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XB-P3-GE-Q-0000-9101 - R00 - General - EGAT Unit 1 - Wet Commissioning Procedure

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142 views122 pages

XB-P3-GE-Q-0000-9101 - R00 - General - EGAT Unit 1 - Wet Commissioning Procedure

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Toi Toi

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XAYABURI POWER COMPANY LIMITED

XAYABURI HYDROELECTRIC POWER PROJECT

LAO PEOPLE'S DEMOCRATIC REPUBLIC

APPROVED BY: CHECKED BY:

DATE: DATE:

00 First Issue 09.08.2017 FC LH-DE RM

Index Modification Date Prepared Checked Approved
Title:
Wet Commissioning Procedure
General – EGAT Unit 1

Client CH. KARNCHANG Drawn 09.08.2017 FC Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP Checked 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
Project N° H100.002288 Approved 09.08.2017 RM 00 Page 1 de / of 122
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DOC Nº XB-P3-GE-Q-0000-9101
#
CONTENT

1 GENERAL ....................................................................................................................................... 9
1.1 Purpose of this Document ......................................................................................................................... 9
1.2 General Conditions ..................................................................................................................................... 9
1.3 Special Conditions ...................................................................................................................................... 9
1.4 Design Parameters and Operational Data ................................................................................................ 9
1.4.1 Turbine .......................................................................................................................................................... 9
1.4.2 Generator .................................................................................................................................................... 11
1.5 List of Reference Documents .................................................................................................................. 13
2 FILLING OF WATERWAYS .............................................................................................................. 14
2.1 Filling of Waterways from Downstream and Associated Tests ........................................................... 14
2.1.1 Filling of Waterways - Downstream............................................................................................................. 14
2.1.1.1 Reference Documents ........................................................................................................................... 14
2.1.1.2 Pre-Condition ......................................................................................................................................... 14
2.1.1.3 Performance of Test............................................................................................................................... 14
2.1.1.4 Conclusion ............................................................................................................................................. 15
2.1.2 Draft Tube Dewatering Test (First Unit only)............................................................................................... 16
2.1.2.1 Pre-Conditions ....................................................................................................................................... 16
2.1.2.2 Performance of Test............................................................................................................................... 17
2.1.2.3 Conclusion ............................................................................................................................................. 17
2.1.3 Filling of Waterways from Downstream – Associated Tests and Activities................................................. 18
2.1.3.1 Cooling Water System ........................................................................................................................... 18
2.1.3.2 Shaft Seal ............................................................................................................................................... 18
2.1.3.3 Conclusion ............................................................................................................................................. 18
2.2 Filling of Waterways - Upstream.............................................................................................................. 19
2.2.1 Filling of Turbine .......................................................................................................................................... 19
2.2.1.1 Reference Documents ........................................................................................................................... 19
2.2.1.2 Pre-Condition ......................................................................................................................................... 19
2.2.1.3 Performance of Test............................................................................................................................... 19
2.2.1.4 Conclusion ............................................................................................................................................. 19
3 FIRST RUN AND MECHANICAL TESTS............................................................................................. 20
3.1 First Run (EGAT PPA - Test) ................................................................................................................... 20
3.1.1 Reference Documents ................................................................................................................................ 20
3.1.2 Preparations and Preconditions .................................................................................................................. 20
3.1.3 First Turn – check mechanical free running ................................................................................................ 21
3.1.4 Increase Speed up to 100% ........................................................................................................................ 21
3.1.4.1 Emergency Stop Test (EGAT PPA – Test) ........................................................................................... 21
3.1.5 Conclusion................................................................................................................................................... 22
3.2 Balancing (EGAT PPA - Test).................................................................................................................. 23
3.2.1 Reference Documents ................................................................................................................................ 23
3.2.2 Performance of Test .................................................................................................................................... 23
3.2.3 Conclusion................................................................................................................................................... 23
3.3 Bearing Heat Run ...................................................................................................................................... 24
3.3.1 Reference Documents ................................................................................................................................ 24
3.3.2 Performance of Test .................................................................................................................................... 24
3.3.3 Conclusion................................................................................................................................................... 24
3.4 Over-Speed Test (EGAT PPA – Test) ...................................................................................................... 25
3.4.1 Reference Documents ................................................................................................................................ 25
3.4.2 Preparation .................................................................................................................................................. 25
3.4.3 Electrical Overspeed ................................................................................................................................... 25
3.4.4 Mechanical Overspeed ............................................................................................................................... 25
3.4.5 Final Works ................................................................................................................................................. 26
3.4.6 Conclusion................................................................................................................................................... 26
Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
Project N° H100.002288 09.08.2017 RM LH-DE 00 Page 2 de / of 122
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3.5 General Inspection After Overspeed-Test (EGAT PPA – Test) ............................................................ 27
3.5.1 Preparation .................................................................................................................................................. 27
3.5.2 Performance ................................................................................................................................................ 27
3.5.3 Conclusion................................................................................................................................................... 27
4 SHORT CIRCUIT TESTS ................................................................................................................. 28
4.1 Reference Documents .............................................................................................................................. 28
4.2 General ....................................................................................................................................................... 28
4.2.1 Sequence of Tests: ..................................................................................................................................... 28
4.2.2 Set-Up of Temporary Power Supply for Excitation System ........................................................................ 28
4.3 3-Phase Short Circuit on Generator Bus Duct (16kV) ........................................................................... 29
4.3.1 Reference Documents ................................................................................................................................ 29
4.3.2 Preparation .................................................................................................................................................. 29
4.3.3 Performance of Test .................................................................................................................................... 32
4.3.3.1 Tests for Generator (EGAT PPA – Test) .............................................................................................. 32
4.3.3.2 Tests for Excitation System (EGAT PPA – Test) .................................................................................. 32
4.3.3.3 Tests for Control System (EGAT PPA_Test) ........................................................................................ 33
4.3.3.4 Tests for Protection System (EGAT PPA – Test) ................................................................................. 33
4.3.4 Final Activities after the 3-phase short circuit test ....................................................................................... 34
4.3.5 Conclusion................................................................................................................................................... 34
4.4 2-Phase Short Circuit Tests (Type Tests) ............................................................................................... 35
4.4.1 General ........................................................................................................................................................ 35
4.4.2 Preparation .................................................................................................................................................. 35
4.4.3 2-Phase Short Circuit Test .......................................................................................................................... 36
4.4.4 2-Phase + N Short Circuit Test ................................................................................................................... 36
4.4.5 Final Activities after the Short Circuit Tests on 16kV Bus-Duct .................................................................. 36
4.4.6 Conclusion................................................................................................................................................... 36
4.5 Short-Circuit on 500kV.............................................................................................................................. 37
4.5.1 General ........................................................................................................................................................ 37
4.5.2 Preparation .................................................................................................................................................. 37
4.5.3 Performance of Test .................................................................................................................................... 38
4.5.3.1 Tests for Control System........................................................................................................................ 39
4.5.3.2 Tests for Protection System (EGAT PPA – Test) ................................................................................. 39
4.5.4 Final Activities after the Short Circuit Test .................................................................................................. 39
4.5.5 Conclusion................................................................................................................................................... 40
4.6 Short Circuit on Unit Auxiliary Transformer .......................................................................................... 41
4.6.1 Preparation .................................................................................................................................................. 41
4.6.2 Performance of Test .................................................................................................................................... 43
4.6.2.1 Tests for Protection System (EGAT PPA – Test) ................................................................................. 43
4.6.3 Final Activities after the Short Circuit Test .................................................................................................. 44
4.6.4 Conclusion................................................................................................................................................... 44
5 EARTH FAULT TESTS .................................................................................................................... 45
5.1 Reference Documents .............................................................................................................................. 45
5.2 General ....................................................................................................................................................... 45
5.3 Earth Fault on Generator Bus Duct (16kV) ............................................................................................. 45
5.3.1 Preparation .................................................................................................................................................. 45
5.3.2 Performance of Test .................................................................................................................................... 45
5.3.2.1 Test for Protection System (EGAT PPA – Test) ................................................................................... 45
5.3.3 Final Activities after the Earth Fault Test .................................................................................................... 46
5.3.4 Conclusion................................................................................................................................................... 46
5.4 Stator Inter-Turn Fault .............................................................................................................................. 47
5.4.1 Preparation .................................................................................................................................................. 47
5.4.2 Performance of Test .................................................................................................................................... 48
5.4.2.1 Test for Protection System (EGAT PPA – Test) ................................................................................... 48
5.4.3 Final Activities after the Earth Fault Test .................................................................................................... 48
5.4.4 Conclusion................................................................................................................................................... 48
5.5 Earth Fault on Generator Neutral Point .................................................................................................. 49

Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
Project N° H100.002288 09.08.2017 RM LH-DE 00 Page 3 de / of 122
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5.5.1 Preparation .................................................................................................................................................. 49
5.5.2 Performance of Test .................................................................................................................................... 50
5.5.2.1 Test for Protection System (EGAT PPA – Test) ................................................................................... 50
5.5.3 Final Activities after the Earth Fault Test .................................................................................................... 51
5.5.4 Conclusion................................................................................................................................................... 51
5.6 Earth Fault on 500kV ................................................................................................................................. 52
5.6.1 Preparation .................................................................................................................................................. 52
5.6.2 Performance of Test .................................................................................................................................... 52
5.6.2.1 Tests for Protection System (EGAT PPA – Test) ................................................................................. 52
5.6.3 Final Activities after the Earth Fault Test .................................................................................................... 53
5.6.4 Conclusion................................................................................................................................................... 53
5.7 Earth Fault at Unit Auxiliary Transformer ............................................................................................... 54
5.7.1 Preparation .................................................................................................................................................. 54
5.7.2 Performance of Test .................................................................................................................................... 54
5.7.2.1 Tests for Protection System (EGAT PPA – Test) ................................................................................. 55
5.7.3 Final Activities after the Earth Fault Test .................................................................................................... 55
5.7.4 Conclusion................................................................................................................................................... 55
6 NO-LOAD TESTS (OPEN CIRCUIT) ................................................................................................. 56
6.1 Reference Documents .............................................................................................................................. 56
6.2 General ....................................................................................................................................................... 56
6.3 Open-Circuit Test without Excitation ...................................................................................................... 56
6.3.1 Performance of Test .................................................................................................................................... 57
6.3.1.1 Generator Phase Sequence Test (EGAT PPA – Test) ......................................................................... 57
6.3.2 Final Activities after the Test ....................................................................................................................... 57
6.4 No-Load Tests with External Excitation Supply .................................................................................... 57
6.4.1 Performance of Test .................................................................................................................................... 57
6.4.1.1 Open Circuit Tests for Generator (EGAT PPA – Test) ......................................................................... 58
6.4.1.2 Open Circuit Tests for Protection System (EGAT PPA – Test) ............................................................ 58
6.4.1.3 Open Circuit Tests for Excitation System (EGAT PPA – Test) ............................................................. 59
6.4.2 Final Activities after the Test ....................................................................................................................... 59
6.5 No-Load Tests with Regular Excitation Supply ..................................................................................... 59
6.5.1 Performance of Test .................................................................................................................................... 59
6.5.1.1 Open Circuit Tests for Excitation System (EGAT PPA – Test) ............................................................. 59
6.5.1.2 No-Load Tests for Turbine Governor (EGAT PPA – Test) ................................................................... 60
6.5.1.3 Tests for Control System (EGAT PPA_Test) ........................................................................................ 60
6.5.2 Final Activities after the Test ....................................................................................................................... 61
6.6 Conclusion ................................................................................................................................................. 61
6.6.1 No-Load Tests for Generator ...................................................................................................................... 61
6.6.2 No-Load Tests for Turbine .......................................................................................................................... 62
6.6.3 No-Load Tests for Excitation System .......................................................................................................... 62
6.6.4 No-Load Tests for Protection System ......................................................................................................... 62
7 SYNCHRONIZING TESTS AND ENERGIZING OF MAIN TRANSFORMER ......................................... 63
7.1 General ....................................................................................................................................................... 63
7.2 First Energizing of Main Transformer and Synchro-Check .................................................................. 63
7.2.1 Reference Documents ................................................................................................................................ 63
7.2.2 Preparation .................................................................................................................................................. 63
7.2.3 First Energizing of Main Transformer .......................................................................................................... 64
7.2.4 Synchro –Check (EGAT PPA Test) ........................................................................................................... 64
7.2.5 Final Activities after the Tests ..................................................................................................................... 65
7.2.6 Conclusion................................................................................................................................................... 65
7.3 Synchronizing Tests (EGAT PPA Test) .................................................................................................. 66
7.3.1 Pre-Condition: ............................................................................................................................................. 66
7.3.2 Reference Documents ................................................................................................................................ 66
7.3.3 Synchronizing Tests with 500kV CB ........................................................................................................... 66
7.3.3.1 Preparation ............................................................................................................................................. 66
7.3.3.2 Performance of Test............................................................................................................................... 66

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7.3.3.3 Tests for Turbine Governor .................................................................................................................... 67
7.3.3.4 Tests for Excitation System.................................................................................................................... 67
7.3.3.5 Tests for Control System........................................................................................................................ 67
7.3.3.6 Conclusion ............................................................................................................................................. 67
7.3.4 Synchronizing Tests with 16kV CB ............................................................................................................. 68
7.3.4.1 Preparation ............................................................................................................................................. 68
7.3.4.2 Performance of Test............................................................................................................................... 68
7.3.4.3 Tests for Turbine Governor .................................................................................................................... 68
7.3.4.4 Tests for Excitation System.................................................................................................................... 68
7.3.4.5 Tests for Control System........................................................................................................................ 69
7.3.4.6 Conclusion ............................................................................................................................................. 69
7.4 Back-Energizing and No-Load Test of Main Transformer (EGAT PPA Test) ...................................... 70
7.4.1 Preparation .................................................................................................................................................. 70
7.4.2 Performance ................................................................................................................................................ 71
7.4.3 Conclusion................................................................................................................................................... 71
8 VERIFICATION OF WATER LEVEL MEASUREMENT (EGAT PPA TEST) .......................................... 72
8.1 Conclusion ................................................................................................................................................. 72
9 THE GENERATOR STABILITY DATA (EGAT PPA TEST) ................................................................. 73
9.1 Unit Inertia Constant H ............................................................................................................................. 73
9.2 Generator Unsaturated Direct Transient Reactance Xd’ ....................................................................... 73
9.3 Generator Unsaturated Direct Sub-Transient Reactance Xd’’ .............................................................. 73
9.4 Generator Open Circuit Transient Time Constant Tdo’ .......................................................................... 73
9.4.1 Purpose of this Test .................................................................................................................................... 73
9.4.2 Preparation of Field Current Decay Test..................................................................................................... 74
9.4.3 Performance of Test .................................................................................................................................... 74
9.4.4 Final Activities. ............................................................................................................................................ 74
9.5 Unit Step-Up Transformer Short-Circuit Reactance Xt .......................................................................... 74
9.6 Unit Excitation System Ceiling Voltage Up ............................................................................................. 75
9.7 Other the Generator Stability Data .......................................................................................................... 75
9.8 Conclusion ................................................................................................................................................. 75
10 UNIT METERING SYSTEM CHECK AND ACCURACY TEST (EGAT PPA TEST) .................................. 76
10.1 Reference Documents .............................................................................................................................. 76
10.2 Tests at Pre-Energization Commissioning Phase ................................................................................. 76
10.2.1 Primary VT and CT Tests ............................................................................................................................ 76
10.2.2 Function Tests ............................................................................................................................................. 76
10.2.3 Conclusion................................................................................................................................................... 76
10.3 Tests at Post-Energization Commissioning Phase ............................................................................... 77
10.3.1 Metering Function Tests .............................................................................................................................. 77
10.3.2 Conclusion................................................................................................................................................... 77
11 FIRST SYNCHRONIZATION ............................................................................................................. 78
11.1 Reference Documents .............................................................................................................................. 78
11.2 Performance of Test.................................................................................................................................. 78
11.2.1 First Synchronization with 16kV GCB ......................................................................................................... 78
11.2.1.1 Initial Condition ....................................................................................................................................... 78
11.2.1.2 First synchronizing attempt in manual mode ......................................................................................... 78
11.2.1.3 Second synchronizing attempt in automatic mode: ............................................................................... 79
11.2.2 First Synchronization with 500kV Unit Feeder CB ...................................................................................... 79
11.2.2.1 Initial Condition ....................................................................................................................................... 79
11.2.2.2 First synchronizing attempt in manual mode ......................................................................................... 79
11.2.2.3 Second synchronizing attempt in automatic mode: ............................................................................... 79
11.3 Conclusion ................................................................................................................................................. 80
12 LOAD TESTS ................................................................................................................................. 81
12.1 General ....................................................................................................................................................... 81
12.2 Reference Documents .............................................................................................................................. 81
12.3 Load Rejection Test – Preliminary (EGAT PPA Test) ........................................................................... 82
Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
Project N° H100.002288 09.08.2017 RM LH-DE 00 Page 5 de / of 122
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12.3.1 Performance of Test .................................................................................................................................... 82
12.3.1.1 Tests for Turbine .................................................................................................................................... 83
12.3.1.2 Tests for Excitation System.................................................................................................................... 83
12.3.1.3 Test for Protection System ..................................................................................................................... 83
12.3.1.4 Tests for Control System........................................................................................................................ 83
12.3.2 Conclusion................................................................................................................................................... 83
12.4 Shut-Down Tests ESD / QSD .................................................................................................................... 84
12.4.1 Performance of Test .................................................................................................................................... 84
12.4.1.1 Tests for Turbine .................................................................................................................................... 84
12.4.1.2 Tests for Control System........................................................................................................................ 84
12.4.2 Conclusion................................................................................................................................................... 85
12.5 Intake Gate Emergency Shut-Down Test ................................................................................................ 86
12.5.1 General ........................................................................................................................................................ 86
12.5.2 Preparation .................................................................................................................................................. 86
12.5.3 Performance of Test .................................................................................................................................... 86
12.5.4 Final Activities ............................................................................................................................................. 86
12.5.5 Conclusion................................................................................................................................................... 86
13 LOAD RUN .................................................................................................................................... 87
13.1 Reference Documents .............................................................................................................................. 87
13.2 Recording of Power Factor Zero Characteristic (V-Curve) ................................................................... 88
13.2.1 Performance of Test .................................................................................................................................... 88
13.2.2 Conclusion................................................................................................................................................... 88
13.3 Load Controller Tests ............................................................................................................................... 89
13.3.1 Load Step Response ................................................................................................................................... 89
13.3.1.1 Reference Documents ........................................................................................................................... 89
13.3.1.2 Performance of test: ............................................................................................................................... 89
13.3.1.3 Conclusion ............................................................................................................................................. 89
13.3.2 Frequency Response Test (EGAT PPA Test) ........................................................................................... 90
13.3.2.1 Reference Documents ........................................................................................................................... 90
13.3.2.2 Performance of test: ............................................................................................................................... 90
13.3.2.3 Conclusion ............................................................................................................................................. 91
13.3.3 Steady-State Load Band ............................................................................................................................. 92
13.3.3.1 Reference Documents ........................................................................................................................... 92
13.3.3.2 Performance of test: ............................................................................................................................... 92
13.3.3.3 Conclusion ............................................................................................................................................. 92
13.4 Turbine Load Tests ................................................................................................................................... 93
13.4.1 Load Run (EGAT PPA Test) ...................................................................................................................... 93
13.4.1.1 Reference Documents: .......................................................................................................................... 93
13.4.1.2 Performance of Test:.............................................................................................................................. 93
13.4.1.3 Conclusion ............................................................................................................................................. 93
13.5 Servo-Motor Indexing Test ....................................................................................................................... 94
13.5.1 Reference Documents ................................................................................................................................ 94
13.5.2 Performance of Test: ................................................................................................................................... 94
13.5.3 Conclusion................................................................................................................................................... 94
13.6 Generator Load Tests, Confirmation of Capability Diagram ................................................................ 95
13.6.1 Load Angle Measurement ........................................................................................................................... 95
13.6.1.1 Reference Documents ........................................................................................................................... 95
13.6.1.2 Performance of test: ............................................................................................................................... 95
13.6.1.3 Conclusion ............................................................................................................................................. 95
13.6.2 Reactive Power Capability Test (EGAT PPA Test).................................................................................... 96
13.6.2.1 Reference Documents ........................................................................................................................... 96
13.6.2.2 Performance of Test:.............................................................................................................................. 96
13.6.2.3 Conclusion ............................................................................................................................................. 97
13.7 Excitation Load Tests and PSS-Tests (EGAT PPA Test) ..................................................................... 98
13.7.1 Reference Documents ................................................................................................................................ 98
13.7.2 Conclusion................................................................................................................................................... 98
14 FULL LOAD HEAT RUN – PRELIMINARY (EGAT PPA TEST) .......................................................... 99
Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
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14.1 Performance of Test.................................................................................................................................. 99
14.2 Data Recorded during the Full Load Heat Run ...................................................................................... 99
14.2.1 Data Relevant for Generator ....................................................................................................................... 99
14.2.2 Data Relevant for Turbine ......................................................................................................................... 100
14.2.3 Data Relevant for Main Transformer ......................................................................................................... 100
14.3 Final Adjustments and Inspections....................................................................................................... 100
14.4 Conclusion ............................................................................................................................................... 100
15 TRANSMISSION CIRCUIT ENERGIZING (EGAT PPA TEST) ........................................................... 101
15.1 Initial Condition ....................................................................................................................................... 101
15.2 Transmission Circuit 1 Energizing ........................................................................................................ 101
15.3 Transmission Circuit 2 Energizing ........................................................................................................ 101
15.4 Conclusion ............................................................................................................................................... 102
16 DETERMINATION OF MACHINE QUANTITY (TYPE TEST) ................................................................ 103
16.1 Sudden Short-Circuit Test ...................................................................................................................... 103
16.1.1 Reference Documents .............................................................................................................................. 103
16.1.2 Preparation ................................................................................................................................................ 103
16.1.3 Performance of Test .................................................................................................................................. 103
16.2 Voltage Recovery Test ............................................................................................................................ 104
16.2.1 Reference Documents .............................................................................................................................. 104
16.2.2 Preparation: ............................................................................................................................................... 104
16.2.3 Performance of Test .................................................................................................................................. 104
16.3 Conclusion ............................................................................................................................................... 104
17 CALORIC DETERMINATION OF PARTIAL LOSSES (EFFICIENCY) ..................................................... 105
17.1 Efficiency Test Heat Runs (Type Test) ................................................................................................. 105
17.1.1 Reference Documents .............................................................................................................................. 105
17.1.2 Preparation ................................................................................................................................................ 105
17.1.3 Performance of Efficiency Test Heat Runs ............................................................................................... 105
17.1.3.1 Zero Excitation Heat Run ..................................................................................................................... 105
17.1.3.2 Open Circuit Heat Run ......................................................................................................................... 105
17.1.3.3 Short Circuit Heat Run ......................................................................................................................... 106
17.1.3.4 Full Load Heat Run .............................................................................................................................. 106
17.2 Measurement of Exciter and Auxiliary Losses .................................................................................... 107
17.2.1 Reference Documents .............................................................................................................................. 107
17.2.2 Performance of Test .................................................................................................................................. 107
17.2.2.1 Excitation System Losses .................................................................................................................... 107
17.2.2.2 Auxiliary Losses ................................................................................................................................... 107
17.3 Conclusion ............................................................................................................................................... 107
18 GENERATING UNIT PERFORMANCE TESTS & FIELD ACCEPTANCE TESTS ..................................... 108
18.1 Load Rejection Test at Rated Head (Hnet = 28.5m) .............................................................................. 108
18.1.1 Performance of Test .................................................................................................................................. 108
18.1.2 Conclusion................................................................................................................................................. 108
18.2 Load Step Response Test at Rated Head (Hnet = 28.5m) .................................................................... 109
18.2.1 Performance of Test .................................................................................................................................. 109
18.2.2 Conclusion................................................................................................................................................. 109
18.3 Heat Run at Nominal Load (EGAT PPA Test) ...................................................................................... 110
18.3.1 Performance of Test .................................................................................................................................. 110
18.3.2 Conclusion................................................................................................................................................. 110
18.4 Index Test ................................................................................................................................................. 111
18.5 Hydraulic Thrust Measurement ............................................................................................................. 112
18.5.3 Conclusion................................................................................................................................................. 112
19 EGAT PPA PERFORMANCE TESTS ............................................................................................. 113
19.1 Modes of Operation Test (EGAT PPA Test) ......................................................................................... 113
19.1.1 Reference Documents .............................................................................................................................. 113
19.1.2 Tests for Control System ........................................................................................................................... 113
19.1.2.1 Check of Sequence Timers .................................................................................................................. 113
Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
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19.1.2.2 Overall Performance Test .................................................................................................................... 113
19.1.3 Tests for Turbine ....................................................................................................................................... 114
19.1.4 Conclusion................................................................................................................................................. 114
19.2 Unit Minimum Capacity Stability Test (EGAT PPA Test).................................................................... 115
19.2.1 Performance of Test .................................................................................................................................. 115
19.2.2 Conclusion................................................................................................................................................. 115
19.3 Maximum Power Output Test / Unit Capacity Test (EGAT PPA Test) ............................................... 116
19.3.1 Reference Documents .............................................................................................................................. 116
19.3.2 Performance of Test .................................................................................................................................. 116
19.3.3 Conclusion................................................................................................................................................. 116
19.4 Unit Loading / De-Loading Test (EGAT PPA Test).............................................................................. 117
19.4.1 Reference Documents .............................................................................................................................. 117
19.4.2 Performance of Test .................................................................................................................................. 117
19.4.3 Conclusion................................................................................................................................................. 117
19.5 Unit Primary Response Test and AGV Performance (EGAT PPA Test) ........................................... 118
19.5.1 Performance of Test .................................................................................................................................. 118
19.5.2 Conclusion................................................................................................................................................. 118
20 UNIT 1 TRIAL RUN ...................................................................................................................... 119
20.1 Unit Trial Run Continuous Operation Test (EGAT PPA Test) ............................................................ 119
20.1.1 Performance of Test .................................................................................................................................. 119
20.1.2 Conclusion................................................................................................................................................. 119
20.2 Unit Trial Run Start and Stop Test (EGAT PPA Test) ......................................................................... 120
20.2.1 Performance of Test .................................................................................................................................. 120
20.2.2 Conclusion................................................................................................................................................. 120
20.3 Unit Trial Run (PTS) ............................................................................................................................... 121
20.3.1 Performance of Test .................................................................................................................................. 121
20.3.2 Conclusion................................................................................................................................................. 121
21 COPYRIGHT ................................................................................................................................ 122

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
1 GENERAL

1.1 Purpose of this Document

This document shall give an overview of the “Wet-” Commissioning activities of Xayaburi Project. It is meant to
be a guide to the complete Commissioning Team either of the Contractors Andritz Hydro as well as of the Cus-
tomer CHK, GOL-E and any of their contracted third parties, without a definite requirement and /or must to per-
form the tests in the same sequence as listed in this document. The respective commissioning engineer of the
Contractor Andritz Hydro is entitled to change the sequence of tests in case it is required due to technical or op-
erational circumstances; this applies especially to short-term changes. Any such change will be communicated
to and coordinated with the entire commissioning team, principally on-site during the upcoming regular Com-
missioning Coordination Meetings. Depending on the operational possibilities of the installation to be tested
some tests can be performed with modified test settings that will be evaluated by the Contractors commission-
ing engineers. For performance of tests the applicable approved standards, essentially IEC Publications shall be
observed.

1.2 General Conditions

All relevant data (bearing vibration, temperatures, pressure & flow measurements, current & voltage measure-
ments etc.) will be monitored and recorded throughout the whole wet testing period.
For details to the tests listed in this document please refer to the latest, actual revision of the relevant Site Test
Procedure / Inspection Test Plan (ITP) / Test Record Sheet.
For electrical tests also refer to the relevant Single Line Diagrams.
All sketches, drawings and pictures in this document are for information only and might not be fully in accord-
ance with the latest revision of the original document.

1.3 Special Conditions

The interface to any third party company at Xayaburi Project to which the Contractor Andritz Hydro does not
have any contractual relationship with (such as P1, P2 and P4) but which are somehow affected by the globally
planned and in this document described Commissioning works (e.g. Impounding, Gates, 550kV Line etc.) is
clearly the responsibility of CHK, thereof also the verification and validation of defined procedures, activities and
data!

1.4 Design Parameters and Operational Data

1.4.1 Turbine

Design parameters of the Kaplan turbine Unit Value

Turbine data

Number of units - 7

Type of units - Kaplan, vertical

Rotational direction of turbine runner, viewed from above - clockwise

Rated turbine discharge m3/s 665.0

Rated turbine output at rated net head, approx. MW 175.0

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
Design parameters of the Kaplan turbine Unit Value

Maximum turbine discharge m3/s 700.0

Maximum turbine output (limited) MW 182.0

Turbine speed rpm 83.33

Runaway speed (nrun) rpm ≤ 235.0

st
1 critical bending speed (turbine and generator) rpm nrun + 20 %

Outer runner diameter, approx. m 8.60

Elevation at wicket gate centre line, approx. m a.s.l. 229.50

Elevation at runner centre line m a.s.l. 226.00

Elevation at entry of draft tube, approx. m a.s.l. 223.50

Elevation at draft tube invert m a.s.l. 206.00

Maximum permissible pressure rise % 15.0

Maximum permissible speed rise for turbine load rejection % 60.0

Maximum working pressure for all turbine parts under water

kPa 700
pressure (design pressure)

Modes of operation

Run of river operation yes

Operating on an isolated grid no

Synchronous condenser operation no

Spinning reserve operation no

Black Start yes

Hydraulic Conditions Unit Value

Headwater levels

Maximum exceptional operating level m a.s.l. 277.50

Maximum water level m a.s.l. 275.00

Minimum water level m a.s.l. 268.00

Tailwater levels

Maximum flood level m a.s.l. 268.70

Maximum operating level m a.s.l. 255.70

Operating level at rated discharge m a.s.l. 245.50

Minimum operating level
m a.s.l. 240.00
with downstream power plant Pak Lay built and in operation

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
Hydraulic Conditions Unit Value
Minimum operating level
m a.s.l. 236.00
without downstream power plant Pak Lay
Turbine net heads
Maximum net head
m 35.0
with downstream power plant Pak Lay build and in operation
Maximum net head
m 39.0
without downstream power plant Pak Lay
Rated net head m 28.5

Minimum net head m 18.3

Minimum net head in exceptional operation m 17.3

Water temperatures
Maximum water temperature
°C 30
(to be used for cavitation guarantee)
Minimum water temperature (to be used for determination of proto-
°C 20
type performance with consideration of scale effects)

Turbine Characteristics Unit Value

Type of turbine - Kaplan
3
Maximum turbine discharge m /s 7 x 700
Range of net head m 17.3 – 39.0
Rated turbine output MW ca. 175.0
Maximum turbine output MW ca. 182.0
Rated frequency Hz 50.0
Rated speed rpm 83.33
Runaway speed nrun rpm ≤ 235
Permissible speed rise for turbine load rejection related to the rated
% ≤ 60.0
speed

1.4.2 Generator

Design parameters of the Generator Unit Value

Number of units - 7
Type 3 phase, syn-
-
chronous
Shaft position - Vertical
Rotational direction of generator rotor, viewed from above clockwise
Type designation (IEC 60034-7) - IM 8225
Current system - three- phase AC

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
Design parameters of the Generator Unit Value
Number of phases - 3
Number of armature winding terminals line side - 3
Number of armature winding terminals neutral side One per phase
and parallel cir-
cuit
Rated apparent power MVA 200
Rated speed (n) rpm 83.33
Runaway speed nrun rpm ≤ 235
Power factor (cos φ) overexcited - 0.9
Rated voltage kV 16.0
Range of voltage variation / regulation % ± 10%
Rated current A 7216.9
Rated frequency Hz 50
Range of frequency variation Hz -3 / +2
Continuous unbalanced load - 12 %
Generator line charging capability apparent power - > 70 %
Insulation of stator / rotor windings (IEC) - Class F
Permissible temperature rises referred to rated power in considera- Class B
tion of IEC 60034 – 1.
Moment of Inertia J (mass x square radius) of generator not less tm2 approx. 20800
than:
Inner diameter of stator for passage turbine components m 13.45
(to be coordinated with turbine data)
Short circuit ratio (s.c.r.) saturated not less than p.u. 1.1
Direct axis saturated subtransient reactance (xd”) not less than % 20
Maximum ambient temperature in power house machine hall °C 40
Cooling water inlet / outlet temperature °C 32 / 37
Powerhouse main crane capacity t 2 x 380
Housing degree of protection - IP 44

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
1.5 List of Reference Documents

XB-P3-GE-Q-0000-9001 General – The Generator Subsystem (ix) – Generating Unit 1

XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
XB-P3-PH-Q-1100-0680 Turbine EGAT – PH Turbine and Auxiliaries EGAT Units 1 - 7
Commissioning and Test Procedure
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
XB-P3-PH-Q-2100-0331 Generator EGAT – PH Commissioning Test Procedure – Efficiency Test
XB-P3-PH-Q-2100-0421 Generator EGAT – PH Diatech Monitoring & Diagnosis System Unit
Commissioning Procedure & Protocol
XB-P3-PH-Q-4011-1287 Excitation System – PH EGAT Units Excitation
Commissioning Procedure & Protocol
XB-P3-PH-Q-4011-1289 Excitation System – PH EGAT Units Excitation – Commissioning Instructions
XB-P3-PH-Q-4011-4561 Generator Voltage Equipment – PH EGAT Units Generator Voltage Equipment
Commissioning Protocol
XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
XB-P3-PH-Q-4081-0385 Control System – PH Common Auxiliary Board
Commissioning Procedure (Test Report)
XB-P3-PH-Q-4081-9993 EGAT Water Level Measurement - Commissioning Procedure
XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
XB-P3-PH-Q-4081-9721 Control System – 550kV Metering Board Unit 1&2&3
Commissioning Report
XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure Dry Test
XB-P3-PH-Q-4091-1239 Protection System – PH EGAT Units – Commissioning Procedure Wet Tests
XB-P3-MT-Q-5000-0080 Main Transformers 220MVA and 80MVA Commissioning Procedure
XB-P3-MT-Q-5000-0081 Main Transformers – Main Transformers 220MVA Unit 1 – Test Record
XB-P3-SG-Q-6000-0080 550kV GIS – Commissioning Procedure
XB-P3-SG-Q-6000-0081 550kV GIS – Unit 1 – Test Record

XB-P3-PH-Q-4011-1295 Excitation System – PH EGAT Units Excitation – Factory Acceptance Protocol

XB-P3-MT-Q-5000-0071 Main transformers – Main Transformer 220MVA Unit 1
Factory Acceptance Test Protocol

XB-P3-PH-D-0000-1249 General – Single Line Diagram Protection System (EGAT Units)

XB-P3-PH-D-0000-4503 General – Overall Electrical System EGAT Units – Single Line Diagram
XB-P3-PH-D-0000-4593 General – Single Line Diagram MV-System (22kV & 6.6kV)

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
2 FILLING OF WATERWAYS

2.1 Filling of Waterways from Downstream and Associated Tests

2.1.1 Filling of Waterways - Downstream

2.1.1.1 Reference Documents

Water filling from downstream shall be performed according to the following documents:
XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 8.1.1 Filling of Waterways – Downstream
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 8.1.1 Filling of Waterways – Downstream
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 8.1.1 Filling of Waterways – Downstream

2.1.1.2 Pre-Condition
 Joint inspection of waterways downstream and upstream done, all works finalized and no foreign ob-
jects inside.
 All manholes and openings are closed.
 Semi-spiral case dewatering valve is OPEN (connection to draft tube).
 Draft tube dewatering valve is CLOSED.
 Turbine ready for filling, wicket gate and runner slightly opened.
 Stand-still shaft seal (maintenance seal) is applied.
 Drainage and dewatering system ready for operation (in auto-mode). Sluice gate between the dewater-
ing pits is open.
 De-aeriation must be available and functional.

2.1.1.3 Performance of Test

The filling process has to be discussed and agreed by all involved parties before any activity is started.
Safety precaution:
 Generator brakes have to be applied during the filling process.
 During water filling no access to rotor is allowed.
Filling of draft tube and semi-spiral case through draft tube filling valves until tail water level is reached. The op-
eration of the filling valves is under responsibility of P2. The velocity is defined and controlled by the two draft
tube filling valves installed at upper draft tube stop-log with diameter 240mm each.
During filling of draft tube and semi-spiral case a permanent check for water leakages at suction cone, turbine
pit and manhole covers shall be performed.
Stop of the filling process and start of dewatering must be possible at any time.
The filling is complete when turbine and waterways are filled with water up to actual downstream water level and
the air is vented.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
2.1.1.4 Conclusion
Filling of waterways from downstream was performed and completed with satisfying results in accordance with
the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
2.1.2 Draft Tube Dewatering Test (First Unit only)
According to Contract Exhibit IV Particular Technical Specification, Volume 3, Part 2 of 3, Section 4.15 Drainage
and Dewatering System a ‘Performance Test’ of the dewatering system has to be performed:
‘The complete dewatering of intake, semi-spiral case and draft tube of one Generating Unit shall be possible
within 10 hours’.
There are two interconnected drainage & dewatering pits installed, each pit is equipped with 4 pumps.
For the dewatering test 5 pumps are required: 4 in permanent operation and one in alternating operation.
Rated power of one pump is 285kW, therefore the power demand for the dewatering test is 1425kW. For the
whole duration of the test a sufficient, uninterrupted power supply must be ensured.

2.1.2.1 Pre-Conditions
 Drainage and dewatering systems have been tested and commissioned according to respective
documents:
XB-P3-PH-I-4150-0411 drainage & dewatering ITP
XB-P3-PH-Q-4150-9700 drainage & dewatering Test Procedure
 Filling of waterways successfully performed according to chapter 2.1.1 of this document.
 Sluice gates at interconnection between pump sumps are open (normal operating condition)
 Draft tube stop-logs are still in initial position and have not been lifted (also not temporary/partially).
 Intake Gate still in closed position.
 Leakage water drained to the dewatering pits from all other Generating Units within acceptable (negligible)
range - otherwise additional dewatering time needs to be considered accordingly).
Remark: It is essential for this test to ensure that intake gates and draft tube stop logs are not opened / moved
prior to the test. Any movement or ‘cracking’ might allow sand, flotsam or any other dirt from impounding getting
trapped at sealing surfaces, causing leakages and resulting in wrongly extended duration of dewatering.

Sketch of waterways between intake gate and draft tube stop-logs (for information only):

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
2.1.2.2 Performance of Test
 Close draft tube filling valves (under responsibility of P2).
 Open draft tube drainage valve and semi-spiral case drainage valve
 Monitoring of water level at drainage pit and pump operation

The following data shall be recorded (in SCADA):

 Semi-spiral case pressure / water level
 Draft tube pressure
 Pump operation data
 Dewatering time

2.1.2.3 Conclusion
Dewatering test was performed and completed with satisfying results.

Draft Tube Dewatering Test

Max. permitted duration of dewatering acc. Contract: Recorded dewatering time during test:
10 Hours ………………… Hours

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
2.1.3 Filling of Waterways from Downstream – Associated Tests and Activities
After successful completion of the dewatering test the final filling of the waterways from downstream shall be
performed.
 Closing draft tube dewatering valve and semi-spiral case dewatering valve
 Opening the filling valves at the draft tube stop-logs (under responsibility of P2).
 Filling process according to chapter 2.1.1.2 of this document.
After completion of re-filling the waterways from downstream the removal of downstream stop-logs shall start
(under responsibility of P2).
In parallel to the removal of downstream stop-logs the following tests shall be performed:
 Water filling of cooling system
 Function checks of cooling water system
 Functional checks of shaft seal

2.1.3.1 Cooling Water System

The cooling water system tests shall be performed according to the following documents:
XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 8.1.2 Cooling Water System
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 8.1.2 Cooling Water System
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 8.1.2 Cooling Water System

2.1.3.2 Shaft Seal

The shaft sealing system tests shall be performed according to the following documents:
XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 8.1.3 Shaft Seal
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 8.1.3 Shaft Seal
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 8.1.3 Shaft Seal

2.1.3.3 Conclusion
Filling of waterways from downstream – Associated Tests and Activities have been performed and completed
with satisfying results in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
2.2 Filling of Waterways - Upstream
2.2.1 Filling of Turbine

2.2.1.1 Reference Documents

Water filling from downstream shall be performed according to the following documents:
XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 8.1.4 Filling of Waterways – Upstream
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 8.1.4 Filling of Waterways – Upstream
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 8.1.4 Filling of Waterways – Upstream

2.2.1.2 Pre-Condition
 Intake stop-logs removed.
 Water filling from downstream completed.
 Drainage and dewatering system in operation.
 Unit ready for rotation.
 Hydraulic governor operational and pressurized.
 ESD/QSD applied.
 Generator brakes applied.

2.2.1.3 Performance of Test

The filling process has to be discussed and agreed by all involved parties before any activity is started.
Filling with small opening of Intake Gate (‘filling position’), this activity is under responsibility of P2.
During first opening of intake gates a trip test has to be performed.
The filling process has to be monitored during the entire period.
The filling is complete when turbine and waterways are filled with water and the air is vented.
After completion of water filling the intake gates shall be opened fully (under responsibility of P2).
Wet-test of intake gates shall be performed after filling from upstream is completed (under responsibility of P2).

2.2.1.4 Conclusion
Filling of waterways from upstream was performed and completed with satisfying results in accordance with the
test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
3 FIRST RUN AND MECHANICAL TESTS

3.1 First Run (EGAT PPA - Test)

3.1.1 Reference Documents

XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 8.1.5 Initial Run
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 8.1.5 Initial Run
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 8.1.5 Initial Run
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.1.1 First Run
Chapter: 8.1.3 Brake Test
Chapter: 8.6 Vibration Measurement
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos.: 8230-0010 first run
8250-0010 vibrations
8250-0040 verification of action of brake system

3.1.2 Preparations and Preconditions

Activities before any attempt is made:
 Visual inspection of the generator (air gap is free, stator-/rotor windings).
 Test of generator brakes from local control panel as well as control system (open/close/open).
 The unit is kept under manual control.
Positions to be occupied by responsible commissioning team member during first run:
 speed governor
 hydraulic governor
 bearing oil system
 turbine pit
 generator ring room
 generator top / slip ring housing
 control system
 vibration monitoring system
 main distribution board (optionally)
 power intake gate
Radio communication between all involved locations / responsible persons must be established.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
3.1.3 First Turn – check mechanical free running
Condition of the unit:
 unit ready for operation
 auxiliaries in operation
 power intake gates are in open position
 generator brakes are applied
 maintenance sealing is deactivated
 cooling system is in normal operation, shaft seal water flow is sufficient
 speed governor in manual operation
 governor oil pressure unit in operation
 opening limiter at turbine governor set to ‘zero’
Activities to start the unit:
 Auxiliaries ON in manual mode (local operation).
 Opening of generator brakes → check if unit start creeping.
 Starting of the turbine with the opening limiter in steps, set the operating limitation of the digital gover-
nor to a low set value for the first start in order to prevent uncontrolled opening.
 Open guide vanes until the unit starts to rotate.
 Slow turning with speed of 2…5% (not exceeding 10% of nominal speed).
 Immediately close guide vanes and runner again.
 During run out, check / listen for abnormal noises, scraping or other phenomenon on the bearings, the
shaft, the runner, etc. until unit is in stand still

3.1.4 Increase Speed up to 100%

In case no abnormalities have been observed during initial rotation, the speed will be increased in steps until
nominal speed. After each step the guide vanes are closed and the run-out is checked.

Speed steps 0 to approx. 25% + check of run-out

+ check for noise or other malfunction
Speed steps approx. 25…50% + continuous checks:
→ bearing temperature on control system
Speed steps approx. 50…75% → vibrations on monitoring system
→ status of cooling system
Speed steps approx. 75…100% → flow meters
→ oil flow and levels

In case no further irregularity appears:

 check of run-out

3.1.4.1 Emergency Stop Test (EGAT PPA – Test)

Emergency-Stop test with unit on 100% speed has to be performed, including test of generator brakes.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
3.1.5 Conclusion
‘First Run’ of Generating Unit was performed and completed with satisfying results in accordance with the test
procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
3.2 Balancing (EGAT PPA - Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Balance, Vibrations and other Mechanical Tests’.

3.2.1 Reference Documents

XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure

Chapter: 8.6 Vibration Measurement
Chapter: 8.6.4 Balancing
XB-P3-PH-S-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos.: 8250-0010 vibrations

3.2.2 Performance of Test

During ‘First Run Tests’ the run-out of the unit is checked. In case the recorded vibrations are too high balancing
weights have to be installed inside of the generator rotor. In any case the peak-peak value of the recorded vibra-
tions must not exceed 70% of total bearing clearance for turbine bearing respectively 50% of total bearing
clearance for generator bearings.
For balancing special safety rules have to be obeyed before entering into generator rotor:
 Generator brakes applied and secured against opening.
 Wicket Gate and Runner must be closed and blocked in closed position (ESD/QSD applied).
 Intake closed (optional).
Remark: Balancing in no-load condition can only be understood as ‘preliminary balancing’ with the intention to
bring the Generating Unit to a vibration range safe for operation during mechanical and electrical no-load tests.
Final balancing will be performed after synchronization during load operation, under consideration of the mag-
netic pull.

3.2.3 Conclusion
Balancing of Generating Unit was checked and is within acceptable limits for performance of mechanical and
electrical no-load tests.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
3.3 Bearing Heat Run
3.3.1 Reference Documents

XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1

Commissioning Inspection and Test Plan
Chapter: 8.1.6 Bearing Run
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 8.1.6 Bearing Run
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 8.1.6 Bearing Run
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.1.2 Bearing Heat Run
XB-P3-PH-S-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos.: 8250-0010 vibrations
8250-0020 bearing run

3.3.2 Performance of Test

The bearing run will be performed with 100% speed until saturation of the temperature behavior is reached (lift-
ing pump = OFF). Expected duration is approximately 4 to 6 hours.
Checks / monitoring of the following systems have to be performed continuously:
 bearing temperature on control system
 cooling water temperature
 vibrations on monitoring system
 irregular development of noise
 status of cooling system
 proper operating conditions of all pumps
 flow of cooling water
 oil levels
 shaft seal
 check of run-out
In case any temperature is increasing too fast or reaching unacceptable high values, the unit has to be shut
down in order to investigate the cause. Furthermore the stabilized temperature should not exceed the guarantee
values.

3.3.3 Conclusion
Bearing Heat Run of Generating Unit was performed and completed with satisfying results in accordance with
the test procedures listed above.
ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
3.4 Over-Speed Test (EGAT PPA – Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Over Speed Test’.

3.4.1 Reference Documents

XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1

Commissioning Inspection and Test Plan
Chapter: 8.1.7 Over-Speed Tests
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 8.1.7 Over-Speed Tests
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 8.1.7 Over-Speed Tests
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.1.4 Verification of Overspeed Protection
XB-P3-PH-S-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos.: 8250-0030 verification of overspeed protection

3.4.2 Preparation
The overspeed test should be performed with the warm bearings only, if possible right after the Bearing Run.
In case this is not possible, the unit should be operated for at least 1 hour with rated speed to warm up the bear-
ings for the test.

3.4.3 Electrical Overspeed

Overspeed: setting ~140% of rated speed (~116.6 rpm).
Test of the electronic overspeed relay. The setting can be reduced for the test (according to evaluation of re-
sponsible commissioning engineer, also depending on available headwater level).

3.4.4 Mechanical Overspeed

Overspeed: adjustment ~144% of rated speed (~120 rpm).
Test correct function of speed pendulum. In case of unsatisfactory result the test shall be repeated until final ad-
justment is found.

Remark: In order to ensure overspeed protection for the Generating Unit in case of failure of the mechanical
overspeed device, the electrical overspeed relay shall be adjusted slightly higher as the max. expected / permit-
ted tripping speed of the mechanical device.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
3.4.5 Final Works
After the overspeed test:
 shut down the unit
 close intake gate and block against re-opening (in responsibility of P2)
 close wicket gate and block in closed position
 installation of flexible connectors at generator stator terminals (bus duct and neutral point).

3.4.6 Conclusion
Overspeed Test of Generating Unit was performed and completed with satisfying results in accordance with the
test procedures listed above.

Test of mechanical over-speed device

max. permitted speed rise acc. expected speed rise acc. to pre- recorded speed rise during test:
Contract: adjustment of device:
Nmax = …..…. % / …….. rpm
Nmax = 150% / 125 rpm Nmax = 144% / 120 rpm

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
3.5 General Inspection After Overspeed-Test (EGAT PPA – Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘General Inspection’.

3.5.1 Preparation
Special safety rules have to be obeyed before entering into generator rotor:
 Generator brakes applied and secured against opening.
 Wicket Gate must be closed and blocked in closed position (ESD/QSD applied).
 Intake closed.
 Visible and safe earthing to be applied on stator and rotor winding.
 Generator standstill heaters are OFF and locked out.
 Where necessary, ladders and safety harness has to be used.

3.5.2 Performance
Generator inspection has to be performed by skilled personnel.
Shoes to be removed and pockets to be emptied before entering into the generator.
 Check of all bolted connections (pole connectors etc.)
 Check for loose parts
 Check for any kind of visible damage (cracks, impact marks etc.)

3.5.3 Conclusion
Visual inspection of Generating Unit was performed and completed with satisfying results in accordance with the
procedures listed above, no damage and/or loose parts could be found.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
4 SHORT CIRCUIT TESTS
In parallel the tests described in Chapter ‘5 Earth Fault Tests’ shall be performed.

4.1 Reference Documents

XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.2 Short-Circuit Tests
XB-P3-PH-Q-4011-1287 Excitation System – PH EGAT Units Excitation
Commissioning Procedure & Protocol
XB-P3-PH-Q-4011-1289 Excitation System – PH EGAT Units Excitation – Commissioning Instructions
XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure Dry Test
XB-P3-PH-Q-4091-1239 Protection System – PH EGAT Units – Commissioning Procedure Wet Tests
XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
XB-P3-PH-D-0000-1249 General – Single Line Diagram Protection System (EGAT Units)
XB-P3-PH-D-0000-4503 General – Overall Electrical System EGAT Units – Single Line Diagram
XB-P3-PH-D-0000-4593 General – Single Line Diagram MV-System (22kV & 6.6kV)

4.2 General
4.2.1 Sequence of Tests:
During execution of Short-Circuit Tests and Earth Fault Tests the most time consuming activities are the instal-
lation and removal of the set-up for the individual tests. In order to optimize the overall duration of these tests
the following testing sequence shall be followed:
1st Test: Chapter 4.3 3-Phase Short Circuit on Generator Bus Duct (16kV)
nd
2 Test: Chapter 4.4.3 2-Phase Short Circuit Test
3rd Test: Chapter 4.4.4 2-Phase + N Short Circuit Test
th
4 Test: Chapter 5.3 Earth Fault on Generator Bus Duct (16kV)
th
5 Test: Chapter 5.4 Stator Inter-Turn Fault
th
6 Test: Chapter 5.5 Earth Fault on Generator Neutral Point
th
7 Test: Chapter 4.5 Short-Circuit on 500kV
th
8 Test: Chapter 5.6 Earth Fault on 500kV
th
9 Test: Chapter 4.6 Short Circuit on Unit Auxiliary Transformer
th
10 Test: Chapter 5.7 Earth Fault at Unit Auxiliary Transformer

Remark: the ‘Sudden Short-Circuit Test’ described in Procedure XB-P3-PH-Q-2100-0330, Chapter 8.2.4 is a
‘Type Test’ and shall be performed together with the Calorimetric Efficiency Test of the Generating Unit.
See Chapter 16.1 of this document. Refer also to TC-P3-097.

4.2.2 Set-Up of Temporary Power Supply for Excitation System

During the short circuit tests it is not possible to supply the excitation transformer from the generator bus bar.
Therefore a temporary power supply for the excitation system is provided.
Technical data of testing transformer: 1000 kVA
22/0.4 kV

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
The testing transformer is transportable by crane; it will be placed close to the excitation system. Power supply
for the transformer is provided by temporary 22kV cable connection from MDB-1; spare feeder =BCA10GH001
+0BCA10.5. shall be used.

LV connection between transformer and excitation system will be done by temporary cables suitable for 1200A.

4.3 3-Phase Short Circuit on Generator Bus Duct (16kV)

4.3.1 Reference Documents
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.2.1 Short-Circuit Saturation Characteristic 3-Phase
XB-P3-PH-S-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos.: 8280-0010 short circuit saturation characteristic 3-phase

4.3.2 Preparation
3-Phase Short Circuit on Generator Bus-Duct for test set-up will be provided on EL. +246.200 by means of
shortening bar.

For installation details of shortening bar please refer to document no.:

XB-P3-PH-D-4011-4539 Generator Voltage Equipment – PH EGAT Units Busbar Shortening Link
Assembly Drawing

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
Project N° H100.002288 09.08.2017 RM LH-DE 00 Page 30 de / of 122
= +
HAV

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
4.3.3 Performance of Test
 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is CLOSED.
 16kV Unit GCB (=1BAC01GS100-Q0) is CLOSED and blocked in closed position.
 External power supply for excitation system is switched on.
 Start of Generating Unit up to rated speed in Auto-Mode.
 Excitation ON in manual mode.
 With the excitation system in manual mode increase the stator current to receive ~5…10% of the gen-
erator rated current.
 Check the measurement of the corresponding currents on all systems (control, metering, protection,
excitation system).
 Increase the current manually in steps of 10% according to the tests to be performed.
 Expected highest current during test is 110% IN Gen = 7940A
 Expected voltage: 0V.

4.3.3.1 Tests for Generator (EGAT PPA – Test)

The Test is performed according to the following test procedure:

XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure incl. Type Tests
Chapter: 8.2.1 Short-Circuit Saturation Characteristic 3-Phase
XB-P3-PH-S-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos.: 8280-0010 short circuit saturation characteristic 3-phase
Items to be checked during the short-circuit test:
 Recording of short circuit saturation characteristic
 Check of current symmetry

4.3.3.2 Tests for Excitation System (EGAT PPA – Test)

The Test is performed according to the following test procedure:

XB-P3-PH-Q-4011-1287 Excitation System – PH EGAT Units Excitation
Commissioning Procedure & Protocol
ITP-Pos. 0220-0000 & 0220-0005
XB-P3-PH-Q-4011-1289 Excitation System – PH EGAT Units Excitation – Commissioning Instructions
Chapter: 6.8.1 Short Circuit Tests

Items to be checked during the short-circuit test:

 Check current transformer circuits
 Pre-calibration of rotor current.
 Check pre-calibration of generator current.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
4.3.3.3 Tests for Control System (EGAT PPA_Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Start and Stop Functions including Emergency Stop’.

The Test is performed according to the following test procedure:

XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
Chapter: 5.14 Command Operation Check
5.16 Interlock and Sequencing Circuits
5.17 Tripping Circuit Check
XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
Chapter: 1.6 Input / Output Point Check
1.10 Test of Application Program (EGAT Test)

Items to be checked during the short-circuit test:

 Current measurement generator.
 Interface tests for excitation and protection system.
 Check of interlocking.
 Test automatic start and stop sequence (step by step mode).

4.3.3.4 Tests for Protection System (EGAT PPA – Test)

The Test is performed according to the following test procedure:

XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure Dry Test
Chapter: 3.1 Short-Circuit on Generator Terminals

Items to be tested during the short circuit test:

 Generator Overcurrent [50/51G]
 Generator Negative Phase Sequence [46G]
 Generator Overload [49G]
 Generator /Transformer Differential Protection [87]
 Generator Minimum Impedance [21G]
 100% Stator Earth Fault [59TN/27TN]
 Undervoltage/Overcurrent [51V]
Operation check of generator differential protection and negative phase sequence:
 Reduce the stator current to a minimum.
 Short circuit the current transformers on one side of the differential protection on the terminals of the
protection cubicle.
 Increase the stator current up to pickup of the generator differential protection.
 Reduce the stator current to a minimum.
 Open the short circuit links at the terminals of the current transformers.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
4.3.4 Final Activities after the 3-phase short circuit test
 After the tests reduce the excitation system to its minimum.
 Excitation OFF.
 Stop of Generating Unit.
 Open 16kV Unit GCB (=1BAC01GS100-Q0).
 Open 16kV Unit Disconnector (=1BAC01GS110-Q1).
 Close 16kV Unit Earthing Switch (=1BAC01GS191-Q91)
 Install temporary earth connection on all 3 phases at bus-duct (at side of short-circuit installation).

4.3.5 Conclusion
Test of 3-Phase Short Circuit on Generator Bus-Duct was performed and completed with satisfying results for all
the involved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
4.4 2-Phase Short Circuit Tests (Type Tests)

4.4.1 General
The 2-phase short-circuit tests shall be performed on Generating Unit 1 only.
The following tests shall be performed:
 2-Phase Short Circuit Test for determination of negative sequence reactance X2 and negative sequence
resistance R2.
 2-Phase Short Circuit Test with Neutral Connection for determination of negative sequence reactance
X0 and negative sequence resistance R0.

4.4.2 Preparation

The test set-up in principle is the same as for the 3-phase short-circuit test. For one phase the disconnecting
link between bus-duct and shorting bar is removed.
For 2-phase + N short-circuit a cable connection has to be installed between shorting bar and generator neutral
point. The cable connection has to be suitable to carry 30% of the generator rated current (= 2165A) for the ex-
pected test duration of 10 minutes. The cable used for this connection should not have any shield or armour.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
4.4.3 2-Phase Short Circuit Test
The Test is performed according to the following test procedure:
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure incl. Type Tests
Chapter: 8.2.2 Short-Circuit Test 2-Phase

 After the tests reduce the excitation system to its minimum.

 Excitation OFF.
 Stop of Generating Unit.
 Open 16kV Unit GCB (=1BAC01GS100-Q0).
 Install temporary earth connection on all 3 phases at bus-duct (at side of short-circuit installation).

4.4.4 2-Phase + N Short Circuit Test

 Install cable connection between shorting bar and neutral point.
 Remove temporary earth connection on all 3 phases at bus-duct (at side of short-circuit installation).
 Close 16kV Unit GCB (=1BAC01GS100-Q0).
The Test is performed according to the following test procedure:
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure incl. Type Tests
Chapter: 8.2.3 Short-Circuit Test 2-Phase with Neutral Connection

4.4.5 Final Activities after the Short Circuit Tests on 16kV Bus-Duct
 After the tests reduce the excitation system to its minimum.
 Excitation OFF.
 Stop of Generating Unit.
 Switch off 22kV supply for excitation transformer.
 Open 16kV Unit GCB (=1BAC01GS100-Q0).
 Open 16kV Unit Disconnector (=1BAC01GS110-Q1).
 Close 16kV Unit Earthing Switch (=1BAC01GS191-Q91).
 Install temporary earth connection on all 3 phases at bus-duct (at side of short-circuit installation).
 Remove short-circuit installation.

4.4.6 Conclusion
2-Phase Short Circuit Tests on Generator Bus-Duct have been performed and completed with satisfying results
accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
4.5 Short-Circuit on 500kV
4.5.1 General
Purpose of this test is to verify correct CT connection and function and to test all relevant protection functions.

4.5.2 Preparation
The shorting busbar at EL. +246.200 is disconnected / removed and the flexible connectors at the bus duct are
installed (connection between generator and main transformer is established).
The short circuit is installed at GIS on earthing switch =1ABA01GS191-QCX.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
The earthing links on the earthing switch =1ABA01GS191-QCX are opened and a temporary short circuit is in-
stalled within the 3 phases (LV-cable 16mm² is sufficient).
Max. expected current during test is 15% of nominal current (approx. max. 35A).
Expected voltage: <0.5kV

Earthing Switch on 500kV GIS

4.5.3 Performance of Test

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
4.5.3.1 Tests for Control System
The Test is performed according to the following test procedure:
XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
Chapter: 1.6 Input / Output Point Check

Items to be checked during the short circuit test:

 Current measurement

4.5.3.2 Tests for Protection System (EGAT PPA – Test)

The protection functions will be blocked by software in order to maintain the unit in operation condition. The
pickup of the protection functions will be checked on the LEDs of the respective protection relay.
The Test is performed according to the following test procedure:
XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure Dry Test
Chapter: 3.2 Short-Circuit on Unit Transformer HV-Side
Items to be tested during the short circuit test:
 Minimum Impedance [21G]
 100% Stator Earth Fault [59TN/27TN]
 Transformer/Generator Overcurrent [50/51]
 95% Stator Earth Fault [64N]
 Stability of main transformer differential protection and generator differential protection [87]
Operation check of step-up transformer differential protection:
 Reduce the stator current to a minimum.
 Short circuit the current transformers on one side of the differential protection on the terminals of the
protection cubicle.
 Increase the stator current up to pickup of the transformer differential protection.
 Reduce the stator current to a minimum.
 Open the short circuit links of the terminals of the current transformers.

4.5.4 Final Activities after the Short Circuit Test

 After the test reduce the excitation system to its minimum.
 Excitation OFF, CB open.
 Stop of Generating Unit.
 Switch off 22kV supply for excitation transformer.
 Open 16kV Unit GCB (=1BAC01GS100-Q0).
 Open 16kV Unit disconnector (=1BAC01GS110-Q1).
 Close 16kV Unit earthing switch (=1BAC01GS191-Q91).
 Open 500kV Unit 1 earthing switch (=1ABA01GS191-QCX)
 Apply temporary earth connection.
 Remove the short circuit.
 Re-install the earthing links on 500kV Unit 1 earthing switch (=1ABA01GS191-QCX).
 Visual inspection of all locations affected during short circuit test.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
4.5.5 Conclusion
Test of 3-Phase Short Circuit on 500kV (GIS) was performed and completed with satisfying results for all the in-
volved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
4.6 Short Circuit on Unit Auxiliary Transformer
4.6.1 Preparation
The short-circuit is installed inside 22kV UAT Feeder +0BCA10.2 at Main Distribution Board 1 on EL +252.200.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
The short circuit is installed at MDB-1 at the 22kV UAT incoming feeder (+BCA10.2), inside the cable chamber
on the ‘P2’-terminals of the CT with KKS-No. =0BCA10.2CE121B.
The short circuit connection is installed by use of flexible single-core LV cable with cross section of min. 16mm².
For installation of the short-circuit connection it is required to enter into the cable chamber of the 22kV trans-
former feeder cubicle. This activity can be performed with energized 22kV bus-bar (installed in separate enclo-
sure). All safety precautions have to be taken accordingly. CB must be in test position (racked out) and OFF, the
earthing switch (=0BCA10.2GS190) at transformer side must be applied.
Expected current during Short Circuit Test is approx. 15% In =80A (at 22kV side).
Expected voltage during Short Circuit Test: < 30V.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
4.6.2 Performance of Test
 16kV Unit 1 earthing switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit 1 disconnector (=1BAC01GS110-Q1) is CLOSED.
 16kV Unit 1 GCB (=1BAC01GS100-Q0) is CLOSED and blocked in closed position.
 500kV Unit 1 disconnectors to 500kV bus (=1ABA01GS130-QB1 & =1ABA01GS140-QB2) are OPEN.
 500kV Unit 1 disconnector (=1ABA01GS120-QB9) is OPEN.
 500kV Unit 1 CB (=1ABA01GS100-QA1) is OPEN.
 500kV Unit 1 by-pass disconnector (=1ABA01GS110-QBX) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS191-QCX) is OPEN.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at Unit 1 side (=0BBT10GS191-Q91) is
OPEN.
 16kV disconnecting switch at Disconnecting Switchgear Cubicle-1 at Unit 1 side (=0BBT10GS110-Q1)
is CLOSED.
 16kV disconnecting switch at Disconnecting Switchgear Cubicle-1 at Unit 2 side (=0BBT10GS120-Q2)
is OPEN.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at Unit 2 side (=0BBT10GS192-Q92) is
CLOSED.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at UAT side (=0BBT10GS193-Q93) is
OPEN.
 22kV earthing switch at MDB-1 UAT incoming Cubicle (=0BCA10.2GS190) is OPEN.
 22kV CB at MDB-1 UAT incoming Cubicle (=0BCA10.2GS200-Q52) is racked-out and OPEN.
 External power supply for excitation system is switched on.
 Start of Generating Unit up to rated speed in Auto-Mode.
 Check measurements with residual voltage.
 Excitation ON in manual mode.
 With the excitation system in manual mode increase the stator current to receive ~5…10% of the UAT
rated current (~36…72A on 16kV and ~26…52A on 22kV).
 Check the measurement of the corresponding currents on all systems (control, protection, metering,
ammeter).
 Increase the current manually according to the tests to be performed (expected max. 15% IN UAT).
 Expected highest current during test is approx. 15% IN UAT = approx. 110A on 16kV and approx. 80A
at 22kV.
 Expected voltage: < 30V.

4.6.2.1 Tests for Protection System (EGAT PPA – Test)

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
Operation check of step-up transformer differential protection:
 Reduce the stator current to a minimum.
 Short circuit the current transformers on one side of the differential protection on the terminals of the
protection cubicle.
 Increase the stator current up to pickup of the transformer differential protection.
 Reduce the stator current to a minimum.
 Open the short circuit links of the terminals of the current transformers.

4.6.3 Final Activities after the Short Circuit Test

 After the test reduce the excitation system to its minimum.
 Excitation OFF, CB open.
 Stop of Generating Unit.
 Switch off 22kV supply for excitation transformer.
 Open 16kV Unit GCB (=1BAC01GS100-Q0).
 Open 16kV Unit disconnector (=1BAC01GS110-Q1).
 Close 16kV Unit earthing switch (=1BAC01GS191-Q91).
 Open 16kV disconnecting switch at Disconnecting Switchgear Cubicle-1 at Unit 1 side
(=0BBT10GS110-Q1).
 Close 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at UAT side (=0BBT10GS193-
Q93).
 Close 22kV earthing switch at MDB-1 UAT incoming Cubicle (=0BCA10.2GS190)
 Remove the short circuit.
 Visual inspection of all locations affected during short circuit test.

4.6.4 Conclusion
Test of 3-Phase Short Circuit on Unit Auxiliary transformer 22kV side was performed and completed with satis-
fying results for all the involved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
5 EARTH FAULT TESTS
The Earth Fault Tests will be performed in parallel with the Tests described in Chapter 4 Short Circuit Tests.

5.1 Reference Documents

XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure

5.2 General
During the earth fault tests it is not possible to supply the excitation transformer from the generator bus bar.
Therefore a temporary power supply for the excitation system is provided as described in Chapter 4.2.2.

5.3 Earth Fault on Generator Bus Duct (16kV)

This test should be performed directly after ‘4.4 2-Phase Short Circuit Tests (Type Tests)’, right after discon-
nection of the shorting bar.

5.3.1 Preparation
The earth fault shall be installed at EL. +246.200 between one phase of the open bus duct and the nearest solid
ground connection / earthing bar. Installation of the earth fault at the same location were the short circuit was in-
stalled, after disconnecting of the shorting bar. For installation of the earth fault a flexible wire with cross section
of 25mm² shall be used, solid bolted connection is required.

5.3.2 Performance of Test

 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is CLOSED.
 16kV Unit GCB (=1BAC01GS100-Q0) is CLOSED and blocked in closed position.
 External power supply for excitation system is switched on.
 Start of Generating Unit up to rated speed in Auto-Mode.
 Excitation ON in manual mode.
 With the excitation system in manual mode increase the stator voltage according to the requirements
of the tests performed.
 Expected highest current during test is max. 5A
 Expected voltage: ~15% (~2400V).

5.3.2.1 Test for Protection System (EGAT PPA – Test)

The Test is performed according to the following test procedure:

XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure Dry Test
Chapter: 3.4 Single Phase Earth Fault on Generator Terminals

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
Items to be tested during the earth fault test:
 100% Stator Earth Fault [59TN/27TN]]
 95% Stator Earth Fault [64N]
 MV Earth Fault [64B]

5.3.3 Final Activities after the Earth Fault Test

5.3.4 Conclusion
Earth Fault Test on generator bus duct was performed and completed with satisfying results for all the involved
systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
5.4 Stator Inter-Turn Fault
5.4.1 Preparation
 The earth fault connection on generator bus-duct remains installed as described in chapter 5.3.1 of this
document.
 In addition install one earth fault connection on generator neutral point as described in chapter 5.5.1 of
this document.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
5.4.2 Performance of Test
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Verification and Calibration of all Protections and Protective Relay’.
Important: This test has to be performed with Residual Voltage only!
The Excitation System must remain SWITCHED OFF for the entire duration of this test.
 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is CLOSED.
 16kV Unit GCB (=1BAC01GS100-Q0) is CLOSED and blocked in closed position.
 External power supply for excitation system is switched OFF.
 Start of Generating Unit up to rated speed in Auto-Mode.
 Expected highest current during test is max. 200A
 Expected voltage: ~200V (Residual Voltage, on healthy phases only).

5.4.2.1 Test for Protection System (EGAT PPA – Test)

Items to be tested during the earth fault test:

 Test of Stator Inter-Turn Protection [95G]

5.4.3 Final Activities after the Earth Fault Test

 After the tests reduce the excitation system to its minimum.
 Excitation OFF.
 Stop of Generating Unit.
 Open 16kV Unit GCB (=1BAC01GS100-Q0).
 Open 16kV Unit Disconnector (=1BAC01GS110-Q1).
 Close 16kV Unit Earthing Switch (=1BAC01GS191-Q91
 Remove the earth fault on generator bus-duct (EL. +246.200).
 Visual inspection of all locations affected during earth fault test.

5.4.4 Conclusion
Stator Inter-Turn Test was performed and completed with satisfying results for all the involved systems in ac-
cordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
5.5 Earth Fault on Generator Neutral Point
5.5.1 Preparation
The earth fault for test will be installed inside the Neutral Grounding Cubicle as indicated in the sketch below
(reference drawing: XB-P3-PH-D-4011-4535 Neutral Grounding Cubicle – Assembly).
For installation of the earth fault a flexible wire with cross section of 25mm² shall be used, solid bolted connec-
tion is required.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
5.5.2 Performance of Test
 Ensure that the earth fault installed at generator bus-duct (EL.+246.200) is removed.
 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is OPEN.
 16kV Unit GCB (=1BAC01GS100-Q0) is OPEN.
 External power supply for excitation system is switched on.
 Start of Generating Unit up to rated speed in Auto-Mode.
 Check protection measurements with residual voltage.
 Excitation ON in manual mode.
 With the excitation system in manual mode increase the stator voltage according to the requirements
of the tests performed.
 Expected highest current during test is < 1A.
 Expected voltage: max. ~15% (~2400V).

5.5.2.1 Test for Protection System (EGAT PPA – Test)

Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Verification and Calibration of all Protections and Protective Relay’.
Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
Project N° H100.002288 09.08.2017 RM LH-DE 00 Page 50 de / of 122
= +
HAV

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
The Test is performed according to the following test procedure:
XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure Dry Test
Chapter: 3.5 Earth Fault on Generator Neutral Point

Items to be tested during the earth fault test:

 100% Stator Earth Fault [59TN/27TN]
 95% Stator Earth Fault [64N]

5.5.3 Final Activities after the Earth Fault Test

 After the tests reduce the excitation system to its minimum.
 Excitation OFF.
 Stop of Generating Unit.
 Remove the earth fault.
 Visual inspection of all locations affected during earth fault test.

5.5.4 Conclusion
Earth Fault Test on generator neutral point was performed and completed with satisfying results for all the in-
volved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
5.6 Earth Fault on 500kV
This Test should be performed directly after ‘4.5 Short-Circuit on 500kV’.

5.6.1 Preparation
After completion of the test ‘4.5 Short-Circuit on 500kV’ remove the temporary installed short circuit connection
between all three phases at GIS on earthing switch =1ABA01GS191-QCX.
Re-install the earthing links on earthing switch =1ABA01GS191-QCX.
Disconnect the mechanical drive at earthing switch =1ABA01GS191-QCX on one phase and close the earthing
contact on this phase manually.
The earthing switch contacts of the other two phases must remain open.

5.6.2 Performance of Test

5.6.2.1 Tests for Protection System (EGAT PPA – Test)

The Test is performed according to the following test procedure:

XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure Dry Test
Chapter: 3.3 Single Phase Earth Fault on Unit Transformer HV-Side

Items to be tested during the earth fault test:

 Check displacement voltage of the 500kV side and on 16kV.
 Negative Phase Sequence [46].
 100% Stator Earth Fault [59TN/27TN].
 95% Stator Earth Fault [64N].
 Transformer Neutral Overcurrent [51N]
 Earth Fault [64REF]

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
5.6.3 Final Activities after the Earth Fault Test
 After the tests reduce the excitation system to its minimum.
 Excitation OFF.
 Stop of Generating Unit.
 Open 16kV Unit GCB (=1BAC01GS100-Q0).
 Open 16kV Unit Disconnector (=1BAC01GS110-Q1).
 Close 16kV Unit Earthing Switch (=1BAC01GS191-Q91).
 Open manually the contact at 500kV Unit 1 earthing switch (=1ABA01GS191-QCX) were the test was
performed.
 Re-install the mechanical drive connection on 500kV Unit 1 earthing switch (=1ABA01GS191-QCX).
 Visual inspection of all locations affected during earth fault test.

5.6.4 Conclusion
Earth Fault Test on 500kV GIS was performed and completed with satisfying results for all the involved systems
in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
5.7 Earth Fault at Unit Auxiliary Transformer
This Test should be performed directly after ‘4.6 Short Circuit on Unit Auxiliary Transformer’.

5.7.1 Preparation
The short circuit is installed at MDB-1 at the 22kV UAT incoming feeder (+BCA10.2), inside the cable chamber
on the ‘P2’-terminals of the CT with KKS-No. =0BCA10.2CE121B at the same location were the short-circuit
was installed.
After removal of the short-circuit in one phase a connection between one ‘P2’-terminal of one CT with KKS-No.
=0BCA10.2CE121B and the next solid earth connection is installed.
The earth fault connection is installed by use of flexible single-core LV cable with cross section of min. 16mm².
For installation of the earth fault connection it is required to enter into the cable chamber of the 22kV transform-
er feeder cubicle. This activity can be performed with energized 22kV bus-bar (installed in separate enclosure).
All safety precautions have to be taken accordingly. CB must be in test position (racked out) and OFF, the
earthing switch (=0BCA10.2GS190) at transformer side must be applied.
Expected current during Earth Fault Test is approx. 15% In =80A (at 22kV side).
Expected voltage during Short Circuit Test: < 30V.

5.7.2 Performance of Test

 16kV Unit 1 earthing switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit 1 disconnector (=1BAC01GS110-Q1) is CLOSED.
 16kV Unit 1 GCB (=1BAC01GS100-Q0) is CLOSED and blocked in closed position.
 500kV Unit 1 disconnectors to 500kV bus (=1ABA01GS130-QB1 & =1ABA01GS140-QB2) are OPEN.
 500kV Unit 1 disconnector (=1ABA01GS120-QB9) is OPEN.
 500kV Unit 1 CB (=1ABA01GS100-QA1) is OPEN.
 500kV Unit 1 by-pass disconnector (=1ABA01GS110-QBX) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS191-QCX) is OPEN.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at Unit 1 side (=0BBT10GS191-Q91) is
OPEN.
 16kV disconnecting switch at Disconnecting Switchgear Cubicle-1 at Unit 1 side (=0BBT10GS110-Q1)
is CLOSED.
 16kV disconnecting switch at Disconnecting Switchgear Cubicle-1 at Unit 2 side (=0BBT10GS120-Q2)
is OPEN.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at Unit 2 side (=0BBT10GS192-Q92) is
CLOSED.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at UAT side (=0BBT10GS193-Q93) is
OPEN.
 22kV earthing switch at MDB-1 UAT incoming Cubicle (=0BCA10.2GS190) is OPEN.
 22kV CB at MDB-1 UAT incoming Cubicle (=0BCA10.2GS200-Q52) is racked-out and OPEN.
 External power supply for excitation system is switched on.
 Start of Generating Unit up to rated speed in Auto-Mode.
 Check measurements with residual voltage.
 Excitation ON in manual mode.
 With the excitation system in manual mode increase the stator voltage according to the requirements
of the tests performed.
 Expected highest current during test is approx. 15% IN UAT = approx. 110A on 16kV and approx. 80A
at 22kV.
 Expected voltage: < 30V.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
5.7.2.1 Tests for Protection System (EGAT PPA – Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Verification and Calibration of all Protections and Protective Relay’.
The protection functions will be blocked by software in order to maintain the unit in operation condition. The
pickup of the protection functions will be checked on the LEDs of the respective protection relay.
The Test is performed according to the following test procedure:
XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure Dry Test
XB-P3-PH-Q-4091-1239 Protection System – PH EGAT Units – Commissioning Procedure Wet Tests
Chapter: 3.7 Short-Circuit and Earth Fault on UAT LV

Items to be tested during the earth fault test:

 UAT neutral overcurrent

5.7.3 Final Activities after the Earth Fault Test

 After the test reduce the excitation system to its minimum.
 Excitation OFF.
 Stop of Generating Unit.
 Switch off 22kV supply for excitation transformer.
 Open 16kV Unit GCB (=1BAC01GS100-Q0).
 Open 16kV Unit disconnector (=1BAC01GS110-Q1).
 Close 16kV Unit earthing switch (=1BAC01GS191-Q91).
 Open 16kV disconnecting switch at Disconnecting Switchgear Cubicle-1 at Unit 1 side
(=0BBT10GS110-Q1).
 Close 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at UAT side (=0BBT10GS193-
Q93).
 Close 22kV earthing switch at MDB-1 UAT incoming Cubicle (=0BCA10.2GS190)
 Remove the earth fault.
 Reverse all temporary wiring manipulations and force markers at all affected systems.
 Visual inspection of all locations affected during earth fault test.

5.7.4 Conclusion
Earth Fault Test on Unit Auxiliary Transformer 22kV side was performed and completed with satisfying results
for all the involved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
6 NO-LOAD TESTS (OPEN CIRCUIT)

6.1 Reference Documents

XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.3 Open-Circuit Tests
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 8.1.8 Speed Controller Tests
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 8.1.8 Speed Controller Tests
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 8.1.8 Speed Controller Tests
XB-P3-PH-Q-4011-1287 Excitation System – PH EGAT Units Excitation
Commissioning Procedure & Protocol
XB-P3-PH-Q-4011-1289 Excitation System – PH EGAT Units Excitation – Commissioning Instructions
Chapter: 6.8.2 Open Circuit Voltage Tests
XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure Dry Test
XB-P3-PH-Q-4091-1239 Protection System – PH EGAT Units – Commissioning Procedure Wet Tests
XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement

6.2 General
During the first part of open-circuit tests (i.e. recording of generator open circuit characteristic, protection tests) it
is not possible to supply the excitation transformer from the generator bus bar. Therefore a temporary power
supply for the excitation system is provided as described in Chapter 4.2.2.
For finalizing the Excitation Open Circuit Tests the temporary test supply will be removed and the final, perma-
nent power supply via Excitation transformer will be established (installation of flexible connectors between bus
duct and excitation transformer).

Remark: The Voltage Recovery Test described in Procedure XB-P3-PH-Q-2100-0330, Chapter 8.3.3 is a
‘Type Test’ and shall be performed together with the ‘Sudden Short Circuit Test’ of the Generating Unit – if re-
quired (refer to TC-P3-098).
See also Chapter 16.2 of this document.

6.3 Open-Circuit Test without Excitation

These tests shall be performed with residual voltage only.
Special care has to be taken since for this test it is necessary to enter into the generator barrel (‘generator ring
room’) with Generating Unit operated on nominal speed and generator terminal covers removed.
For safety reasons it is required two people to perform the test, uninterrupted communication via radio must be
ensured.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
6.3.1 Performance of Test
 External power supply for excitation system is switched OFF and secured against energizing.
 Start of Generating Unit up to rated speed in Auto-Mode.
 Excitation system remains SWITCHED OFF.
 Test engineers to enter into the generator barrel and perform the measurements direct on the genera-
tor terminals (required instruments: phase sequence meter).

6.3.1.1 Generator Phase Sequence Test (EGAT PPA – Test)

The Test is performed according to the following test procedure:

XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.3.2 Phase Sequence Check
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP-Pos. 8310-0030 phase sequence

Remark: measuring of Residual Voltage direct on the generator terminals can be performed together with the
Phase Sequence Test.

6.3.2 Final Activities after the Test

 Stop of Generating Unit.
 Visual inspection of all locations affected during test.

6.4 No-Load Tests with External Excitation Supply

These tests are performed with temporary power supply for the excitation system is provided as described in
Chapter ‘4.2.2 Set-Up of Temporary Power Supply for Excitation System’.

6.4.1 Performance of Test

 Temporary power supply for the excitation system is provided as described in Chapter 4.2.2.
 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is OPEN.
 16kV Unit GCB (=1BAC01GS100-Q0) is OPEN.
 External power supply for excitation system is switched on.
 Start the unit up to rated speed in Auto-Mode.
 Excitation ON in manual mode.
 With the excitation system in manual mode increase the stator voltage to receive ~10% of the genera-
tor rated voltage.
 Check the measurement of the corresponding voltages on all systems (control, metering, protection,
excitation system).
 Increase the rotor current respectively the voltage manually according to the tests to be performed.
 Expected voltage: max. 130% (20.8kV).

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
6.4.1.1 Open Circuit Tests for Generator (EGAT PPA – Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Open Circuit Test’.
‘Voltage Wave Form’
‘Residual Voltage’

The Test is performed according to the following test procedure:

XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.3.1 Open Circuit Saturation Characteristic
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP-Pos. 8310-0010 open circuit saturation characteristic
8310-0020 voltage symmetry
8310-0040 voltage wave form
8310-0050 shaft voltage
8310-0060 vibrations

Items to be checked during the no load test:

 No-load Saturation Characteristic
 Voltage balance/ symmetry
 Residual Voltage
 Voltage wave form including telephonic harmonic factor
 Shaft voltage
 Relative shaft vibration

6.4.1.2 Open Circuit Tests for Protection System (EGAT PPA – Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Verification and Calibration of all Protections and Protective Relay’.

The Test is performed according to the following test procedure:

XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure
Chapter: 3.8 No-Load Tests

The protection functions will be blocked by software in order to maintain the unit in operation condition. The
pickup of the protection functions will be checked on the LEDs of the respective protection relay.
Items to be tested during the no load test:
 Generator Overvoltage [59]
 Generator Undervoltage [27]
 Generator Overfrequency / Underfrequency [81]
 Generator Overfluxing [24]
 Rrotor Earth Fault [64R]
 Excitation Overcurrent [50/51ET]
 Voltage Balance [60]
 Inadvertent Energizing [50/27]
 Undervoltage / Overcurrent [51V]
 100% Stator Earth Fault [59TN/27TN]
 95% Stator Earth Fault / MV Earth Fault [64N/64B]
 Shaft current
Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
Project N° H100.002288 09.08.2017 RM LH-DE 00 Page 58 de / of 122
= +
HAV

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
6.4.1.3 Open Circuit Tests for Excitation System (EGAT PPA – Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Voltage Regulator / Adjustment for No-load Operation’.

The Test is performed according to the following test procedure:

XB-P3-PH-Q-4011-1287 Excitation System – PH EGAT Units Excitation
Commissioning Procedure & Protocol
ITP-Pos. 0221-0000 to 0221-0050
XB-P3-PH-Q-4011-1289 Excitation System – PH EGAT Units Excitation – Commissioning Instructions
Chapter: 6.8.2 Open Circuit Voltage Tests

Items to be checked during the no load test:

 Check voltage transformer circuits & phase sequence
 Functional check of the field current regulator
 Measure the no load characteristic (with generator)
 Pre-calibration of the generator voltage
 Check rotor earth fault protection

6.4.2 Final Activities after the Test

6.5 No-Load Tests with Regular Excitation Supply

These Tests shall be performed after ‘7.2 First Energizing of Main Transformer and Synchro-Check’.
The temporary test supply is removed and the final, permanent power supply via Excitation Transformer is es-
tablished (installation of flexible connectors between bus duct and excitation transformer).

6.5.1 Performance of Test

 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is OPEN.
 16kV Unit CB (=1BAC01GS100-Q0) is OPEN.
 External power supply for excitation system is switched on.
 Start the unit up to rated speed in Auto-Mode.
 Excitation ON in manual mode, performance of test according to the relevant procedure.

6.5.1.1 Open Circuit Tests for Excitation System (EGAT PPA – Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Voltage Regulator / Adjustment for No-load Operation’.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
The Test is performed according to the following test procedure:
XB-P3-PH-Q-4011-1287 Excitation System – PH EGAT Units Excitation
Commissioning Procedure & Protocol
ITP-Pos. 0221-0000 to 0221-0050 No-Load Tests
ITP-pos. 0222-0010 check excitation performance during start/stop sequence
XB-P3-PH-Q-4011-1289 Excitation System – PH EGAT Units Excitation – Commissioning Instructions
Chapter: 6.8.2 Open Circuit Voltage Tests
Items to be checked during the no load test:
 Check excitation transformer
 Rotor Current regulator tests (optimization of setting, check of stability by set value changes)
 Check of start up with Rotor Current regulator
 Test of start in manual mode
 Test of rotor current regulator
 Switch over to voltage regulator
 Voltage regulator tests
 Change over tests (check auto-balancing, change over AUTO-MANUAL)
 Test of automatic start sequence until "Excitation ON"
 Test of automatic stop sequence

6.5.1.2 No-Load Tests for Turbine Governor (EGAT PPA – Test)

The Test is performed according to the following test procedure:

XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 8.1.8.1 Tuning of Speed Controller
8.1.8.2 Steady State Speed Band
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 8.1.8.1 Tuning of Speed Controller
8.1.8.2 Steady State Speed Band
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 8.1.8.1 Tuning of Speed Controller
8.1.8.2 Steady State Speed Band

Items to be checked during the no load test:

 Automatic start-up test to nominal speed.
 Speed control loop via step functions in the set point (small and large speed set point steps are
passed to the governor (1%, 2%, 5%), record the transient response)
 Steady state operation

6.5.1.3 Tests for Control System (EGAT PPA_Test)

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
The Test is performed according to the following test procedure:
XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
Chapter: 5.14 Command Operation Check
5.16 Interlock and Sequencing Circuits
5.17 Tripping Circuit Check
XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
Chapter: 1.6 Input / Output Point Check
1.10 Test of Application Program (EGAT Test)

Items to be checked during the short-circuit test:

 Voltage measurement generator.
 Test automatic start and stop sequence (auto mode).

6.5.2 Final Activities after the Test

 After the test reduce the excitation system to its minimum.
 Excitation OFF.
 Stop of Generating Unit.
 Close 16kV Unit earthing switch (=1BAC01GS191-Q91).

6.6 Conclusion
6.6.1 No-Load Tests for Generator
The No-Load Tests for Generator have been performed and completed with satisfying results in accordance
with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
6.6.2 No-Load Tests for Turbine
The No-Load Tests for Turbine have been performed and completed with satisfying results in accordance with
the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

6.6.3 No-Load Tests for Excitation System

The No-Load Tests for Excitation System have been performed and completed with satisfying results in accord-
ance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

6.6.4 No-Load Tests for Protection System

The No-Load Tests for Protection System have been performed and completed with satisfying results in ac-
cordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
7 SYNCHRONIZING TESTS AND ENERGIZING OF MAIN TRANSFORMER

7.1 General
For performance of these tests a temporary external power supply for the excitation system is required as de-
scribed in chapter 4.2.2. of this document.
During energizing of the main transformer also both bus-bars shall be energized (for first generating unit only,
for all other generating units one bus-bar measurement is sufficient).
At nominal voltage a final check of all VT measurements required for synchronization have to be performed.
Since during the test all VT’s involved in synchronization are energized by a voltage from the same source, also
all the measurements must be equal (check voltage and phase angle on synchronizing device / synchro-check
relay, check phase sequence on VT terminals).

7.2 First Energizing of Main Transformer and Synchro-Check

7.2.1 Reference Documents
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.3.4 Synchrochecks
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP-Pos. 8310-0080
XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
XB-P3-SG-Q-6000-0080 550kV SF6 Gas Insulated Switchgear - Commissioning Procedure
XB-P3-SG-Q-6000-0081 550kV SF6 Gas Insulated Switchgear - Unit 1 Feeder - Test Record

7.2.2 Preparation
Both 500kV bus-bars at GIS are de-energized, bus-bar coupling is open.
Test set-up with check of synchronizing measurement at 500kV bus-1:
 Temporary power supply for the excitation system is provided as described in Chapter 4.2.2.
 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is CLOSED.
 16kV Unit GCB (=1BAC01GS100-Q0) is CLOSED and blocked in closed position.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at Unit 1 side (=0BBT10GS191-Q91) is
OPEN.
 16kV disconnecting switch at Disconnecting Switchgear Cubicle-1 at Unit 1 side (=0BBT10GS110-Q1)
is OPEN.
 16kV disconnecting switch at Disconnecting Switchgear Cubicle-1 at Unit 2 side (=0BBT10GS120-Q2)
is OPEN.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at Unit 2 side (=0BBT10GS192-Q92) is
CLOSED.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at UAT side (=0BBT10GS193-Q93) is
CLOSED.
 500kV Unit 1 disconnector to 500kV bus-1 (=1ABA01GS130-QB1) is CLOSED.
 500kV Unit 1 disconnector to 500kV bus-2 (=1ABA01GS140-QB2) is OPEN.
 500kV Unit 1 disconnector (=1ABA01GS120-QB9) is CLOSED.
 500kV Unit 1 CB (=1ABA01GS100-QA1) is CLOSED and blocked in closed position..
 500kV Unit 1 by-pass disconnector (=1ABA01GS110-QBX) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS191-QCX) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS192-QC2) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS193-QC1) is OPEN.
Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
Project N° H100.002288 09.08.2017 RM LH-DE 00 Page 63 de / of 122
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HAV

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
7.2.3 First Energizing of Main Transformer
Pre-condition for energizing of main transformer is the successful completion of Main Transformer commission-
ing tests including performance of transformer firefighting system test according to the relevant test procedures:
XB-P3-MT-Q-5000-0080 Main Transformers 220MVA and 80MVA Commissioning Procedure
XB-P3-MT-Q-5000-0081 Main Transformer 220MVA Unit 1 Test Record
The Test is performed according to the following test procedure:
XB-P3-SG-Q-6000-0080 550kV SF6 Gas Insulated Switchgear - Commissioning Procedure
Chapter: 7.21 Step 5.1 Energizing
XB-P3-SG-Q-6000-0081 550kV SF6 Gas Insulated Switchgear - Unit 1 Feeder - Test Record
Chapter: 5.1 Energizing
During the energizing test the main transformer shall be attended by one commissioning engineer and checked
for abnormal behaviour and noise. In case any abnormality is observed the test shall be stopped immediately.
 External power supply for excitation system is switched on.
 Start the unit up to rated speed in Auto-Mode.
 Excitation ON in manual mode.
 With the excitation system in manual mode increase the stator voltage to receive 10% of the generator
rated voltage.
 Check the measurement of the corresponding voltages on all systems (control, metering, protection,
excitation system).
 Increase the rotor current respectively the voltage manually in steps of 10% (50kV) until 110% (550kV)
of nominal voltage UN.
 After each 10% step wait for confirmation from the commissioning engineer attending the transformer
before initiating the next step.
 After reaching 110% UN = 550kV and confirmation from the commissioning engineer attending the
transformer, reduce to 100% UN = 500kV.
The ‘First Energizing of Main Transformer’ is completed and the ‘Synchro -Check’ shall be performed.

7.2.4 Synchro –Check (EGAT PPA Test)

To be performed right after completion of ‘7.2.3 First Energizing of Main Transformer’.

Performance of Test:
 Check phase sequence at all VT’s involved in synchronizing and energized during this test:
=1BAC01CE210 and =1BAC01CE220 on 16kV Unit 1 CB cubicle
=1ABA01GV111 on 500kV Unit 1 Feeder (GIS)
=0ABA01CE200 on 500kV Bus-1 (GIS)
 Check voltages
 Activate synchronizing device for check of voltage, frequency and phase angle (SYN 3000 at Unit
Control Board)
 Activate and check synchro-check relay (breaker selection / bus selection at Unit Control Board)

After successful performance of synchro-check with 500kV Bus-1 the test shall be performed also with 500kV
bus-2. For change of test set-up it is not required to stop the Unit.
Change of test set-up for check of synchronizing measurement at 500kV bus-2:
 Keep Unit in operation; reduce excitation (stator voltage) to its minimum.
 Excitation OFF
Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
Project N° H100.002288 09.08.2017 RM LH-DE 00 Page 64 de / of 122
= +
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Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
 Open 500kV Unit 1 CB (=1ABA01GS100-QA1)
 Open 500kV Unit 1 disconnector to 500kV Bus-1 (=1ABA01GS130-QB1)
 Close 500kV Unit 1 disconnector to 500kV Bus-2 (=1ABA01GS140-QB2)
 Close 500kV Unit 1 CB (=1ABA01GS100-QA1)
 Excitation ON in manual mode.
 With the excitation system in manual mode increase the stator voltage to receive 100% UN (=500kV).
 Check phase sequence and voltage on Bus-2 VT =0ABA02CE200
 Activate and check synchro-check relay (breaker selection / bus selection at Unit Control Board)

VT Phase Sequence Date / Signature Remark

=1BAC01CE210

=1BAC01CE220

=1ABA01GV111

=0ABA01CE200

7.2.5 Final Activities after the Tests

 After the test reduce the excitation system to its minimum.
 Excitation OFF.
 Stop of Generating Unit.
 Switch off 22kV supply for excitation transformer.
 Close 16kV Unit Earthing Switch (=1BAC01GS191-Q91).
 Open 16kV Unit Disconnector (=1BAC01GS110-Q1).
 Open 16kV Unit GCB (=1BAC01GS100-Q0), re-establish interlocking and normal operating condition.
 Open 500kV Unit 1 disconnector to 500kV bus-2 (=1ABA01GS140-QB2).
 Open 500kV Unit 1 disconnector (=1ABA01GS120-QB9).
 Open 500kV Unit 1 CB (=1ABA01GS100-QA1), re-establish interlocking and normal operating condi-
tion.
 Check all locations affected during the test.
The temporary test supply for Excitation System via external transformer is disconnected and the final, perma-
nent power supply via Excitation Transformer is established (installation of flexible connectors between bus duct
and excitation transformer).

7.2.6 Conclusion
First Energizing of Main Transformer and Synchro-Check was performed and completed with satisfying results
for all the involved systems in accordance with the test procedures listed above.
ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
7.3 Synchronizing Tests (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Synchronization Test’.

7.3.1 Pre-Condition:
 All No-Load Tests (Short-Circuit, Earth Fault and Open Circuit Tests) are completed, all electrical pro-
tections have been tested successfully.
 All electrical- (hardwired) and mechanical interlocks on 15kV and 220kV are tested and are working
correctly.
 Excitation System is connected to its final supply (generator bus-duct).

7.3.2 Reference Documents

XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
Chapter: 1.7 Synchronization Test (EGAT Test)
1.8 16kV Breaker Test (EGAT Test)
1.9 500kV Breaker Test (EGAT Test)
XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
Chapter: 5.18 Synchronization Check
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.3.4 Synchrochecks
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP-Pos. 8310-0080

7.3.3 Synchronizing Tests with 500kV CB

7.3.3.1 Preparation
 500kV Line and Bus-1 are energized.
 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is CLOSED.
 16kV Unit GCB (=1BAC01GS100-Q0) is CLOSED (from CB pre-selection).
 Excitation System is connected to its final supply (generator bus-bar).
 500kV Unit 1 disconnector to 500kV bus-1 (=1ABA01GS130-QB1) is CLOSED.
 500kV Unit 1 disconnector to 500kV bus-2 (=1ABA01GS140-QB2) is OPEN.
 500kV Unit 1 by-pass disconnector (=1ABA01GS110-QBX) is OPEN.
 500kV Unit 1 disconnector (=1ABA01GS120-QB9) is OPEN.
 500kV Unit 1 CB (=1ABA01GS100-QA1) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS191-QCX) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS192-QC2) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS193-QC1) is OPEN.
 Selector switch for Synchronization is switched OFF.

7.3.3.2 Performance of Test

 Manipulate interlock between 500kV Unit 1 disconnector (=1ABA01GS120-QB9) and 500kV Unit 1
CB (=1ABA01GS100-QA1):
500kV Unit 1 disconnector (=1ABA01GS120-QB9) must stay in OPEN position but feedback should
show ‘CLOSED’.
Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
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Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
 Disconnect ‘CB ON Feedback Command’ from 500kV Unit 1 CB (=1ABA01GS100-QA1) to Turbine
Controller in order to prevent automatic opening of Guide Vanes after closing of CB.
 Check phase sequence at VT =0ABA01CE200 on 500kV Bus-1 (GIS) (must be same as measured
during Synchro-Check in Chapter 7.2.4 of this document).
 Start the unit in auto-mode up to no-load operation (idle run, excitation on, nominal generator voltage
16kV).
 Switch Synchronization to MANUAL.
 Check measurements (voltage, frequency, phase angle), give higher / lower commands for speed
(frequency) and voltage, confirm function.
 Perform one test (dummy) synchronization manually by giving CB close command.
 After successful manual dummy-synchronization re-open CB.
 Switch Synchronization to AUTO.
 Perform one auto-dummy-synchronization.
 After successful auto-dummy-synchronization open 500kV CB and initiate auto-stop of generating
unit.
 Undo the manipulation on 500kV Unit 1 disconnector (=1ABA01GS120-QB9).

7.3.3.3 Tests for Turbine Governor

 Check signals from synchronizing equipment to electronic governor.
 Check signals from push buttons to electronic governor.

7.3.3.4 Tests for Excitation System

 Check signals from synchronizing equipment to voltage regulator.
 Check signals from push buttons to voltage regulator.

7.3.3.5 Tests for Control System

 Check of voltage measurement.
 Check of synchronising circuits (VT secondaries).
 Check of voltage difference measured by the synchronizing relay.
 Check of angle difference by the synchronizing relay.
 Check of angle difference by the synchronoscope.
 Check of frequency difference by the synchronizing relay.

7.3.3.6 Conclusion

Synchronizing Test with 500kV Unit Feeder CB was performed and completed with satisfying results for all the
involved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
7.3.4 Synchronizing Tests with 16kV CB
In parallel to this test also the ‘7.4 Back-Energizing and No-Load Test of Main Transformer’ shall be start-
ed. For the synchronizing test with 16kV CB it is required to energize the Main Transformer from 500kV grid.
The Main Transformer shall remain energized until the no-load test is completed.

7.3.4.1 Preparation
 Excitation System is connected to its final supply (generator bus-bar).
 500kV Line and Bus-1 are energized.
 500kV Unit 1 disconnector to 500kV bus-1 (=1ABA01GS130-QB1) is CLOSED.
 500kV Unit 1 disconnector to 500kV bus-2 (=1ABA01GS140-QB2) is OPEN.
 500kV Unit 1 by-pass disconnector (=1ABA01GS110-QBX) is OPEN.
 500kV Unit 1 disconnector (=1ABA01GS120-QB9) is CLOSED.
 500kV Unit 1 CB (=1ABA01GS100-QA1) is CLOSED, Unit 1 Main Transformer is energized.
 500kV Unit 1 earthing switch (=1ABA01GS191-QCX) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS192-QC2) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS193-QC1) is OPEN.
 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is CLOSED.
 16kV Unit GCB (=1BAC01GS100-Q0) is OPEN.
 Selector switch for Synchronization is switched OFF.

7.3.4.2 Performance of Test

 Disconnect ‘CB ON Command’ from synchronizing device ‘SYN 3000’ to 16kV Unit GCB
(=1BAC01GS100-Q0)
 Check phase sequence at VT =1ABA01GV111 and =1BAC01CE220 (must be same as measured
during Synchro-Check in Chapter 7.2.4 of this document).
 Start the unit auto-mode up to no-load operation (idle run, excitation on, nominal generator voltage
16kV).
 Switch Synchronization to MANUAL.
 Check measurements (voltage, frequency, phase angle), give higher / lower commands for speed
(frequency) and voltage, confirm function.
 Perform one test (dummy) synchronization manually by giving CB close command and check output /
LED at SYN 3000.
 After successful manual dummy-synchronization switch Synchronization to AUTO.
 Perform one auto-dummy-synchronization, check output / LED at SYN 3000.
 After successful auto-dummy-synchronization initiate auto-stop of generating unit.

7.3.4.3 Tests for Turbine Governor

 Check signals from synchronizing equipment to electronic governor.
 Check signals from push buttons to electronic governor.

7.3.4.4 Tests for Excitation System

 Check signals from synchronizing equipment to voltage regulator.
 Check signals from push buttons to voltage regulator.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
7.3.4.5 Tests for Control System
 Check of voltage measurement.
 Check of synchronising circuits (VT secondaries).
 Check of voltage difference measured by the synchronizing relay.
 Check of angle difference by the synchronizing relay.
 Check of angle difference by the synchronoscope.
 Check of frequency difference by the synchronizing relay.

7.3.4.6 Conclusion

Synchronizing Test with 16kV GCB was performed and completed with satisfying results for all the involved sys-
tems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
7.4 Back-Energizing and No-Load Test of Main Transformer (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.4 ‘The Generator Subsystem (iv): Xayaburi Switchyard’
2.4.1 ‘Pre-Connection Commissioning Phase’
Test Item: ‘AC Voltage Withstand Test’.
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.4 ‘The Generator Subsystem (iv): Xayaburi Switchyard’
2.4.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Back-Energization from Loei 2 Substation by Transmission Circuit 1’
‘Back-Energization from Loei 2 Substation by Transmission Circuit 2’

Pre-Condition:
Successful performance of the test ‘7.2 First Energizing of Main Transformer and Synchro-Check’.
At least one 500kV bus at GIS is energized from 500kV grid.
Remark:
After successful completion of the No-Load Test of Main Transformer the UAT 1 can be energized for supply to
the 22kV station service distribution.
The Test is performed according to the following test procedure:
XB-P3-SG-Q-6000-0080 550kV SF6 Gas Insulated Switchgear - Commissioning Procedure
Chapter: 7.22 Step 5.2 AC Withstand Test
XB-P3-SG-Q-6000-0081 550kV SF6 Gas Insulated Switchgear - Unit 1 Feeder - Test Record
Chapter: 5.2 AC Withstand Test

7.4.1 Preparation
 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is OPEN.
 16kV Unit GCB (=1BAC01GS100-Q0) is OPEN.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at Unit 1 side (=0BBT10GS191-Q91) is
OPEN.
 16kV disconnecting switch at Disconnecting Switchgear Cubicle-1 at Unit 1 side (=0BBT10GS110-Q1)
is OPEN.
 16kV disconnecting switch at Disconnecting Switchgear Cubicle-1 at Unit 2 side (=0BBT10GS120-Q2)
is OPEN.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at Unit 2 side (=0BBT10GS192-Q92) is
CLOSED.
 16kV earthing switch at Disconnecting Switchgear Cubicle-1 at UAT side (=0BBT10GS193-Q93) is
CLOSED.
 500kV Unit 1 disconnector to 500kV bus-1 (=1ABA01GS130-QB1) CLOSED or alternative 500kV Unit
1 disconnector to 500kV bus-2 (=1ABA01GS140-QB2) is CLOSED – depending on which 500kV bus
is energized.
 500kV Unit 1 disconnector (=1ABA01GS120-QB9) is CLOSED.
 500kV Unit 1 CB (=1ABA01GS100-QA1) is OPEN.
 500kV Unit 1 by-pass disconnector (=1ABA01GS110-QBX) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS191-QCX) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS192-QC2) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS193-QC1) is OPEN.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
7.4.2 Performance
 Close 500kV Unit 1 CB (=1ABA01GS100-QA1).
 Keep Main Transformer energized for minimum 24h.
 Recording of voltage and temperatures in SCADA
 perform regular visual inspection, check for oil leakages and abnormal noise
In case of interruption of grid connection (i.e. grid failure) the test is interrupted and shall continue after grid
availability is re-established.
In case of trip due to transformer protection an investigation of the fault is required. Thereafter it shall be decid-
ed if the test can be continued or if it has to be re-started.

7.4.3 Conclusion
The No-Load Test of Main Transformer was performed and completed with satisfying results in accordance with
the test procedures listed above.

Start of No-Load Test Date: Time: Signature:

End of No-Load Test Date: Time: Signature:

Comments:

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
8 VERIFICATION OF WATER LEVEL MEASUREMENT (EGAT PPA TEST)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘Water Measuring System Checks (with First Generating Unit only)’.

The test is performed according to the following document:

XB-P3-PH-Q-4081-9993 EGAT Water Level Measurement - Commissioning Procedure

8.1 Conclusion
Verification of Water Level Measurement has been performed and completed with satisfying results for all the
involved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
9 THE GENERATOR STABILITY DATA (EGAT PPA TEST)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energization Commissioning Phase’
Test Item: ‘The Generator Stability Data’.

9.1 Unit Inertia Constant H

Reference is also made to Exhibit IV: Particular Technical Specifications, Part 1 of 3, Section 1.1: Turbines and
Governors: Unit No. 1-7, Chapter 13.3.2 ‘Commissioning Tests’.

The Test shall not be performed; the Unit Inertia Constant (H) shall be determined by calculation.
Refer also to Workflow Note HAV-TRANSMIT-004422, dated 21-Jul-2017
Noted:
Please noted that this is our CHK Package 3 comments on this document as following:
TC-P3-096: EGAT already accepted that Unit Inertia constant (H) test is not required, and H will be determined
by the calculation and AH design drawings. Please refer to MoM with EGAT, held on 21 March 2017, Item1.5.

9.2 Generator Unsaturated Direct Transient Reactance Xd’

Refer to Chapter ‘16.1 Sudden Short-Circuit Test’ of this document.

9.3 Generator Unsaturated Direct Sub-Transient Reactance Xd’’

Refer to Chapter ‘16.1 Sudden Short-Circuit Test’ of this document.

9.4 Generator Open Circuit Transient Time Constant Tdo’

9.4.1 Purpose of this Test
This test shall be performed for determination of the Generator Direct-Axis Open Circuit Transient Time Con-
stant Tdo’ and Direct-Axis Open Circuit Sub-Transient Time Constant Tdo’’ .
Basically there are two methods for determination of Tdo’ and Tdo’’:
 Field Current Decay Test
 Voltage Recovery Test

The Field Current Decay Test is requested by the EGAT PPA. It is possible to perform this test on each generat-
ing unit.
In case Field Current Decay test proves as not practicable, Voltage Recovery Test could be performed instead.
In this case the test shall be performed as a Type Test on Unit 1 only together with the ‘Sudden Short-Circuit
Test’ since the test set-up is identical.
Voltage Recovery Test set-up and performance is described in Chapter ‘16.2 Voltage Recovery Test’ of this
document.
Refer also to TC-P3-098.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
9.4.2 Preparation of Field Current Decay Test
Set-up of measuring circuit for Field Current Decay Test:

 The de-excitation resistor must be short-circuited for the duration of this test.
 The test may be performed in current regulation mode.

9.4.3 Performance of Test

 15kV GCB is open.
 Test shunt and equipment is installed.
 Unit in operation at rated speed, excited and at no load.
 Shorten and disconnect excitation circuit (rotor circuit).
 Recording of decaying armature voltage, excitation current and slip ring voltage till steady state.

9.4.4 Final Activities.

 Stop of unit.
 Disconnect and remove temporary cables, short-circuit bar and test-shunts etc.

9.5 Unit Step-Up Transformer Short-Circuit Reactance Xt

The Unit Step-Up Transformer Short-Circuit Reactance Xt is determined during FAT and shall not be repeated
during Commissioning. Reference is made to EGAT PPA Schedule 17, Part I, Chapter 5 ‘Factory Acceptance
Test’.
XB-P3-MT-Q-5000-0071 Main transformers – Main Transformer 220MVA Unit 1
Factory Acceptance Test Protocol
Routine Test Report, Chapter 9 ‘Measuring of Short-Circuit Impedance’

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
9.6 Unit Excitation System Ceiling Voltage Up
The Unit Excitation System Ceiling Voltage Test is performed during FAT and shall not be repeated during
Commissioning. Reference is made to EGAT PPA Schedule 17, Part I, Chapter 5 ‘Factory Acceptance Test’.
XB-P3-PH-Q-4011-1295 Excitation System – PH EGAT Units Excitation – Factory Acceptance Protocol
Chapter: 7 Functional Tests

9.7 Other the Generator Stability Data

The tests and data specified in EGAT PPA Schedule 1, Part II: Determination in Respect of Stability Limit are al-
ready covered by the routine tests of the relevant systems.
In case additional or more detailed tests are required it should be communicated in due time before or during
commissioning phase and mutually agreed.

9.8 Conclusion
The Generator Stability Data Tests have been performed and completed for all involved systems with satisfying
results in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
10 UNIT METERING SYSTEM CHECK AND ACCURACY TEST (EGAT PPA TEST)

10.1 Reference Documents

XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
XB-P3-PH-Q-4081-9721 Control System – 550kV Metering Board Unit 1&2&3
Commissioning Report
Chapter: 1.6 Metering Unit 1 Functional Step (EGAT Test)

10.2 Tests at Pre-Energization Commissioning Phase

10.2.1 Primary VT and CT Tests

Reference is made to following document:
XB-P3-PH-Q-4081-9721 Control System – 550kV Metering Board Unit 1&2&3
Commissioning Report
Chapter: 1.6.1 Primary VT and CT Test

These tests are performed as part of 500kV GIS commissioning. The results are documented in the following
test record:
XB-P3-SG-Q-6000-0081 550kV SF6 Gas Insulated Switchgear - Unit 1 Feeder - Test Record

10.2.2 Function Tests

Reference is made to following documents:
XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
Chapter: 5.15 Measuring Instrument
5.19 Communication Tests
XB-P3-PH-Q-4081-9721 Control System – 550kV Metering Board Unit 1&2&3
Commissioning Report
Chapter: 1.6.2 Secondary Injection Tests
1.6.3 Communication Tests

10.2.3 Conclusion
Pre-Energization Commissioning Tests have been performed and completed with satisfying results for all the in-
volved systems in accordance with the test procedures listed above.
ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
10.3 Tests at Post-Energization Commissioning Phase
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Unit Metering System Check and Accuracy Test’.

10.3.1 Metering Function Tests

Reference is made to following documents:
XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
Chapter: 5.19 Communication Tests
XB-P3-PH-Q-4081-9721 Control System – 550kV Metering Board Unit 1&2&3
Commissioning Report
Chapter: 1.6.3 Communication Tests

10.3.2 Conclusion
Post-Energization Commissioning Tests have been performed and completed with satisfying results for all the
involved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
11 FIRST SYNCHRONIZATION
Pre-Condition: Synchronizing Tests completed and Step-Up Transformer No-load Test finalized.

11.1 Reference Documents

XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
Chapter: 5.18.2.5 First Manual Synchronization wet test
Chapter: 5.18.2.6 First Automatic Synchronization wet test
XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 9.1.1 First Synchronizing
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 9.1.1 First Synchronizing
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 9.1.1 First Synchronizing

11.2 Performance of Test

Preferable the first hot synchronizing attempt shall be made with 16kV GCB.
Prior to the first hot synchronizing attempt the ‘dummy synchronization’ as described under ‘7.3.4 Synchroniz-
ing Tests with 16kV CB’ shall be repeated.

11.2.1 First Synchronization with 16kV GCB

11.2.1.1 Initial Condition
 Excitation System is connected to its final supply (generator bus-bar).
 500kV Line and Bus-1 are energized.
 500kV Unit 1 disconnector to 500kV bus-1 (=1ABA01GS130-QB1) is CLOSED.
 500kV Unit 1 disconnector to 500kV bus-2 (=1ABA01GS140-QB2) is OPEN.
 500kV Unit 1 by-pass disconnector (=1ABA01GS110-QBX) is OPEN.
 500kV Unit 1 disconnector (=1ABA01GS120-QB9) is CLOSED.
 500kV Unit 1 CB (=1ABA01GS100-QA1) is CLOSED, Unit 1 Main Transformer is energized.
 500kV Unit 1 earthing switch (=1ABA01GS191-QCX) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS192-QC2) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS193-QC1) is OPEN.
 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is CLOSED.
 16kV Unit GCB (=1BAC01GS100-Q0) is OPEN.
 ‘CB ON Command’ from synchronizing device ‘SYN 3000’ to 16kV Unit GCB (=1BAC01GS100-Q0) is
re-connected.
 Selector switch for Synchronization is switched OFF.
11.2.1.2 First synchronizing attempt in manual mode
 Pre-select synchronizing with 16kV GCB
 Check function of ‘Breaker Selection 16kV / 500kV’ at Unit Control Board.
 Start the unit auto-mode up to no-load operation (idle run, excitation on, nominal generator voltage
16kV).
 Switch Synchronization to MANUAL.
 Check measurements (voltage, frequency, phase angle), give higher / lower commands for speed
(frequency) and voltage as required.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
 Establish synchronizing condition and give CB close command via push-button.
 Go to minimum adjustable load, check measurements and stability.
 Stop Unit by pressing of Emergency Stop.
11.2.1.3 Second synchronizing attempt in automatic mode:
 Start the unit auto-mode up to no-load operation (idle run, excitation on, nominal generator voltage
16kV).
 Switch Synchronization to AUTO.
 Check function of synchronizing device (higher / lower commands for speed and voltage).
 After synchronization go to minimum adjustable load.
 Stop Unit by initiating ‘Normal Stop’.

11.2.2 First Synchronization with 500kV Unit Feeder CB

11.2.2.1 Initial Condition
 500kV Line and Bus-1 are energized.
 16kV Unit Earthing Switch (=1BAC01GS191-Q91) is OPEN.
 16kV Unit Disconnector (=1BAC01GS110-Q1) is OPEN.
 16kV Unit GCB (=1BAC01GS100-Q0) is OPEN.
 500kV Unit 1 disconnector to 500kV bus-1 (=1ABA01GS130-QB1) is CLOSED.
 500kV Unit 1 disconnector to 500kV bus-2 (=1ABA01GS140-QB2) is OPEN.
 500kV Unit 1 by-pass disconnector (=1ABA01GS110-QBX) is OPEN.
 500kV Unit 1 disconnector (=1ABA01GS120-QB9) is OPEN.
 500kV Unit 1 CB (=1ABA01GS100-QA1) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS191-QCX) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS192-QC2) is OPEN.
 500kV Unit 1 earthing switch (=1ABA01GS193-QC1) is OPEN.
 Selector switch for Synchronization is switched OFF.
11.2.2.2 First synchronizing attempt in manual mode
 Pre-select synchronizing with 500kV Unit Feeder CB
 Check function of ‘Breaker Selection 16kV / 500kV’ at Unit Control Board.
 Start the unit auto-mode up to no-load operation (idle run, excitation on, nominal generator voltage
16kV).
 Switch Synchronization to MANUAL.
 Check measurements (voltage, frequency, phase angle), give higher / lower commands for speed
(frequency) and voltage as required.
 Establish synchronizing condition and give CB close command via push-button.
 Go to minimum adjustable load.
 Select ‘No Load Operation’ on Unit Control Board.
 Keep Unit running in ‘No Load Operation’
11.2.2.3 Second synchronizing attempt in automatic mode:
 Unit running in ‘No Load Operation’
 Switch Synchronization to AUTO.
 Check function of synchronizing device (higher / lower commands for speed and voltage).
 Go to 25% load.
 Check measurements, stability, vibrations etc.
 Perform 25% ESD.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
11.3 Conclusion
First Synchronization was performed and completed with satisfying results for all the involved systems in ac-
cordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
12 LOAD TESTS

12.1 General
The Load Tests shall be performed together (load rejections and shut-down tests) in load steps of 25%:
1st Step 25% Load Rejection and Shut-Down Tests (ESD / QSD)
2nd Step 50% Load Rejection and Shut-Down Tests (ESD / QSD)
3rd Step 75% Load Rejection and Shut-Down Tests (ESD / QSD)
4th Step 100% Load Rejection and Shut-Down Tests (ESD / QSD)
ESD at minimum load and at 25% load was already performed together with ‘First Synchronization’ and there-
fore does not need to be repeated.
For all tests the relevant data shall be recorded:
 Actual head
 Actual load
 Position of wicket gate and runner
 Speed rise
 Pressure in semi spiral case and draft tube
 vibrations
At each load step the generating unit shall be operated for approx. 15 minutes for recording of vibrations and
check of balancing. Final balancing is performed during load tests / load operation. Installation of balancing
weights shall be done preferable in the morning prior to start of test, when the temperature inside the generator
is still low. It might be advisable to open one generator top cover over night for cooling.
Refer to Chapter ‘3.2 Balancing (EGAT PPA - Test)’ for installation of balancing weights and safety precau-
tions.

12.2 Reference Documents

XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 9.1.2 Load Rejection / Trip tests
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 9.1.2 Load Rejection / Trip tests
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 9.1.2 Load Rejection / Trip tests
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.4.2 Load Rejection Tests
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
Chapter: 1.10 Test of Application Program (EGAT Test)
1.11 Start/Stop Sequence Check
XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure
Chapter: 3.9 Load Tests
XB-P3-PH-Q-4011-1287 Excitation System – PH EGAT Units Excitation
Commissioning Procedure & Protocol
XB-P3-PH-Q-4011-1289 Excitation System – PH EGAT Units Excitation – Commissioning Instructions

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
12.3 Load Rejection Test – Preliminary (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Active Load Rejection Test (25%, 50%, 75%, 100%Load)’.

The Load Rejection Test is to be performed with the actual available Head. The test is classified ‘preliminary’
since it has to be repeated at Rated Net Head (Hnet = 28.5m) during the ‘18.1 Load Rejection Test at Rated
Head (Hnet = 28.5m)’.
If it can be arranged to perform this test at Rated Net Head (Hnet = 28.5m) already during this phase of commis-
sioning, the test shall be witnessed and the results documented according to the requirements of the ‘Error!
Reference source not found. Error! Reference source not found.’. In such case the test shall be valid as
‘Performance Test’ according to PTS and shall not be repeated.

12.3.1 Performance of Test

The Test is performed according to the following test procedures:
XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 9.1.2.5 Load Rejection
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 9.1.2.5 Load Rejection
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 9.1.2.5 Load Rejection
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.4.2 Load Rejection Tests
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP-Pos. 8340-0020 load rejection
XB-P3-PH-Q-4011-1287 Excitation System – PH EGAT Units Excitation
Commissioning Procedure & Protocol
ITP-Pos. 0224-0000 check of power measurement
ITP-Pos. 0224-0015 check excitation behavior during load rejections
ITP-Pos. 0224-0020 check of limiters
XB-P3-PH-Q-4011-1289 Excitation System – PH EGAT Units Excitation – Commissioning Instructions
Chapter: 6.9 Load Tests
XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
Chapter: 1.10 Test of Application Program (EGAT Test)

Test Procedure:
 Generating Unit is synchronized, load for test is adjusted
 Operate for approx. 15 minutes on test load for recording of vibrations and check of balancing
 Initiate load rejection by opening of 16kV GCB (with count-down for correct start of recording)
 Verify correct behaviour of turbine governor
 After stabilization of generating unit at No-load Operation the next step shall be initiated
Remark: Load Rejection Test should not be performed with cold bearings!

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
12.3.1.1 Tests for Turbine
 Optimization of parameters for speed controller

12.3.1.2 Tests for Excitation System

 Check of power measurement
 At load rejection steps of 25% & 50% check of minimum field current limiter).
 At load rejection steps of 75% & 100%. check of maximum field current limiter, load angle limiter, sta-
tor current limiter

12.3.1.3 Test for Protection System

 Stability checks of protection systems

12.3.1.4 Tests for Control System

 Start-stop sequence tests
 Load Rejection and re-synchronization

Results:
Load Load [MW] Net-Head [m] Max. Speed Rise [%]

25%

50%

75%

100%

12.3.2 Conclusion
Load rejection Tests have been performed and completed with satisfying results for all the involved systems in
accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
12.4 Shut-Down Tests ESD / QSD
According to contractual requirement (PTS) it is requested to perform the following shut-down tests:
 Electric Quick Shut-Down (QSD-2) at 50% load
 Mechanical Quick Shut-Down (QSD-1) at 100% load
 Emergency Shut-Down (ESD) at 100% load.
In case this load steps are found insufficient during performance of the tests, additional load steps shall be de-
fined by mutual agreement and performed.

12.4.1 Performance of Test

The Test is performed according to the following test procedures:
XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 9.1.2.1 Quick shutdown mechanical (QSD-M)
9.1.2.2 Emergency shutdown mechanical (ESD-M)
9.1.2.3 Quick shutdown electrical (QSD-E)
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 9.1.2.1 Quick shutdown mechanical (QSD-M)
9.1.2.2 Emergency shutdown mechanical (ESD-M)
9.1.2.3 Quick shutdown electrical (QSD-E)
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 9.1.2.1 Quick shutdown mechanical (QSD-M)
9.1.2.2 Emergency shutdown mechanical (ESD-M)
9.1.2.3 Quick shutdown electrical (QSD-E)
XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
Chapter: 1.10 Test of Application Program (EGAT Test)
1.11 Start/Stop Sequence Check

Test Procedure:
 Generating Unit is synchronized, load for test is adjusted
 Simulate a trip from protection system with the required criteria for the shut-down to be tested (with
count-down for correct start of recording)
 Verify correct behaviour of turbine governor
 After stop of generating unit it shall be re-started for the next test.

12.4.1.1 Tests for Turbine

 Optimization of parameters for speed controller

12.4.1.2 Tests for Control System

 Start-stop sequence tests
 Shut-down sequence test ESD
 Shut-down sequence test QSD

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
Results:

Load Net-Head Max. Speed Rise [%]

Load
[MW] [m] ESD QSD-1 (M) QSD-2 (E)

25%

50%

75%

100%

12.4.2 Conclusion
Shut-Down Tests have been performed and completed with satisfying results for all the involved systems in ac-
cordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
12.5 Intake Gate Emergency Shut-Down Test
12.5.1 General
The test should prove a safe Full Load Water-Flow Cut-Off by closing of Intake Gate with Generating Unit at full
load operation. The test should be performed with maximum available Head, at least with nominal head.
The Intake Gates are in scope of P2, therefore operation and monitoring of Intake Gates and associated equip-
ment during the test is under responsibility of P2.
P2 has to confirm the suitability of intake gates and associated equipment for this test and inform about closing
speed, durations and other relevant parameters for the test.
It must be ensured that all three intake roller gates of the Generating Unit 1 are closing simultaneously.
The generating unit shall remain on the grid with max. load possible until Intake gate is closed and/or the gener-
ator is tripped by reverse power protection.

12.5.2 Preparation
 Intake Gates are fully open.
 Unit is running with 100% load in normal grid operation.
 Temporary block Wicket Gate and Turbine Runner in open position.
 Temporary block any electrical function that may take the Unit from the grid if Intake Gate start closing
(hard wired, software, sequence from Control etc.)
 Electric protection functions must remain active (especially Reverse Power Trip).

12.5.3 Performance of Test

 Closing of Intake gate via Emergency Closing command.
 Verify pressure and noise.
 Once Intake Gate is fully closed → immediately unblock Wicket Gate and Runner.
 In case of any unforeseen event or problem at Intake Gates (unbalanced closing or blocking etc.)
→ immediately unblock Wicket Gate and Runner.

12.5.4 Final Activities

 Unblock all electrical functions that had been blocked for this test (hard wired, software, sequence
from Control etc.) and confirm proper function.

12.5.5 Conclusion
The Intake Gate Emergency Shut-Down Test has been performed and completed with satisfying results for all
the involved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
13 LOAD RUN
The purpose of the Load Run tests is the optimization of the generating unit operation performance. Optimiza-
tion of all operational parameters for Turbine Controller, Excitation System, Control System and Protection Sys-
tem is performed.
During Load Run Tests a continuous check of vibrations for fine-tuning of balancing shall be performed. Installa-
tion of balancing weights shall be done preferable in the morning prior to start of test, when the temperature in-
side the generator is still low. It might be advisable to open one generator top cover over night for cooling.
Refer to Chapter ‘3.2 Balancing (EGAT PPA - Test)’ for installation of balancing weights and safety precau-
tions.

13.1 Reference Documents

XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 9.1.3 Load Controller Tests
9.1.4 Load Tests
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 9.1.3 Load Controller Tests
9.1.4 Load Tests

XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 9.1.3 Load Controller Tests
9.1.4 Load Tests
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.4.1 Power Factor Zero Characteristics
8.4.5 Load Angle Measurement
8.4.6 Reactive Power Capability Test
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP-Pos. 8340-0010
XB-P3-PH-Q-4081-9700 Control System – Commissioning – Method Statement
XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
Chapter: 1.10 Test of Application Program (EGAT Test)
1.11 Sequence Timers (EGAT Test)
XB-P3-PH-Q-4091-1232 Protection System – PH EGAT Unit 1 – Commissioning Procedure
Chapter: 3.9 Load Tests
XB-P3-PH-Q-4011-1287 Excitation System – PH EGAT Units Excitation
Commissioning Procedure & Protocol
ITP-Pos. 0224-0000 to 0224-0035
XB-P3-PH-Q-4011-1289 Excitation System – PH EGAT Units Excitation – Commissioning Instructions
Chapter: 6.9 Load Tests

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
13.2 Recording of Power Factor Zero Characteristic (V-Curve)
13.2.1 Performance of Test
The Test is performed according to the following test procedures:
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.4.1 Power factor Zero Characteristics
XB-P3-PH-Q-2100-0331 Generator EGAT – Efficiency Test
Chapter: 7.5.5 Zero Power Factor Characteristics
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP-Pos. 8340-0010 characteristic cos phi 0 overexc. / underexc.
Applicable Standards: IEC 60034-4; 6.8; IEEE 115, 4.2.10

Start of test:
 Start of generating unit in auto-mode up to grid operation at min. load
 Change turbine governor to manual mode
 Adjust min. active power were safe turbine operation is possible and protection is still stable (e.g. re-
verse power)
 Change excitation to manual mode
 Increase reactive power in predefined steps up to the required maximum of test (over-excitation 0.7 *
Ir and under-excitation 0.4 * Ir) or to the limitations given by the grid conditions
 For each step the relevant data is recorded (active/reactive power, stator voltage & current, field cur-
rent etc.)

13.2.2 Conclusion
Recording of Power Factor Zero Characteristic has been performed and completed with satisfying results in ac-
cordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
13.3 Load Controller Tests
13.3.1 Load Step Response
The Load Step Response Test is to be performed with the actual available Head. The test is classified ‘prelimi-
nary’ since it has to be repeated at Rated Net Head (Hnet = 28.5m) during the ‘18.2 Load Step Response Test
at Rated Head (Hnet = 28.5m)’.
If it can be arranged to perform this test at Rated Net Head (Hnet = 28.5m) already during this phase of commis-
sioning, the test shall be witnessed and the results documented according to the requirements of the ‘18 Gen-
erating Unit Performance Tests & Field Acceptance Tests’. In such case the test shall be valid as ‘Perfor-
mance Test’ according to PTS and shall not be repeated.

13.3.1.1 Reference Documents

13.3.1.2 Performance of test:

 Start of generating unit in auto-mode up to grid operation at min. load
 Small and larger load set points are sent to the governor
 Tuning of the load controller until satisfactory behaviour is reached
 After finalizing the settings a series of step-responses is recorded (up and down)
Recorded Values:
 Regulating device position
 Speed
 Active power
 Pressure in semi spiral case and draft tube
 Load controller set point

13.3.1.3 Conclusion
Load Step Response Tests have been performed and completed with satisfying results in accordance with the
test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
13.3.2 Frequency Response Test (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Unit Primary response Test’.
This Chapter ‘Frequency Response Test’ only covers the test specified EGAT PPA Schedule 17, Part IV, Chap-
ter 12 ‘Specific requirements for Testing Unit Primary Response’ and Sub-Chapter 13.1.
For the Primary Response Tests combined with AGV refer to Chapter ‘19.5 Unit Primary Response Test and
AGV Performance (EGAT PPA Test)’ of this document.

13.3.2.1 Reference Documents

13.3.2.2 Performance of test:

 Start of generating unit in auto-mode up to grid operation at min. load
 Governor droop adjusted to 4%
 Adjust load for test (usually started with full load but covering full operating range)
 Start of test by simulating 100% speed and wait until the generating unit has stabilized at target out-
put value.
 Keep steady-state operation for minimum 120 seconds.
 Simulate a frequency change of +150mHz plus the magnitude of the deadband to the speed signal.
 Measure the power change not more than 25 seconds after the frequency change injection (expected
load decrease is 7.5%).
 The frequency disturbance is set to zero again and the governor will control the output back to the
original set value.
 Keep steady-state operation for minimum 120 seconds.
 Simulate a frequency change of -150mHz plus the magnitude of the deadband to the speed signal.
 Measure the power change not more than 25 seconds after the frequency change injection (expected
load increase is 7.5%).
 The frequency disturbance is set to zero again and the governor will control the output back to the
original set value.
 Keep steady-state operation for minimum 120 seconds.
 Repeat the test for different loads.
 Repeat the test for different load controller modes (opening, power and flow control mode).

Recorded Values:
 Position of turbine regulating device
 Speed
 Active power (measured at Unit Metering Point)

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DOC Nº XB-P3-GE-Q-0000-9101
 Opening/power controller set-point
 Droop setting
 Dead band setting
 Controller output
Documentation of the results in SCADA and with revenue meter records.

13.3.2.3 Conclusion
Frequency Response Tests have been performed and completed with satisfying results in accordance with the
test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
13.3.3 Steady-State Load Band
To be performed after finalization of load controller tuning.

13.3.3.1 Reference Documents

13.3.3.2 Performance of test:

 Start of generating unit in auto-mode up to grid operation at min. load
 Adjust first load setting
 Wait for stabilization of pressure in semi spiral case and draft tube
 Operate unit at respective load control with fixed set-point for 5 to 15 minutes (primary control disa-
bled)
 Thereafter the distributor is fixed to a constant set-point for about 5 to 15 minutes
 Repeat test at next set-point (over the whole operating range)
Recorded Values:
 Turbine regulating device, speed, active power
 Pressure in semi spiral case and draft tube
 Load controller set-point and unit output
 Load controller active / fixed distributor position active

13.3.3.3 Conclusion

Steady State Load Band Tests has been performed and completed with satisfying results in accordance with the
test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
13.4 Turbine Load Tests
13.4.1 Load Run (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Initial load test by taking up load in predefined steps up to full load’.

13.4.1.1 Reference Documents:

13.4.1.2 Performance of Test:

 The load is increased in steps of 5 to 10% from the lower limit of operating range to full load (depend-
ing on actual head).
 Hold point after each load step for stabilization of measured values.

Recorded Values:
 Time
 Head water level and tail water level
 Active power
 Turbine regulating device position and servo motor pressure
 Cooling water temperatures and flow
 Bearing temperatures
 Ambient temperatures
 Pressure in semi spiral case and draft tube

13.4.1.3 Conclusion
Load Run Test / Initial Load Test of generating unit was performed and completed with satisfying results in ac-
cordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
13.5 Servo-Motor Indexing Test
13.5.1 Reference Documents
The Test is performed according to the following test procedures:
XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 9.1.4.2 Servo-Motor Indexing Test
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 9.1.4.2 Servo-Motor Indexing Test
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 9.1.4.2 Servo-Motor Indexing Test

13.5.2 Performance of Test:

Servo motor indexing is performed in no-load and load conditions.
Each test is performed two times.
Servo Motor Indexing No-Load Test:
Generating Unit is started from standstill to rated speed and stopped again.

Servo Motor Indexing Load Test:

 Generating Unit is synchronized to the grid, load 0 MW is adjusted.
 The Generating unit is slowly loaded until full load.
 After approx. 1 minute on full load the load is slowly reduced again to 0 MW.
 Guide Vane positions are changed with a gradient of 0.3 to 1% per second, the runner blades shall
follow the guide vanes in CAM relation.
Recorded Values:
 Active power
 Pressure in semi spiral case and draft tube
 Turbine regulating device position
 Turbine regulating device servomotor pressure for Guide Vanes and Runner Blades (servomotor pres-
sure is recorded directly at servomotor / oil head)

13.5.3 Conclusion
Servo Motor Indexing Tests have been performed and completed with satisfying results in accordance with the
test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
13.6 Generator Load Tests, Confirmation of Capability Diagram
13.6.1 Load Angle Measurement
The goal of the test is to measure the increased angle of the phase indicator in accordance to the voltage wave
form of the machine when the load is increased. This load angle can be used in order to evaluate the quadra-
ture reactance Xq.

13.6.1.1 Reference Documents

The Test is performed according to the following test procedures:
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.4.5 Load Angle Measurement
Applicable Standards: IEC 60034-4, 38, 39

13.6.1.2 Performance of test:

 Start of generating unit in auto-mode up to grid operation at min. load
 Adjust pre-defined set-point (usually over 50% nominal load)
 After stabilizing of load point recording of active power, reactive power and voltage wave form in ref-
erence to phase indicator.
 Repeat for other load set-points as required.

13.6.1.3 Conclusion

Generator Load Angle Measurement Test has been performed and completed with satisfying results in accord-
ance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
13.6.2 Reactive Power Capability Test (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Generator Reactive Capability Test’.

13.6.2.1 Reference Documents

The Test is performed according to the following test procedures:
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.4.6 Reactive Power Capability Test

Reactive Power Capability Diagram

13.6.2.2 Performance of Test:

 Start of generating unit in auto-mode up to grid operation at min. load.
 Predefined active and reactive power values are adjusted in the control system.
 Actual power values and power factor are measured and recorded at the metering point.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
Contracted Values Registered Values
Reactive Active Reactive Active
Power Power
Power Power Power Power
Factor Factor
[MVAr] [MW] [MVAr] [MW]
Maximum Lagging
81.0 61.0 0.60
Capability
Maximum Lagging
84.0 174.0 0.90
Capability
Maximum Lagging
85.0 176.0 0.90
Capability
Maximum Leading
47.0 61.0 0.79
Capability
Maximum Leading
87.0 180.0 0.90
Capability
Maximum Leading
88.0 182.0 0.90
Capability

13.6.2.3 Conclusion

The Reactive Power Capability Test has been performed and completed with satisfying results in accordance
with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
13.7 Excitation Load Tests and PSS-Tests (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Power System Stabilizer Test’.

13.7.1 Reference Documents

The Test is performed according to the following test procedures:
XB-P3-PH-Q-4011-1287 Excitation System – PH EGAT Units Excitation
Commissioning Procedure & Protocol
ITP-Pos. 0224-0005 check step response of voltage regulator
ITP-Pos. 0224-0025 check of VAR and PF regulator
ITP-Pos. 0224-0030 performance of PSS
XB-P3-PH-Q-4011-1289 Excitation System – PH EGAT Units Excitation – Commissioning Instructions
Chapter: 6.9 Load Tests
6.9.2 Over Excitation Limiter (Volt/Hertz Limiter)
6.9.3 Field Current Limiter (max., delayed and undelayed)
6.9.4 Field Current Limiter (min., undelayed)
6.9.5 Stator Current Limiter
6.9.6 Load Angle (under-excitation) Limiter
6.9.7 Active Load Stabilization / Power System Stabilizer PSS
6.9.7.1 PSS Field Testing Procedure

13.7.2 Conclusion
The Excitation Load Tests and Power System Stabilizer Test have been performed and completed with satisfy-
ing results in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
14 FULL LOAD HEAT RUN – PRELIMINARY (EGAT PPA TEST)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energizing Commissioning Phase’
Test Item: ‘Heat Run Test at Nominal Load’.
The Full Load Heat Run is to be performed with the actual available Head. The test is classified ‘preliminary’
since it has to be repeated at Nominal Load / Rated Net Head (Hnet = 28.5m) during the ‘18.3 Heat Run at
Nominal Load (EGAT PPA Test)’.
If it can be arranged to perform this test at nominal load at Rated Net Head (Hnet = 28.5m) or higher already dur-
ing this phase of commissioning, the test shall be witnessed and the results documented according to the re-
quirements of the ‘18 Generating Unit Performance Tests & Field Acceptance Tests’. In such case the test
shall be valid as ‘Performance Test’ according to PTS and shall not be repeated.

14.1 Performance of Test

The Test is performed according to the following test procedure:
XB-P3-PH-I-1100-0481 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1
Commissioning Inspection and Test Plan
Chapter: 9.1.6 Heat Run
XB-P3-PH-Q-1100-0680 Turbine EGAT - PH Turbine and Auxiliaries EGAT Units 1-7
Commissioning and Test Procedure
Chapter: 9.1.6 Heat Run
XB-P3-PH-Q-1100-0781 Turbine EGAT – PH Turbine and Auxiliaries EGAT Unit 1 – Record Sheet
Chapter: 9.1.6 Heat Run
XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.4.4 Full Load Heat Run
8.6 Vibration Measurement
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos. 8340-0040 heat run
8340-0070 vibrations
Applicable Standards: IEC 60034-1; 8; IEEE 115, 6.2.1
The generating unit is continuously operated on full load, depending on available head (max. load, nominal cos
φ = 0.9) until saturation of the temperatures.
Saturation of temperatures is reached if temperature variance of all monitored temperatures is < 1K/h.
All operational data and all relevant temperatures are recorded in SCADA. In addition some temperatures shall
be recorded manually as defined in the relevant commissioning procedures of turbine and generator.
Hot-spot checks on transformers and on all accessible / visible high current connections shall be performed.

14.2 Data Recorded during the Full Load Heat Run

14.2.1 Data Relevant for Generator
 Iron temperatures
 Winding temperatures
 Bearing temperatures (metal and oil)
 Cooling water temperatures
 Air temperatures
 Active power
 Apparent power

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 Power factor
 Currents, voltages
 Vibrations
 Noise measurement
Check of pressure at oil vapour extraction.

14.2.2 Data Relevant for Turbine

 Bearing temperatures (metal and oil)
 Air temperature around bearing
 Cooling water temperatures
 Labyrinth temperatures
 Shaft seal temperatures and flow
 Governor oil temperatures

14.2.3 Data Relevant for Main Transformer

 Currents, voltages
 Temperatures (oil, core, winding)
 Cooling fans operation

14.3 Final Adjustments and Inspections

 Adjustment and calibration of field instruments
 Final setting of spare parts for excitation system and control system
 Inspection of all locations affected during testing, closing of covers
The alarm and trip values for temperatures and vibrations shall be re-evaluated according to the real tempera-
tures and vibrations which occur during full load operation.

14.4 Conclusion
The Full Load Heat Run of Generating Unit 1 was performed and completed with satisfying results for all the in-
volved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
15 TRANSMISSION CIRCUIT ENERGIZING (EGAT PPA TEST)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Transmission Circuit 1 energizing from the facility’ and
Test Item: ’Transmission Circuit 2 energizing from the facility’.
During normal operating conditions both transmission lines remain in service at all times, regardless of the
number of Generating Units in operation.
The test describes the case of tripping and re-energizing of one line at a time, in accordance to EGAT PPA
Schedule 1, Part IV, Chapter 1 ‘Normal Configuration of the Transmission Line’.
Remark: In case a ‘Line Charging’ test might also be required, reference is made to TQ-P3-015.

15.1 Initial Condition

 Both incoming Line Feeders are in operation and connected to the 500kV Bus at GIS:
Line Feeder 1 is connected to 500kV Bus-1
Line Feeder 2 is connected to 500kV Bus-2
 Bus Coupling is CLOSED (CB =0ABA10GS100-QA1 is closed)
 Generating Unit is synchronized to one 500kV bus and in normal grid operation.

15.2 Transmission Circuit 1 Energizing

 Adjust predefined load for test
 Trip of Line-1 Feeder CB =0ABA11GS100-QA1
 Check of stability, recording of all relevant data (voltage, frequency, active and reactive power etc.)
 Confirm stabilization of operating condition
 Closing of Line-1 Feeder CB =0ABA11GS100-QA1
 Check of stability, recording of all relevant data (voltage, frequency, active and reactive power etc.)
 Confirm stabilization of operating condition

15.3 Transmission Circuit 2 Energizing

 Adjust predefined load for test
 Trip of Line-2 Feeder CB =0ABA21GS100-QA1
 Check of stability, recording of all relevant data (voltage, frequency, active and reactive power etc.)
 Confirm stabilization of operating condition
 Closing of Line-2 Feeder CB =0ABA21GS100-QA1
 Check of stability, recording of all relevant data (voltage, frequency, active and reactive power etc.)
 Confirm stabilization of operating condition

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
15.4 Conclusion
The Transmission Circuit Energizing Test with Generating Unit 1 was performed and completed with satisfying
results for all the involved systems in accordance with the test procedure described above.

De-Energizing Line-1 Feeder Date: Time: Signature:

Re-Energizing Line-1 Feeder Date: Time: Signature:

De-Energizing Line-2 Feeder Date: Time: Signature:

Re-Energizing Line-2 Feeder Date: Time: Signature:

Comments:

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
16 DETERMINATION OF MACHINE QUANTITY (TYPE TEST)

16.1 Sudden Short-Circuit Test

Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.2 ‘Pre-Energizing Commissioning Phase’
Test Item: ‘The Generator Stability Data’.
Reference is also made to Exhibit IV: Particular Technical Specifications, Part 1 of 3, Section 1.1: Generators
and Auxiliaries: Unit No. 1-7, Chapter 13.3.2 ‘Commissioning Test’.
The Sudden Short Circuit test shall be performed with the 16kV GCB.
This test shall be performed prior to the ‘17 Caloric Determination of Partial Losses (Efficiency)’ since the test
set-up is identical (external excitation supply, short-circuit bar installed).

16.1.1 Reference Documents

XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.2.4 Sudden Short Circuit Test 3-Phase
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos. 8430-0010 sudden short-circuit
TC-P3-057 & TC-P3-098 Technical Clarification Sudden Short-Circuit Test

Applicable Standards: IEC 60034-4; 6.12; IEEE115, 11.7

16.1.2 Preparation
 Excitation system is connected to external supply as described in Chapter ‘4.2.2 Set-Up of Tempo-
rary Power Supply for Excitation System’.
 Short-circuit bar is installed as described in Chapter ‘4.3 3-Phase Short Circuit on Generator Bus
Duct (16kV)’.
 16kV GCB is OPEN.
 Test shunts and equipment is foreseen and connected.

16.1.3 Performance of Test

 Start the unit, adjust nominal speed.
 Excitation ON in manual mode.
 With minimum excitation perform one ‘test shot’ by closing of 15kV GCB for confirmation of proper
function of test equipment.
 If ‘test shot’ was successful, open 16kV GCB and prepare for first test.
 Increase the rotor current respectively the stator voltage manually to 10% of rated voltage.
 Initiate a sudden short-circuit by closing of 16kV GCB.
 Recording of current measurements.
Repeated with 20%, 30% and 40% rated stator voltage.
Items to be checked during the short circuit test:
 Direct axis transient reactance Xd’
 Direct axis sub-transient reactance Xd’’
 Direct-axis transient short-circuit time constant Td’
 Direct-axis sub-transient short-circuit time constant Td’’
 Armature short-circuit time constant Ta

Internal Nº
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16.2 Voltage Recovery Test
The voltage recovery test is another possibility to obtain the measurement value of the direct axis transient
open-circuit time constant Td0’ and the sub-transient direct-axis open-circuit time constant Td0’’.
It only shall be performed if the ‘Field Current Decay Test’ described in Chapter 9.4 of this Document proves
as not practicable.

16.2.1 Reference Documents

XB-P3-PH-Q-2100-0330 Generator EGAT – PH Commissioning Test Procedure
Chapter: 8.3.3 Voltage Recovery Test
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos. 8430-0030 field current decay test / voltage recovery
TC-P3-057 Technical Clarification Field Current Decay Test / Voltage Recovery Test
Applicable Standards: IEC 60034-1; 9.2; IEEE115, 11.10

16.2.2 Preparation:
The test set-up is basically the same as for the ‘Sudden Short-Circuit Test’, therefore the Voltage Recovery test
shall be performed directly after the Sudden Short Circuit Test.
 Excitation system is connected to external supply as described in Chapter ‘4.2.2 Set-Up of Tempo-
rary Power Supply for Excitation System’.
 Short-circuit bar is installed as described in Chapter ‘4.3 3-Phase Short Circuit on Generator Bus
Duct (16kV)’.
 16kV GCB is OPEN.
 Test shunts and equipment is foreseen and connected.

16.2.3 Performance of Test

 Start the unit, adjust nominal speed.
 Close 16kV GCB (short-circuit).
 Excitation ON in manual mode.
 With the excitation system in manual mode increase the stator current to receive 50% of the genera-
tor rated current (~3600 A).
 Open 16kV GCB and record stator voltage and current measurements.

16.3 Conclusion
The Sudden Short Circuit Test and the Voltage Recovery Test (if applicable) have been performed and com-
pleted with satisfying results in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
17 CALORIC DETERMINATION OF PARTIAL LOSSES (EFFICIENCY)

17.1 Efficiency Test Heat Runs (Type Test)

Reference is made to Exhibit IV: Particular Technical Specifications, Part 1 of 3, Section 1.1: Generators and
Auxiliaries: Unit No. 1-7, Chapter 13.3.3.2 ‘Site Efficiency Test’.

17.1.1 Reference Documents

XB-P3-PH-Q-2100-0331 Generator EGAT – PH Commissioning Test Procedure
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos. 8370-0010 zero-excitation (mechanical) heat run
ITP Pos. 8370-0020 open-circuit heat run
ITP Pos. 8370-0030 short-circuit heat run
ITP Pos. 8370-0040 bearing calorimetric
Applicable Standards: IEC 60034-1, 8; IEC 60034-4, 6.4; 6.5;
IEEE115, 4.5

17.1.2 Preparation
 Excitation system is connected to external supply as described in Chapter ‘4.2.2 Set-Up of Tempo-
rary Power Supply for Excitation System’.
 Short-circuit bar is installed as described in Chapter ‘4.3 3-Phase Short Circuit on Generator Bus
Duct (16kV)’.
 16kV GCB is OPEN.
 Excitation system is in manual operation.
 Generator is ready prepared with thermal insulation installed.
 Temporary measuring sensor setup installed according to Doc. XB-P3-PH-Q-2100-0331 Chapter 5
and Chapter 7.3.

17.1.3 Performance of Efficiency Test Heat Runs

17.1.3.1 Zero Excitation Heat Run
The Test is performed according to the following test procedures:
XB-P3-PH-Q-2100-0331 Generator EGAT – PH Commissioning Test Procedure
Chapter: 7.5.1 No-Load Tests – Zero Excitation Heat Run
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos. 8370-0010 zero-excitation (mechanical) heat run
Applicable Standards: IEC 60034-4, 6.4
Performance of Test:
 Start the unit, adjust nominal speed.
 Operate the unit until saturation of all temperatures
 Excitation and 16kV GCB remain OFF for the entire test.

17.1.3.2 Open Circuit Heat Run

The Test is performed according to the following test procedures:
XB-P3-PH-Q-2100-0331 Generator EGAT – PH Commissioning Test Procedure
Chapter: 7.5.2 No-Load Tests – Open Circuit Heat Run
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos. 8370-0020 open-circuit heat run
Client CH. KARNCHANG 09.08.2017 FC ASM Filename GENERAL - EGAT UNIT 1 - WET
Plant XAYABURI HEPP 09.08.2017 LH-DE Ind. Date Filedate 09.08.2017
Project N° H100.002288 09.08.2017 RM LH-DE 00 Page 105 de / of 122
= +
HAV

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
Applicable Standards: IEC 60034-4, 6.4
Performance of Test:
 Start the unit, adjust nominal speed.
 Excitation ON in manual mode, adjust nominal Voltage.
 Operate the unit until saturation of all temperatures.
 16kV GCB remain OPEN for the entire test.

17.1.3.3 Short Circuit Heat Run

The Test is performed according to the following test procedures:
XB-P3-PH-Q-2100-0331 Generator EGAT – PH Commissioning Test Procedure
Chapter: 7.5.3 No-Load Tests – Short-Circuit Heat Run
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos. 8370-0030 short-circuit heat run
Applicable Standards: IEC 60034-4, 6.5
Performance of Test:
 Start the unit, adjust nominal speed.
 16kV GCB is CLOSED.
 Excitation ON in manual mode, adjust 50% of nominal stator current (3610 A).
 Operate the unit until saturation of all temperatures.
 Increase excitation to 70% of nominal stator current (5052 A).
 Operate the unit until saturation of all temperatures.
 Increase excitation to 85% of nominal stator current (6135 A).
 Operate the unit until saturation of all temperatures.
 Increase excitation to 100% of nominal stator current (7217 A).
 Operate the unit until saturation of all temperatures.

17.1.3.4 Full Load Heat Run

The Test is performed according to the following test procedures:
XB-P3-PH-Q-2100-0331 Generator EGAT – PH Commissioning Test Procedure
Chapter: 7.5.4 Full Load Heat Run
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos. 8370-0040 bearing calorimetric
Applicable Standards: IEC 60034-1, 8

Preparation:
 Short-circuit bar is removed, flexible connectors on Generator Bus Duct are installed, covers closed.
 Temporary power supply for excitation system is removed, excitation system is in shunt-connection
(normal operating condition)
Performance of Test:
 Start the unit in auto-mode until synchronization and operation on minimum load.
 Go to full load.
 Operate the unit until saturation of all temperatures.

Remark: The operating head respectively the load shall be kept constant, especially during the final
phase of the test

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
17.2 Measurement of Exciter and Auxiliary Losses
17.2.1 Reference Documents
XB-P3-PH-Q-2100-0331 Generator EGAT – PH Commissioning Test Procedure
Chapter: 7.5.6 Excitation System Losses
XB-P3-PH-I-2100-0313 Generator EGAT Units – Generator Inspection Test Plan (ITP)
ITP Pos. 8400-0010 exciter losses
ITP Pos. 8400-0020 auxiliary losses

17.2.2 Performance of Test

17.2.2.1 Excitation System Losses
Applicable Standards: IEC 60034-2-1; 3.15.3.3
The performance of test is basically the same as described in Chapter ‘13.2 Recording of Power Factor Zero
Characteristic (V-Curve)’.
Start of Test:
 Start of generating unit in auto-mode up to grid operation at min. load
 Change turbine governor to manual mode
 Adjust min. active power were safe turbine operation is possible and protection is still stable (e.g. re-
verse power)
 Change excitation to manual mode
 Increase reactive power in predefined steps up to the required maximum of test (over-excitation 0.7 *
Ir and under-excitation 0.4 * Ir) or to the limitations given by the grid conditions
 For each step the relevant data is recorded (active/reactive power, stator voltage & current, field cur-
rent etc.)

17.2.2.2 Auxiliary Losses

For determination of the Auxiliary Losses the power consumption of all auxiliary equipment of the generating
unit is measured (e.g. HPU, cooling water pumps, oil vapour exhaust etc.)

17.3 Conclusion
The Sudden Short Circuit Test and the Voltage Recovery Test (if applicable) have been performed and com-
pleted with satisfying results in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
18 GENERATING UNIT PERFORMANCE TESTS & FIELD ACCEPTANCE TESTS

18.1 Load Rejection Test at Rated Head (Hnet = 28.5m)

Reference is made to Exhibit IV: Particular Technical Specifications, Part 1 of 3, Section 1.1: Turbines and
Governors: Unit No. 1-7, Chapter 13 ‘Field Acceptance Tests’ – Final Load Rejection Test.
Remark: PTS Field Acceptance Tests are to be conducted under Rated Head (Hnet = 28.5m).

18.1.1 Performance of Test

Performance of test is identical to ‘12.3 Load Rejection Test – Preliminary (EGAT PPA Test)’

This Test shall not be repeated if ‘12.3 Load Rejection Test – Preliminary (EGAT PPA Test)’
had been performed at Rated Head.

Results:
Load Load [MW] Net-Head [m] Max. Speed Rise [%]

25%

50%

75%

100%

18.1.2 Conclusion
Load Rejection Tests at Rated Head have been performed and completed with satisfying results for all the in-
volved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
18.2 Load Step Response Test at Rated Head (Hnet = 28.5m)
Reference is made to Exhibit IV: Particular Technical Specifications, Part 1 of 3, Section 1.1: Turbines and
Governors: Unit No. 1-7, Chapter 13 ‘Field Acceptance Tests’ – Load Step Response Test.
Remark: PTS Field Acceptance Tests are to be conducted under Rated Head (Hnet = 28.5m).

18.2.1 Performance of Test

Performance of test is identical to ‘13.3.1 Load Step Response’

This Test shall not be repeated if ‘13.3.1 Load Step Response’ had been performed at Rated Head.

18.2.2 Conclusion
Load Step Response Tests at Rated Head have been performed and completed with satisfying results for all the
involved systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
18.3 Heat Run at Nominal Load (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Heat Run Test at Nominal Load’.

18.3.1 Performance of Test

Performance of test is identical to ‘14 Full Load Heat Run – Preliminary (EGAT PPA Test)’

This Test shall not be repeated if ‘14 Full Load Heat Run – Preliminary (EGAT PPA Test)’ had
been performed at Nominal Load.

18.3.2 Conclusion
Heat Run at Nominal Load has been performed and completed with satisfying results for all the involved sys-
tems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
18.4 Index Test
Reference is made to Exhibit IV: Particular Technical Specifications, Part 1 of 3, Section 1.1: Turbines and
Governors: Unit No. 1-7, Chapter 13 ‘Field Acceptance Tests’ – Index test with the Winter-Kennedy method.
Remark: PTS Field Acceptance Tests are to be conducted under Rated Head (Hnet = 28.5m).

18.4.1 Reference Documents

18.4.2 Performance of Test:

Several runner blade angles were tested in combination with different guide vane angels at each runner blade
position. This test serves to optimize the On-CAM curve (correlation between guide vane and runner blade an-
gle) of the governor at available head.
Test Procedure
 Set the appropriate load in On-CAM operation
 Fix the runner blade position
 Set the appropriate guide vane angle i.e. go Off-CAM
 Wait until the unit is in steady state
 Continue with the next measuring point
Recorded Values
 Head and tail water Level
 Semi-spiral case pressure and draft tube pressure
 Active power
 Turbine regulating device position
 Turbine flow

18.4.3 Conclusion
Turbine Load Tests have been performed and completed with satisfying results in accordance with the test pro-
cedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
18.5 Hydraulic Thrust Measurement
Reference is made to Exhibit IV: Particular Technical Specifications, Part 1 of 3, Section 1.1: Turbines and
Governors: Unit No. 1-7, Chapter 13 ‘Field Acceptance Tests’ – Hydraulic Thrust for continuous and transient
conditions.
Remark: PTS Field Acceptance Tests are to be conducted under Rated Head (Hnet = 28.5m).

18.5.1 Preparation
Instrumentation of thrust bearing pads with load cells for load measurement during erection of the generator.
The load cells are pre-calibrated at the testing bay of ANDRITZ generator factory.

18.5.2 Performance of Test

Recording of axial thrust during different operating conditions:
 During Full Load Heat Run for continuous conditions
 During normal start/stop sequence for transient condition
 During Load Rejection Tests for transient conditions
Recorded Values
 Axial thrust measurement
 Head and tail water Level
 Semi-spiral case pressure and draft tube pressure
 Active power
 Turbine regulating device position
 Turbine flow
 Unit speed
Recording of data shall be performed by storage oscilloscope and in SCADA for all relevant data.

18.5.3 Conclusion
Hydraulic Thrust measurement for continuous and transient conditions has been performed and completed with
satisfying results in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
19 EGAT PPA PERFORMANCE TESTS

19.1 Modes of Operation Test (EGAT PPA Test)

Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Modes of Operation’.

19.1.1 Reference Documents

19.1.2 Tests for Control System

19.1.2.1 Check of Sequence Timers

The Test is performed according to the following test procedure:

XB-P3-PH-Q-4081-0384 Control System – PH Unit Control Board – Commissioning Procedure
Chapter: 1.11 Start / Stop Sequence Check (EGAT Test)

For the test the unit shall be operated from touch screen on unit control board and/or SCADA system.
The following mode changes are foreseen for test of sequence timers:

Test Item Time Date / Signature

Standstill to Turbine Operation
Turbine Operation to No Load Operation
No Load Operation to Line Operation
Line Operation to No Load Operation
No Load Operation to Turbine Operation

19.1.2.2 Overall Performance Test

The Test is performed according to the following test procedure:

XB-P3-PH-Q-4081-0391 Control System – Control Room Board – Commissioning Procedure
Chapter: 1.7 Communication Tests

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
The test is performed with Generating Unit working in different operating modes:
 Generation mode (opening, power and flow control mode)
 Active power joint control
 Reactive power joint control
For the test all possible start/stop and sequence change commands shall be given from SCACA/Joint Control,
the performance data is recorded by SCADA system.

19.1.3 Tests for Turbine

The Mode Change / Sequence Tests are performed to confirm the stable behaviour of the unit during transient
conditions.

Recorded Values:
 Turbine regulating device position
 Speed
 Pressure in semi spiral case and draft tube
 Active power
 Load controller set-point
 Start/stop command
 Start/end of sequence

19.1.4 Conclusion
The Mode of Operation Test has been performed and completed with satisfying results for all involved sub-
systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
19.2 Unit Minimum Capacity Stability Test (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Registered XYB Unit Minimum Capacity Stability Test’.

19.2.1 Performance of Test

 Start and synchronize the generating unit
 Decrease the load in opening control to the minimum power were stable operating conditions can be
maintained (less than 3% deviation from power set-point over 60 seconds).
 Compare measured results with Hill Chart
 Compare power measurement at Unit Metering Point with requirements specified in EGAT PPA
Schedule 1, Part III, Table 1.2.2 ‘Contracted XYB Unit Minimum Capacity’

Actual Gross Head Actual Net Head Active Power Date / Signature

…..…… m ..……… m ….……... MW

Comments:

19.2.2 Conclusion
The Unit Minimum Capacity Stability Test has been performed and completed with satisfying results for all in-
volved sub-systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
19.3 Maximum Power Output Test / Unit Capacity Test (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Registered XYB Unit 1 Capacity Test’
Reference is also made to Exhibit IV: Particular Technical Specifications, Part 1 of 3, Section 1.1: Turbines and
Governors: Unit No. 1-7, Chapter 13 ‘Field Acceptance Tests’ – Power Output Test.
Remark: PTS Field Acceptance Tests are to be conducted under Rated Head (Hnet = 28.5m).

19.3.1 Reference Documents

19.3.2 Performance of Test

 Start and synchronize the generating unit
 Increase the load in opening control to the maximum power at the given operating conditions.
 Compare measured results with Hill Chart
 Compare power measurement at Unit Metering Point with requirements specified in EGAT PPA
Schedule 1, Part III, Table 1.2.1 ‘Contracted XYB Unit Maximum Capacity’

Actual Gross Head Actual Net Head Active Power Date / Signature

…..…… m ..……… m ….……... MW

19.3.3 Conclusion
The Maximum Power Output Test / Registered Unit Capacity Test has been performed and completed with sat-
isfying results for all involved sub-systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
19.4 Unit Loading / De-Loading Test (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Load Increasing / Decreasing Test (MW/minute)’.

19.4.1 Reference Documents

19.4.2 Performance of Test

The test shall be performed in accordance to EGAT PPA Schedule 1, Part III, Chapter 3 ‘Unit Loading/De-
Loading Rate.

Contractual Values Registered Values

Loading Deloading Loading Rate Deloading Date / Signature
Rate Rate Rate

25 MW/min 25 MW/min .…… MW/min .…… MW/min

19.4.3 Conclusion
The Unit Loading / Deloading Test has been performed and completed with satisfying results for all involved
sub-systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
19.5 Unit Primary Response Test and AGV Performance (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Unit Primary Response’.
The test specified in EGAT PPA Schedule 17, Part IV, Chapter 12 ‘Specific Requirements for Testing Unit Pri-
mary Response’ is already covered with Chapter ‘13.3.2. Frequency Response Test (EGAT PPA Test)’

19.5.1 Performance of Test

 The Generating Unit is operated in Automatic Generation Control mode.
 Power measurement is recorded at Unit Metering Point.
 Three (3) types of the active power set-point signals are employed for this test:
→ Test Mode (TE mode)
→ Fixed Base Mode (BA mode)
→ Base Regulation Mode (BR mode)
 Active power set-point is initiated from NCC.
 Increase / decrease of Generating Unit active power output is measured at the Unit Metering Point.
 Documentation of the results in SCADA and with revenue meter records.
Contractual requirements according to EGAT PPA Schedule 17, Part IV, Chapter 13.2 and Schedule 1, Part II,
Chapter 3.2.1:
 Response to active power set-point from NCC shall start within less than 24 seconds.
 Contracted unit loading / de-loading rate is 25MW/min (0.416MW/s).

Contractual Values Actual Values

Mode Loading/De- Response Loading/De- Response Date / Sign.
Loading Rate Time Loading Rate Time

TE mode 25 MW/min < 24 sec .…… MW/min …….. sec

BA mode 25 MW/min < 24 sec .…… MW/min …….. sec

BR mode 25 MW/min < 24 sec .…… MW/min …….. sec

19.5.2 Conclusion
The Unit Primary Response Test has been performed and completed with satisfying results for all involved sub-
systems in accordance with the test procedures listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
20 UNIT 1 TRIAL RUN

20.1 Unit Trial Run Continuous Operation Test (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Unit Trial Run Continuous Operation Test’.

20.1.1 Performance of Test

The Generating Unit shall be operated at stable operating conditions for a period of 72 hours without any failure
or interruption due to reasons attributable to the generating unit.
The Generating Unit shall operate at varying active power output as by EGAT grid demand.
EGAT shall not initiate more than tree (3) start and stop cycles during the Continuous Operation Test Period.
All relevant operational data is recorded in SCADA system.

Start of No-Load Test Date: Time: Signature:

End of No-Load Test Date: Time: Signature:

Comments:

20.1.2 Conclusion
The Unit Trial Run Test for Continuous Operation according to EGAT PPA Schedule 17 has been performed
and completed with satisfying results for all involved sub-systems in accordance with the test conditions listed
above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
20.2 Unit Trial Run Start and Stop Test (EGAT PPA Test)
Reference is made to EGAT PPA Schedule 17, Part II ‘Testing and Commissioning’
Chapter: 2.9 ‘The Generator Subsystem (ix) to (xv): Generating Units’
2.9.3 ‘Post-Energization Commissioning Phase’
Test Item: ‘Unit Trial Run Start and Stop Test’.

20.2.1 Performance of Test

The Generating Unit shall be operated at stable operating conditions for a period of up to 72 hours (minimum 24
hours) and up to ten (10) Start and Stop Cycles without any failure or interruption due to reasons attributable to
the generating unit.
End of test after 10 start and stop cycles or 72 hours, whatever occurs earlier.
The interval between two start and stop cycles shall be minimum 1 hour.
The Generating Unit shall operate at varying active power output as by EGAT grid demand.
All relevant operational data is recorded in SCADA system.

Start of Start/Stop Test Date: Time: Signature:

End of Start/StopTest Date: Time: Signature:

Comments:

20.2.2 Conclusion
The Unit Trial Run Test for Start/Stop Tests according to EGAT PPA Schedule 17 has been performed and
completed with satisfying results for all involved sub-systems in accordance with the test conditions listed
above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
20.3 Unit Trial Run (PTS)
20.3.1 Performance of Test
Reference is made to Exhibit IV: Particular Technical Specifications, Part 1 of 3, Section 1.1: Generators and
Auxiliaries: Unit No. 1-7, Chapter 13.3.4 ‘Trial Run’.

After the completion of the EGAT PPA Trial Run the PTS trial run shall continue with normal operation accord-
ing to the grid requirements, for a total duration of two months (60 days).

During the Unit Trial Run Test the training of Owner’s personnel shall be conducted.

Start of Unit Trial Run Date: Time: Signature:

End of Unit Trial Run Date: Time: Signature:

Comments:

20.3.2 Conclusion
The Unit Trial Run Test according to PTS has been performed and completed with satisfying results for all in-
volved sub-systems in accordance with the test conditions listed above.

ANDRITZ HYDRO PÖYRY CH. KARNCHANG

Name: …………………………….. Name: …………………………….. Name: ……………………………..

Date: ………………………………. Date: ………………………………. Date: ……………………………….

Signature: Signature: Signature:

Remarks:

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101
21 COPYRIGHT
© This document constitutes confidential and proprietary information of ANDRITZ HYDRO Gmbh.
Any party accepting receipt of this drawing does so on express understanding and agreement that it will neither
copy, reproduce, disclose to third parties nor use this document for any purpose other than those expressly
agreed to by ANDRITZ HYDRO Gmbh.

Internal Nº
DOC Nº XB-P3-GE-Q-0000-9101

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