronization and Step Loading of Unit 31
4.4 GENERATOR 32
4.4.1 Balancing 32
4.4.2 Shaft Voltage Measurement33
4.4.3 Characteristic Curves (Short Circuit & Open Circuit) 34
4.4.4 On-load Characteristics 36
4.4.5 Heat Run 36
4.4.6 Load Rejections 37
4.5 EXCITATION 38
4.5.1 Automatic Voltage Build-up Curve with the Automatic Channel (unit 1) 38
4.5.2 De-excitation Curve with the Automatic Channel by Field Breaker Opening (unit
1) 38
4.5.3 De-excitation Curve by Protection Trip with the Automatic Channel (unit 1) 39
4.5.4 +10% Stator Voltage Step with the Automatic Channel in Operation (unit 1) 39
4.5.5 Power System Stabilizer Tuning at rated Active Power without/with PSS (unit 2)
40
4.5.6 Transmission Line Charging with Unit 2 41
4.6 UNIT TRANSFORMERS 42
4.6.1 Heat Run 42
4.7 PENSTOCK BUTTERFLY VALVE 42
5 GENERATOR PERFORMANCE TESTS43
5.1 OHMIC RESISTANCE OF THE ROTOR WINDING 43
5.2 OHMIC RESISTANCE OF THE STATOR WINDING 43
5.3 OPEN-CIRCUIT CHARACTERISTIC 43
5.4 THREE-PHASE SHORT-CIRCUIT CHARACTERISTIC 43
5.5 DIRECT AXIS SYNCHRONOUS REACTANCE AND SHORT-CIRCUIT RATIO 44
5.6 DETERMINATION OF MOMENT OF INERTIA 44
5.7 WAVE FORM DEVIATION FACTOR 44
5.8 DETERMINATION OF RATED EXCITATION CURRENT 44
5.9 DETERMINATION OF GENERATOR EFFICIENCY 45
FICHTNER JV II
6 COMMISSIONING SCHEDULE 46
6.1 Basic Commissioning Schedule Dated 20.11.2009 46
FICHTNER JV III
1 INTRODUCTION
2 REFERENCE DOCUMENTS
Most of the information included in this document has been extracted from the following Test
Protocols prepared by the Manufacturers. The following listing gives the details:
Alstom O&M Manuals (Lot E):
Voith Siemens O&M Manuals Lot M:

Part 12 - Commissioning Common Systems
Part 13 - Commissioning Protocols Unit 1
Part 14 - Commissioning Protocols Unit 2
AREVA O&M Manuals (Lot SS1):
3 TESTS DURING ASSEMBLY AND PRE-COMMISSIONING

3.1 MAIN INLET VALVES
3.1.1 MIV Closing in Dead Water
MIV No. 1 Opening Time 39 sec. Closing Time 84 sec.

MIV No. 2 Opening Time 41 sec. Closing Time 86 sec.
March 2010 FICHTNER JV 1

3.2 TURBINES
3.2.1 Opening and Closing Time of Wicket Gate in Dry Condition

3.2.2 Closing Tendency of Wicket Gate

3.3 TURBINE GOVERNORS
3.3.1 Oil Accumulator Volume Test

3.3.2 Governor Dead Band/Sensitivity Test (at Factory)


3.3.3 Governor Dead Time Test (at Factory)
3.4 GENERATORS
3.4.1 Stator Winding HV Testing

AC-Voltage test was carried out with 29.4 kV (against ground) after installing the bottom
winding layer of the stator winding.
A second AC-Voltage test was conducted with 25.7 kV (against ground) after completion of
the winding.
High voltage tests of RTD’s with 2000 VAC
In addition, the following tests were conducted on the stator bars during manufacturing:
 High-voltage test on all bars with 4xUN = 44 kV.
 Dielectric loss factor measurement on all bars with 2.2 up to 13.2 kV (in steps of 0.2xU N
from 0.2xUN to 1.2xUN)
 Insulation breakdown test of main insulation on slot portion on two bars of the first
production batch of first unit each one lower and upper bar. The insulation broke down
(perforated) by 74 respectively 76 kV.
STATOR WINDING - INSULATION TESTS WITH 500 VDC
INSULATION Measurement of each

RESISTANC phase to the others and
E to the ground

UNIT 1 UNIT 1
Phase Phase Phas Phase
Phase U Phase V
W U eV W

12.05.20 12.06.20 12.08.2 28.07.2 28.06 28.06.
Date of test
08 08 008 008 .2007 2007

[kVd
Test voltage 0.5 0.5 0.5 0.5 0.5 0.5
c]
Winding temperature 27.5 27.5 27.5 31.5 31.5 32 [°C]
Ambient air temperature 26 28 28 29 29 29 [°C]
Relative humidity 72 71 74 67 67 66 [%]
Insulation after 1 min [MΩ
(R1)
138 172 164 368 375 361
]
Insulation after 10 min [MΩ
(R10)
152 180 167 423 435 419
]
Pol. Index(IP=R 10R1) 1.10 1.05 1.02 1.15 1.16 1.16

Unit 1 Unit 2
31.666
3 phases winding temperature (average temp.) 27.5 [°C] [°C]
7

3.4.2 Stator Winding Insulation Resistance Measurement
3.4.3 Stator Winding Ohmic Resistance Measurement
OHMIC

RESISTANCE UNIT 1 UNIT 2
PHASE U
Test 1 Test 2 Test 3 Average Test 1 Test 2 Test 3 Average
Applied
82.25 82.28 82.28 82.99 83.01 83.01 [mVdc]
voltage
Applied
10.000 10.000 10.000 10.000 10.000 10.000 [Adc]
current
Ohmic
8.225 8.228 8.228 8.227 8.299 8.301 8.301 8.3 [mΩ]
resistance
Ohmic
resistance 7.99 7.99291 7.99291 7.99194 7.94088 7.9428 7.94216 7.94216 [mΩ]
(at 20°C)
OHMIC RESISTANCE Test 1 Test 2 Test 3 Average Test 1 Test 2 Test 3 Average
PHASE V
Applied
2.20 82.21 82.22 83.11 83.1 83.13 [mVdc]
voltage
Applied
10.000 10.000 10.000 10.000 10.000 10.000 [Adc]
current
Ohmic 8.22 8.221 8.222 8.221 8.311 8.31 8.313 8.311 [mΩ]
resistance

Ohmic
resistance 7.98514 7.98611 7.98709 7.98611 7.95236 7.95141 7.95428 7.95268 [mΩ]
(at 20°C)

OHMIC RESISTANCE Test 1 Test 2 Test 3 Average Test 1 Test 2 Test 3 Average
PHASE W
Applied
82.21 82.23 82.28 83.13 83.14 83.15 [mVdc]
voltage
Applied
10.000 10.000 10.000 10.000 10.000 10.000 [Adc]
current
Ohmic
8.221 8.223 8.226 8.223 8.313 8.314 8.315 8.314 [mΩ]
resistance
Ohmic
resistance 7.98611 7.98806 7.99097 7.98838 7.95428 7.95523 7.95619 7.95523 [mΩ]
(at 20°C)

average winding
27.5 [°C] average winding temperature 31.5 [°C]
temperature
ambient temperature [°C] ambient temperature
20 29 [°C]

3.4.4 Inside Diameter Stator Wound
3.4.5 Rotor Winding – Ohmic Resistance Measurement
UNIT 1 UNIT 2
Average Average
Injected current 10.0 10.0 10.0 10.0 10.0 10.0 [Adc]
Voltage 0.5762 0.5763 0.57627 0.5866 0.5869 0.58677 [Vdc]
Ohmic resistance 0.05762 0.05763 0.06763 0.05866 0.05869 0.05868 [Ω]
Ohmic resistance (at 0.05599 0.056 0.066 0.05654 0.05657 0.05655 [Ω]
20°C)
UNIT 1 UNIT 2
Rotor winding temp. 27.4 29.6 [°C] (average all RTDs)
Ambient temp. 28 28 [°C}

3.4.6 Rotor Winding AC Voltage Test

The complete rotor windings were tested with 1.5 kV AC voltage applied for the duration of
one minute. The insulation resistance was measured both before and after the AC test with
500 VDC applied to the winding for the duration of one minute.
3.4.7 Rotor Winding – Insulation Resistance Measurement
GENERATOR 1 GENERATOR 2
Date Measured 12.08.2008 14.11.2008 28.07.2008 18.11.2008
Test Voltage (kVdc) 0.5 0.5 0.5 0.5
Winding Temperature (°C) 27.4 31.5 29.6 31
Ambient Temperature (°C) 26 29 29 31
Relative Humidity (%) 27 39 66 38
Insulation Resistance after 1 min. (R1) MΩ 1.9 3000 43.6 2500
Insulation resistance after 10 min. (R10) MΩ 2.4 4000 51.9 3500
Pol. Index (IP=R10/R1) 1.26 1.33 1.19 1.4
3.4.8 Diameter Rotor Complete
UNIT 1
Deviation to
Position NDT DE AVERAGE
3610,00mm
Pole 1-10 3610.98 3609.90 3610.44 +0.44
Pole 2-11 3611.03 3609.93 3610.48 +0.48
Pole 3-12 3610.73 3610.02 3610.38 +0.38
Pole 4-13 3610.78 3609.98 3610.38 +0.38
Pole 5-14 3610.80 3610.00 3610.40 +0.40
Pole 6-15 3610.75 3609.88 3610.32 +0.32
Pole 7-16 3610.78 3609.98 3610.38 +0.38
Pole 8-17 3611.00 3609.90 3610.45 +0.45
Pole 9-18 3610.95 3609.92 3610.44 +0.44
Total Average 3610.41 +0.41
Average Air Gap: 19.98 mm (19.80 - 20.70) 8 measurements

UNIT 2
Deviation to
Position NDT DE AVERAGE
3610,00mm
Pole 1-10 3609.37 3,608.85 3609.11 -0.89
Pole 2-11 3609.15 3609.14 3609.15 -0.85
Pole 3-12 3609.23 3608.60 3608.92 -1.08
Pole 4-13 3609.43 3608.80 3609.12 -0.88
Pole 5-14 3609.35 3608.80 3609.08 -0.92

Pole 6-15 3609.41 3608.69 3609.05 -0.95

Pole 7-16 3609.27 3608.77 3609.02 -0.98
Pole 8-17 3609.35 3608.77 3609.06 -0.94
Pole 9-18 3609.45 3608.77 3609.11 -0.89
Total Average 3609.07 -0.93
Average Air Gap: 19.88 mm (19.20 - 20.25) 8 measurements
3.5 EXCITATION SYSTEM
3.6 CO2 GENERATOR FIRE EXTINGUISHING SYSTEM

In addition to the standard commissioning tests a live discharge test was carried out in one
generator with 200 kg CO2 (4 bottles)
3.7 UNIT TRANSFORMERS
3.7.1 Insulation Resistance
Main IR Value
Transf. SI. No Temperature
winding 15 sec 60 Sec 600 sec PI
HV/E 8.27 27.9 117 4.19 32°C
B-29814 unit 1 HV/LV 7.92 20.8 164 7.89 32°C
LV/E 7.44 50.3 69.9 1.38 32°C
HV/E 9.34 36.6 77.4 2.11 32°C
B-29816 unit 1 HV/LV 5.21 37.9 119 3.13 32°C
LV/E 5.42 25.8 66.6 2.58 32°C
HV/E 5.31 13.4 42.4 3.16 32°C
B-29820 unit 1 HV/LV 4.89 19.7 72.7 3.69 32°C
LV/E 5.08 14.4 40.9 2.84 32°C
HV/E 17.3 64.4 128 1.98 32°C
B-29815 unit 2 HV/LV 10.6 48.9 185 3.78 32°C
LV/E 6.84 51.3 115 2.24 32°C
HV/E 8.15 24.1 67.8 2.81 32°C
B-29818 unit 2 HV/LV 9.91 48.1 128 2.66 32°C
LV/E 6.77 28.9 76.5 2.64 32°C
HV/E 6.01 19.6 56.8 2.89 32°C
B-29817 unit 2 HV/LV 5.66 36.7 104 2.83 32°C
LV/E 5.83 22.8 50.7 2.22 32°C
HV/E 9.21 14.72 37.8 2.56 32°C
B-29819 Spare HV/LV 7.02 13.9 49.0 3.52 32°C
LV/E 4.65 10.5 27.6 2.62 32°C
3.7.2 Ratio Test
Tap No. Connection Measured Ratio Calculated Ratio

1 U-N/ u-n 7.64 7.6
2 U-N/ u-n 7.46 7.4
3 U-N/ u-n 7.28 7.2
4 U-N/ u-n 7.09 7.06
5 U-N/ u-n 6.91 6.88

Same measured ratio in all 7 transformers.
3.7.3 Magnetizing Current Test
Applied Voltage Measured

Transformer SI. No Side Tap No.
in Volt Current in mA
1 223.6 1.1
HV 3 223.0 1.5
B-29814 unit 1
5 222.3 1.1
LV 3 224 39.3
1 224 2.5
HV 3 224 3.3
B-29816 unit 1
5 224 2.4
LV 3 223 39.6
1 224 0.7
HV 3 222 0.7
B-29820 unit 1
5 223.8 0.9
LV 3 223 40.9
1 226.9 1.8
HV 3 226.9 1.7
B-29815 unit 2
5 226.9 1.8
LV 3 227 40.4
1 227.2 1.9
HV 3 227.0 2.3
B-29818 unit 2
5 226.8 2.5
LV 3 226.8 41.2
1 228.2 1.6
HV 3 227.8 1.7
B-29817 unit 2
5 227.0 1.6
LV 3 227.8 40.6
1 228.1 1.7
B-29819 Spare HV 3 228.3 2.1
5 227.7 2.2
LV 3 228.3 43.4
3.7.4 Short Circuit Test
Transformer SI. Applied voltage in Measured Current Measured Current

Tap No.
No Volt in HV in LV
1 223.3 2.78 20.3
B-29814 unit 1 3 224.0 3.15 22.9
5 223.5 3.54 24.3
1 223 2.79 20.8
B-29816 unit 1 3 223 3.0 23.0
5 223.4 3.56 24.5
1 223.2 2.6 21.2
B-29820 unit 1 3 223.4 3.0 22.8
5 223.3 3.4 24.4
1 226.5 2.5 20.9
B-29815 unit 2 3 226.6 2.9 22.6
5 226.6 3.5 24.4
1 225.7 2.6 22.0
B-29818 unit 2 3 226.3 3.0 23.2
5 226 3.5 24.8
B-29817 unit 2 1 225.6 2.6 21.4

3 226.3 3.0 22.9

5 226.4 3.5 24.7
1 225.7 2.75 21.3
B-29819 Spare 3 226.0 3.08 22.8
5 226.1 3.56 24.6
3.7.5 Winding Resistance
Transformer SI.
Tap No. HV Side in ohms LV Side in milli ohms
No
1 0.86
2 0.83
B-29814 unit 1 3 0.81 11.52
4 0.78
5 0.76
1 0.86
2 0.83
B-29816 unit 1 3 0.81 11.53
4 0.78
5 0.76
1 0.87
2 0.84
B-29820 unit 1 3 0.81 11.59
4 0.79
5 0.77
1 0.86
2 0.83
B-29815 unit 2 3 0.81 11.46
4 0.78
5 0.76
1 0.86
2 0.84
B-29818 unit 2 3 0.81 11.58
4 0.79
5 0.77
1 0.86
2 0.84
B-29817 unit 2 3 0.81 11.63
4 0.79
5 0.76
1 0.86
2 0.84
B-29819 Spare 3 0.81 11.65
4 0.79
5 0.77

3.8 110 BATTERIES
3.8.1 Power House Discharge Test 10 Hours 110 A
3.8.2 Headworks Discharge Test 10 Hours 54.6 A

3.9 132 & 33 KV TRANSMISSION LINES
3.9.1 Measurement Insulation Resistance 132 kV Line
3.9.2 Measurement Insulation Resistance 33 kV Line

3.9.3 Attenuation Measurement OPGW 132 kV Line

3.9.4 Attenuation Measurement ADSS 33 kV Line

3.9.5 Contact Resistance Measurement of ACSR Conductor Joint at TW1 of 132 kV Line

4 RUNNING TESTS
4.1 MAIN INLET VALVE
4.1.1 Closing under Flow
Unit No. 1 Unit No. 2

Test No. MW DP penstock Closing time MW DP penstock Closing time
above steady without end above steady without end
state (bar) pos. throttling state (bar) pos. throttling
1 9.8 2.2 52 10 51
2 20.2 2.35 38.5 20 40.5
3 30.3 2.4 29.5 30 2.57 31.5
4 41.4 2.8 24 40 2.6 27
During the commissioning tests it was observed that the weight of the counterweights was not
sufficient (occasionally the MIVs did not leave the fully open position when close command
was given). Additional weights of 1000 kg (500 on each side) were added. Because of these
additional weights, the throttles which regulate the closing time had to be adjusted. Because
of this some MIV closing tests under flow had to be repeated. Accordingly in the
commissioning reports of Voith there are records for following closing tests:
Tests before increasing the size Tests after increasing the size of
of counterweights counterweights
MIV 1 At: 10, 20, 30 and 41.5 MW At: 10 MW
MIV 2 At: 10, 20 and 30 MW At: 10, 20, 30 and 40 MW
Rated closing time at 45 m3/sec is 30 sec.


4.2 TURBINE
4.2.1 Overspeed Test
Unit 1 Unit 2
Overspeed Devices Test Operated Max. Final Test Operated Max. Final
setting at (%) speed setting setting at (%) speed setting
(%) rise (%) (%) (%) rise (%) (%)
Mech. (hydraulic) 165 167 171.4 165
Electrical No.1 105 105 - 167
(digital governor)
Electrical No.2 115 114 -- 165
(speed relay )

4.2.2 Load Rejection Tests (LRT) Units 1 and 2

The below figures are calculated from the recorded graphs

MW Brutto Max. SCCL Speed MW Head Max. SCCL Speed
(p_max_SCCL) rise (p_max_SCCL) rise (%)
Head
pressure recorded (bar) (%) pressure recorded (bar)

9.69 106.01 125.33 10.9

20.49 106.17 122.48 26.0
29.67 106.29 131.98 40.9
41.50 106.49 139.35 54.8
LRT Unit 1 at 41.5 MW
LRT Unit 2 at 41.3 MW

4.2.3 Emergency Shut Down (ESD) Tests

The below figures are calculated from the recorded graphs

MW Brutto Max. SCCL Speed MW Head Max. SCCL Speed
(p_max_SCCL) rise (p_max_SCCL) rise (%)
Head
pressure recorded (bar) (%) pressure recorded (bar)
9.85 106 118.44 8.1
20.43 106.13 123.48 22.4
30.41 106.29 139.03 35.0
41.50 106.33 141.20 49.0
ESD Unit 1 at 41.5 MW

ESD Unit 2 at 41.4 MW

4.2.4 Heat Run at Generator Nominal Load – Bearing and Cooling water Temperatures

4.2.5 Heat Run at Generator Nominal Load – Bearing Temperatures and Levels

4.2.6 Vibration Measurement

4.3 TURBINE GOVERNOR
4.3.1 Optimization Start-Up Curve

4.3.2 Optimization Speed No-Load

4.3.3 Optimization without Frequency Influence

4.3.4 Synchronization and Step Loading of Unit

4.4 GENERATOR
4.4.1 Balancing
BALANCING OF GENERATOR
Balancing Weights UNIT 1 UNIT 2
Plane NDE NDE DE NDE NDE DE

Angle 120 160 160 80 160 160 [°]

Mass 36 48 8 55 17 7.5 [kg]

MEASUREMNTS
speed 333 332 333 331 333 333 [min -1]
active power 34.8 10.2 20.2 29.5 38.2 34.7 [MW]
reactive power 18.4 1.6 1.96 2.31 3.45 16.6 [Mvar]
stator voltage 11.4 10.8 10.8 10.8 10.8 11 [kV]
stator current 1.95 551 1084 1571 2042 2010 [A]
field current 1339 379 416 473 528 659 [A]

[mm/s
NDE bearing X-45° Overall 0.19 0.6 0.45 0.4 0.4 0.4
rms]
1st harm. [mm/s
0.07 0.4 0.4 0.4 0.4 0.4
Ampl. rms]
1st harm.
153 235 223 222 221 220 [°]
Phase
[mm/s
DE bearing X Overall 0.34 0.75 0.43 0.22 0.2 0.21
rms]
1st harm, [mm/s
0.06 0.12 0.1 0.1 0.1 0.1
Ampl. rms]
1st harm.
318 200 200 207 208 201 [°]
Phase
NDE Shaft X Overall 172 141 140 148 155 160 [umpp]
1st harm,
58 20 14.5 15 15 17 [umpp]
Ampl.
1st harm.
91 66 43 28 15 10 [°]
Phase
Y Overall 185 118 [umpp]

1st harm,
75 8 [umpp]
Ampl.
1st harm.
119 293 [°]
Phase
DE Shaft X Overall 121 63 60 47 46 47 [umpp]
1st harm,
109 40 40 37 38 38 [umpp]
Ampl.
1st harm.
260 188 188 188 190 186 [°]
Phase
Y Overall 118 33 [umpp]

1st harm,
106 20 [umpp]
Ampl.
1st harm.
267 87 [°]
Phase
4.4.2 Shaft Voltage Measurement

Shaft Voltage Measurement

UNIT 1 UNIT 2

Measurements
speed Vn Vn Vn Vn Vn [min-1]
active power -- 30 -- 4 25 [MW]
reactive power -- 0.8 -- 4.8 1.8 [Mvar]
stator voltage Un 10.8 Un 10.8 10.8 [kV]
stator current -- 1.65 -- 0.34 1.3 [kA]
field current 730 939 732 818 874 [A]

NDE Side voltage to earth 0 0 0 0 0 [Vdc]
10.9 11.3 10 10 11.7 [Vac rms]
34 31.6 30 30 34.5 [Vac pp]
main frequency 150 150 149 149 150 [Hz]
4.4.3 Characteristic Curves (Short Circuit & Open Circuit)



4.4.4 On-load Characteristics
GENERATOR ON LOAD CHARACTERISTIC
MEASUREM. UNIT 1 UNIT 2
PF 0.9
stator S 38.90 37.43 38.42 42.37 [MVA]
P 35.46 33.80 34.66 38.50 [MW]
Q 15.94 16.07 16.57 17.65 [Mvar]
PF 0.91 0.90 0.90 0.90
U 11.45 11.46 11.02 11.02 [kV]

I 1959 1887 2013 2210 [A]
Hz 49.92 49.00 49.90 49.65 [Hz]

Uf 95.10 95.90 88.90 105.00 [V]
rotor
1328.0 1318.0 1318.0 1386.0
If [A]
0 0 0 0

PF 1.0
stator S 9.98 19.83 29.42 40.99 42.25 43.01 3.95 9.94 10.00 19.94 35.27 [MVA]
P 9.84 19.54 29.37 40.78 40.8 42.85 3.93 9.86 9.98 19.91 35.14 [MW]
Q -0.9 -1.8 7.85 4.1 11 6.5 0.42 -1.27 -0.62 -1.02 3.03 [Mvar]
PF 0.99 0.99 1.00 1.00 1.00
U 10.78 10.75 11.20 10.55 10.67 10.65 10.67 10.85 10.75 [kV]

I 2199 2326 0.21 0.54 0.54 1.06 1.89 [kA]
Hz 49.70 49.80 49.60 49.77 50.30 [Hz]

Uf 45 49 81.7 72.3 99.3 54.4 .. .. .. .. 67.9 [V]
rotor
If 657.4 732 840 1100 1285 1094 688 683 786.8 952 [A]

4.4.5 Heat Run
GENERATOR HEAT RUN TEST
UNIT 1 UNIT 2
Generator short-
TEST n0:1 n0 1 n0 1
circuited
At rated load
n0:2 n02 n02

0 0 0
n 3: Generator overload n3 n3
date 20.01. 03.02.09 05.12.08 14.01.09 14.02.09
duration 3 5 2 4 4 [h]

ELECTRICAL
stator S 0 38.5 0 35 42.2 [MVA]
DATA
P 0 35 0 35 38.8 [MW]
Q 0 16 0 3 16.8 [Mvar]
cosΦ 0 0.9 NA 0.99 0.92
U 0 11.4 0 10.8 11.1 [kv]
I 2.05 1.95 2.05 1.86 2.2 [kA]
rotor Uf 43.6 96 46.3 70 105 [V]
if 666 1309 732 1000 1364 [A]



stator
TEMPERATURE average 53 70.5 53.1 62 82.3 [°C]
winding
max. 55 74 54 64 84 [°C]
stator core average 33 55 33 47.3 60.5 [°C]
max. 33 55 33 47.3 61 [°C]
rotor winding 36.4 74 27 50 84.9 [°C]
cooling air air inlet average 17 22.5 18 18.8 25.5 [°C]
max. 17 23 19 20.3 26 [°C]
air
average 31.2 45 30 37.2 49 [°C]
outlet
max. 32.2 45 30 37.3 49 [°C]
cooling water inlet 12 14 12.4 10.8 12 [°C]
cooling water outlet 15 21 16.5 17.1 22 [°C]
NDE bearing guide segment 40.4 41.2 52.4 44.6 44.8 [°C]
thrust segment 61.4 65.6 66 65 65.8 [°C]
oil 35.9 37 42 36.4 37 [°C]
guide bearing oil 36.4 38 42 36.6 38 [°C]
oil inlet 30 31 35 32.1 33 [°C]
oil outlet 36 38 43 37.8 39 [°C]
cooling water outlet 16 21 16.5 17.1 [°C]
DE bearing guide segment 46.7 45.8 53 51.9 50.4 [°C]
oil 37.9 39 41 43.4 44 [°C]
guide bearing oil 38.1 39 41 43.5 44 [°C]
oil inlet
35 36 37 37.3 38 [°C]

oil outlet 40 41 43 45.2 46 [°C]
cooling water outlet 16 21 16.5 17.1 [°C]

TEMPERATURE stator winding max.
38 48 35 45.2 58.5 [K]
RISE
stator core max.
(above cold air) 16 32.5 14 28.5 36.5 [K]

rotor winding
19.4 51.6 11 31.2 59.4 [K]

cooling air
15.2 22.5 11 18.5 23.5 [K]

air cooler cooling water 12 14 [K]

4.4.6 Load Rejections

Refer Sub-section 4.2.2

4.5 EXCITATION
4.5.1 Automatic Voltage Build-up Curve with the Automatic Channel (unit 1)
4.5.2 De-excitation Curve with the Automatic Channel by Field Breaker Opening (unit 1)

4.5.3 De-excitation Curve by Protection Trip with the Automatic Channel (unit 1)
4.5.4 +10% Stator Voltage Step with the Automatic Channel in Operation (unit 1)

4.5.5 Power System Stabilizer Tuning at rated Active Power without/with PSS (unit 2)

4.5.6 Transmission Line Charging with Unit 2

4.6 UNIT TRANSFORMERS
4.6.1 Heat Run

The transformer temperatures of unit 2 transformers were verified during generator heat run
test at overload (refer to clause 4.4.5 above). The unit was operated with approximately 42.2
MVA (38.8 MW and 16.8 Mvar) for about 4 hours. The winding/oil temperatures in the three
single phase transformers reached the following values by an ambient temperature of approx.
26 °C:
Transformer winding: 74 – 78 – 79 °C; Temp. rise over ambient of 26 °C: 48 – 52 – 53 °C;
Transformer Oil: 64 – 61 – 66 °C; Temp. rise over ambient of 26 °C: 38 – 35 – 40 °C;
These figures can be compared with the limit values spelled out in the contract as follows:
Max. temperature rise over ambient of 35 °C: Top oil/average winding (°C): 50/55;
Although the generator was operated at overload (rated output 39 MVA overload capability
47 MVA), the load at which the test was conducted (42.2 MVA) represented less than the
rated power of the transformers (3x14.5 = 43.5 MVA).
4.7 PENSTOCK BUTTERFLY VALVE

Closure of the penstock butterfly valve was tested against 25, 50, 75 and 100% of the
maximum flow. The tests were successful and the pressure rise in the tunnel remained well
below the permissible limits. The test data at the 100% flow are shown in the table below:
Penstock butterfly valve closure under flow:
Unit U1 U2 Limit
Power MW 37,5 36.9
Q total m3/s 85
HWL masl 625.2
H stat. PBV m 26.17
H max PBV m 43.1 74.9
The test confirmed safe functioning of the penstock valve.
The test was carried out with total flow of 85 m 3/s, this being the design flow for the valve.
But with both units operating at maximum opening and maximum head, approx. 2x41 MW
can be produced at the turbine shafts with a total flow of about 92 m 3/s.

5 GENERATOR PERFORMANCE TESTS

Performance tests (type tests) were carried out on generator No. 2. The below data are
extracted from the test records submitted by Alstom.
For details, reference is made to Alstom O&M manual W01-06, Index 12.
5.1 OHMIC RESISTANCE OF THE ROTOR WINDING

Measured: 58.7 mOhm at 31.0 °C; Calculated: 68.4 Ohm at 75.0 °C
5.2 OHMIC RESISTANCE OF THE STATOR WINDING

Measured: 8.3083 average per phase mOhm at 31.5 °C; Calculated: 9.6645 mOhm at 75.0 °C
5.3 OPEN-CIRCUIT CHARACTERISTIC

For result, see item 4.4 below.
5.4 THREE-PHASE SHORT-CIRCUIT CHARACTERISTIC


5.5 DIRECT AXIS SYNCHRONOUS REACTANCE AND SHORT-CIRCUIT RATIO

Calculated from Open-Circuit and Three-Phase Short-Circuit Characteristic
Measured Field Current

Air-gap field current Ifg = 612 A
Excitation current at rated armature voltage Ifo = 718 A
Excitation current at rated armature current Ifk = 662 A

Synchronous Reactance in Directional Axis
xd

Unsaturated value xd (measured) xd = Ifk / Ifg = 662 / 612 = 1.082 p. u.

Design value xd = 1.043 p. u.

Saturated value xd (measured) xd = Ifk / Ifo = 662 / 718 = 0.922 p.u.

Design value xd = 0.977 p. u.

Short - Circuit Ration Kc (Standard: IEC 60034-4 (1985) SECT. 27)

Field current at rated armature voltage Ifo = 718 A
Field current at rated armature current Ifk = 662 A
Kc = Ifo / Ifk = 718 / 662 =
Measured Value 1.08

Design value Kc = 1.06

5.6 DETERMINATION OF MOMENT OF INERTIA

The moment of inertia was determined by recording the essentially linear rate of speed rise
(63.5 rpm) during the first 1.04 sec. immediately following a load rejection at nominal load
(Standard: IEC 60034 – 4 (1985) Cl. 70, 71).
Result: Moment of Inertia (J) = 157 tm 2; (Design value 156 tm 2 (without turbine shaft and
runner).
Acceleration Time Constant: 5.46 sec.
5.7 WAVE FORM DEVIATION FACTOR

Measured deviation factor: 1.261%; Guaranteed value: ± 5%

5.8 DETERMINATION OF RATED EXCITATION CURRENT

The determination was done according standard IEEE 115 -1995 Cl. 5.3.
Measured Value: 1296 A; Calculated: 1288 A.
5.9 DETERMINATION OF GENERATOR EFFICIENCY
LOAD % 100 75 50
GENERATOR

DATA

APPARENT POWER MVA 39.00 29.25 19.50
ACTIVE POWER MW 35.10 26.33 17.55
REACTIVE
MVAr 17.00 12.74 8.50
POWER
POWER FACTOR
0.90 0.90 0.90
(overexcited)
ARMATURE VOLTAGE kV 11.00 11.00 11.00
ARMATURE CURRENT A 2046.97 1535.23 1023.48
ROTOR
V 88.62 76.45 65.65
VOLTAGE
ROTOR
A 1296.00 1118 960
CURRENT

MEASURED LOSSES

WINDAGE LOSSES P (windage)* kW 92.45 92.45 92.45
LOWER GUIDE BEARING LOSSES kW 10.31 10.31 10.31
COMBINED THRUST - GUIDE BEARING
kW 54.40 54.40 54.40
LOSSES
TOTAL MECHANICAL BRUSH LOSSES PB mech kW 1.30 1.30 1.30
TOTAL ELECTRICAL BRUSH LOSSES PB EL kW 5.18 4.47 3.84
ARMATURE COPPER LOSSES PCU 75* kW 121.48 68.34 30.37
ARMATURE STRAY LOSSES PSL* kW 62.71 35.27 15.68
CORE LOSSES PFE* kW 119.58 119.58 119.58
ROTOR LOSSES Pt75* kW 114.86 85.47 63.02
EXCITATION LOSSES PEX (Excit. Transformer and
kW 10.00 8.00 6.00
converters)

TOTAL MEASURED
kW 592.27 479.60 396.95
LOSSES

TEST DATA

GENERATOR ACTIVE kW 35100.00 26325.00 17550.00

POWER
GENERATOR ACTIVE INPUT POWER kW 35692.27 26804.60 17946.95

MEASURED EFFICIENCY % 98.34 98.21 97.79

GUARANTEED VALUES

GUARANTEED EFFICIENCY
% 98.420 98.320 97.950
(CONTRACT)
TOTAL GUARANTEED LOSSES kW 563.483 449.817 367.305
TOTAL GUARANTEED LOSSES (Maximum)* kW 619.831 494.799 404.035
DIFFERENCE TOTAL GUARANTEED kW 27.56 15.20 7.080
LOSSES - TOTAL MEASURED

LOSSES

* Max. Losses with the tolerance of - 10% x (1-η) according IEC 60034-1 Sect. 11 Standard

6 COMMISSIONING SCHEDULE
6.1 BASIC COMMISSIONING SCHEDULE DATED 20.11.2009
The wet commissioning of MMHEP was carried out based on the below schedule

PCR V4 P4C Commissioning

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PCR V4 P4C Commissioning

Uploaded by

Copyright:

Available Formats

Nepal Electricity Authority

Kreditanstalt für Wiederaufbau

Middle Marsyangdi Hydroelectric Project (MMHEP)

Project Completion Report

- Project Commissioning Report-

Fichtner GmbH & Co. KG Statkraft Grøner ASOslo- Consulting Engineers

Fichtner JV Site Office

Phone: +977 (19) 542 509

Fichtner JV Kathmandu Office

Phone: +977 (1) 55 36 768

4.1 MAIN INLET VALVE 18

Voith Siemens O&M Manuals Lot M:

3 TESTS DURING ASSEMBLY AND PRE-COMMISSIONING

3.1.1 MIV Closing in Dead Water

MIV No. 1 Opening Time 39 sec. Closing Time 84 sec.

March 2010 FICHTNER JV 1

3.2.1 Opening and Closing Time of Wicket Gate in Dry Condition

March 2010 FICHTNER JV 2

3.2.2 Closing Tendency of Wicket Gate

March 2010 FICHTNER JV 3

3.3 TURBINE GOVERNORS

3.3.1 Oil Accumulator Volume Test

March 2010 FICHTNER JV 4

3.3.2 Governor Dead Band/Sensitivity Test (at Factory)

March 2010 FICHTNER JV 5

March 2010 FICHTNER JV 6

3.3.3 Governor Dead Time Test (at Factory)

3.4.1 Stator Winding HV Testing

STATOR WINDING - INSULATION TESTS WITH 500 VDC

INSULATION Measurement of each

March 2010 FICHTNER JV 7

3.4.2 Stator Winding Insulation Resistance Measurement

3.4.3 Stator Winding Ohmic Resistance Measurement

March 2010 FICHTNER JV 8

3.4.4 Inside Diameter Stator Wound

3.4.5 Rotor Winding – Ohmic Resistance Measurement

March 2010 FICHTNER JV 9

3.4.6 Rotor Winding AC Voltage Test

3.4.7 Rotor Winding – Insulation Resistance Measurement

3.4.8 Diameter Rotor Complete

March 2010 FICHTNER JV 10

Pole 6-15 3609.41 3608.69 3609.05 -0.95

3.5 EXCITATION SYSTEM

3.6 CO2 GENERATOR FIRE EXTINGUISHING SYSTEM

3.7 UNIT TRANSFORMERS

3.7.1 Insulation Resistance

3.7.2 Ratio Test

Tap No. Connection Measured Ratio Calculated Ratio

March 2010 FICHTNER JV 11

Same measured ratio in all 7 transformers.

3.7.3 Magnetizing Current Test

Applied Voltage Measured

3.7.4 Short Circuit Test

Transformer SI. Applied voltage in Measured Current Measured Current

March 2010 FICHTNER JV 12

3 226.3 3.0 22.9

3.7.5 Winding Resistance

March 2010 FICHTNER JV 13

3.8 110 BATTERIES

3.8.1 Power House Discharge Test 10 Hours 110 A

3.8.2 Headworks Discharge Test 10 Hours 54.6 A

March 2010 FICHTNER JV 14

3.9 132 & 33 KV TRANSMISSION LINES