pcr v4 p4c commissioning

Nepal Electricity AuthorityKreditanstalt für Wiederaufbau

Middle Marsyangdi Hydroelectric Project (MMHEP)

Project Completion ReportVolume 4C

- Project Commissioning Report-

Fichtner GmbH & Co. KGStuttgart

Statkraft Grøner ASOslo-Lysaker

Consulting Engineers Salzgitter GmbH, Salzgitter

FICHTNER JV

Middle Marsyangdi Hydroelectric ProjectProject Completion Report - Volume 4C

Nepal Electricity Authority – NEAProject Commissioning Report

FICHTNER JV

Middle Marsyangdi Hydroelectric Project

Fichtner JV Site OfficeLamjung DistrictNepal

Phone: +977 (19) 542 509Fax: +977 (19) 542 510

Fichtner JV Kathmandu OfficeP.O. Box: 200 79Pulchowk, LalitpurKathmandu, Nepal

Phone: +977 (1) 55 36 768Fax: +977 (1) 55 36 831Email: [email protected]

[email protected]



TABLE OF CONTENTS

1 INTRODUCTION 1

2 REFERENCE DOCUMENTS 1

3 TESTS DURING ASSEMBLY AND PRE-COMMISSIONING 13.1 MAIN INLET VALVES 1

3.1.1 MIV Closing in Dead Water 13.2 TURBINES 2

3.2.1 Opening and Closing Time of Wicket Gate in Dry Condition23.2.2 Closing Tendency of Wicket Gate 3

3.3 TURBINE GOVERNORS 43.3.1 Oil Accumulator Volume Test 43.3.2 Governor Dead Band/Sensitivity Test (at Factory) 53.3.3 Governor Dead Time Test (at Factory) 6

3.4 GENERATORS 73.4.1 Stator Winding HV Testing 73.4.2 Stator Winding Insulation Resistance Measurement 73.4.3 Stator Winding Ohmic Resistance Measurement 83.4.4 Inside Diameter Stator Wound 83.4.5 Rotor Winding – Ohmic Resistance Measurement 93.4.6 Rotor Winding AC Voltage Test 93.4.7 Rotor Winding – Insulation Resistance Measurement 93.4.8 Diameter Rotor Complete 9

3.5 EXCITATION SYSTEM 103.6 CO2 GENERATOR FIRE EXTINGUISHING SYSTEM 103.7 UNIT TRANSFORMERS 10

3.7.1 Insulation Resistance 103.7.2 Ratio Test 113.7.3 Magnetizing Current Test 113.7.4 Short Circuit Test 113.7.5 Winding Resistance 12

3.8 110 BATTERIES 133.8.1 Power House Discharge Test 10 Hours 110 A 133.8.2 Headworks Discharge Test 10 Hours 54.6 A13

3.9 132 & 33 KV TRANSMISSION LINES 143.9.1 Measurement Insulation Resistance 132 kV Line 143.9.2 Measurement Insulation Resistance 33 kV Line 143.9.3 Attenuation Measurement OPGW 132 kV Line 153.9.4 Attenuation Measurement ADSS 33 kV Line 163.9.5 Contact Resistance Measurement of ACSR Conductor Joint at TW1 of 132 kV

Line 17

4 RUNNING TESTS 18

FICHTNER JV I



4.1 MAIN INLET VALVE 184.1.1 Closing under Flow18

4.2 TURBINE 204.2.1 Overspeed Test 204.2.2 Load Rejection Tests (LRT) Units 1 and 2 214.2.3 Emergency Shut Down (ESD) Tests234.2.4 Heat Run at Generator Nominal Load – Bearing and Cooling water Temperatures

244.2.5 Heat Run at Generator Nominal Load – Bearing Temperatures and Levels 264.2.6 Vibration Measurement 27

4.3 TURBINE GOVERNOR 284.3.1 Optimization Start-Up Curve 284.3.2 Optimization Speed No-Load 294.3.3 Optimization without Frequency Influence 304.3.4 Synchronization and Step Loading of Unit 31

4.4 GENERATOR 324.4.1 Balancing 324.4.2 Shaft Voltage Measurement334.4.3 Characteristic Curves (Short Circuit & Open Circuit) 344.4.4 On-load Characteristics 364.4.5 Heat Run 364.4.6 Load Rejections 37

4.5 EXCITATION 384.5.1 Automatic Voltage Build-up Curve with the Automatic Channel (unit 1) 384.5.2 De-excitation Curve with the Automatic Channel by Field Breaker Opening (unit

1) 384.5.3 De-excitation Curve by Protection Trip with the Automatic Channel (unit 1) 394.5.4 +10% Stator Voltage Step with the Automatic Channel in Operation (unit 1) 394.5.5 Power System Stabilizer Tuning at rated Active Power without/with PSS (unit 2)

404.5.6 Transmission Line Charging with Unit 2 41

4.6 UNIT TRANSFORMERS 424.6.1 Heat Run 42

4.7 PENSTOCK BUTTERFLY VALVE 42

5 GENERATOR PERFORMANCE TESTS435.1 OHMIC RESISTANCE OF THE ROTOR WINDING 435.2 OHMIC RESISTANCE OF THE STATOR WINDING 435.3 OPEN-CIRCUIT CHARACTERISTIC 435.4 THREE-PHASE SHORT-CIRCUIT CHARACTERISTIC 435.5 DIRECT AXIS SYNCHRONOUS REACTANCE AND SHORT-CIRCUIT RATIO 445.6 DETERMINATION OF MOMENT OF INERTIA 445.7 WAVE FORM DEVIATION FACTOR 445.8 DETERMINATION OF RATED EXCITATION CURRENT 445.9 DETERMINATION OF GENERATOR EFFICIENCY 45

FICHTNER JV II



6 COMMISSIONING SCHEDULE 466.1 Basic Commissioning Schedule Dated 20.11.2009 46

FICHTNER JV III

Middle Marsyangdi Hydroelectric Project Project Completion Report - Volume 4C


1 INTRODUCTION

2 REFERENCE DOCUMENTSMost of the information included in this document has been extracted from the following Test Protocols prepared by the Manufacturers. The following listing gives the details:

Alstom O&M Manuals (Lot E):

Voith Siemens O&M Manuals Lot M:

Part 12 - Commissioning Common Systems

Part 13 - Commissioning Protocols Unit 1

Part 14 - Commissioning Protocols Unit 2

AREVA O&M Manuals (Lot SS1):

3 TESTS DURING ASSEMBLY AND PRE-COMMISSIONING

3.1 MAIN INLET VALVES

3.1.1 MIV Closing in Dead Water

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

MIV No. 2 Opening Time 41 sec. Closing Time 86 sec.

March 2010 FICHTNER JV 1



3.2 TURBINES

3.2.1 Opening and Closing Time of Wicket Gate in Dry Condition




3.2.2 Closing Tendency of Wicket Gate




3.3 TURBINE GOVERNORS

3.3.1 Oil Accumulator Volume Test




3.3.2 Governor Dead Band/Sensitivity Test (at Factory)




3.3.3 Governor Dead Time Test (at Factory)

3.4 GENERATORS

3.4.1 Stator Winding HV TestingAC-Voltage test was carried out with 29.4 kV (against ground) after installing the bottom winding layer of the stator winding.

A second AC-Voltage test was conducted with 25.7 kV (against ground) after completion of the winding.

High voltage tests of RTD’s with 2000 VAC

In addition, the following tests were conducted on the stator bars during manufacturing:

High-voltage test on all bars with 4xUN = 44 kV. Dielectric loss factor measurement on all bars with 2.2 up to 13.2 kV (in steps of 0.2xUN

from 0.2xUN to 1.2xUN) Insulation breakdown test of main insulation on slot portion on two bars of the first

production batch of first unit each one lower and upper bar. The insulation broke down (perforated) by 74 respectively 76 kV.

STATOR WINDING - INSULATION TESTS WITH 500 VDC

INSULATION RESISTANCE

Measurement of each phase to the others and to the ground




UNIT 1 UNIT 1

Phase U Phase V Phase W

Phase U

Phase V

Phase W

Date of test 12.05.2008

12.06.2008

12.08.2008

28.07.2008

28.06.2007

28.06.2007

Test voltage 0.5 0.5 0.5 0.5 0.5 0.5 [kVdc]

Winding temperature 27.5 27.5 27.5 31.5 31.5 32 [°C] Ambient air temperature 26 28 28 29 29 29 [°C] Relative humidity 72 71 74 67 67 66 [%]

Insulation after 1 min (R1) 138 172 164 368 375 361 [MΩ

]

Insulation after 10 min (R10) 152 180 167 423 435 419 [MΩ

] Pol. Index(IP=R 10R1) 1.10 1.05 1.02 1.15 1.16 1.16 Unit 1 Unit 2

3 phases winding temperature (average temp.) 27.5 [°C] 31.6667 [°C]

3.4.2 Stator Winding Insulation Resistance Measurement

3.4.3 Stator Winding Ohmic Resistance Measurement

OHMIC RESISTANCE PHASE U

UNIT 1 UNIT 2

Test 1 Test 2 Test 3 Average Test 1 Test 2 Test 3 Average Applied voltage 82.25 82.28 82.28 82.99 83.01 83.01 [mVdc]

Applied current 10.000 10.000 10.000 10.000 10.000 10.000 [Adc]

Ohmic resistance 8.225 8.228 8.228 8.227 8.299 8.301 8.301 8.3 [mΩ]

Ohmic resistance (at 20°C)

7.99 7.99291 7.99291 7.99194 7.94088 7.9428 7.94216 7.94216 [mΩ]

OHMIC RESISTANCE PHASE V

Test 1 Test 2 Test 3 Average Test 1 Test 2 Test 3 Average

Applied voltage 2.20 82.21 82.22 83.11 83.1 83.13 [mVdc]


Ohmic resistance

8.22 8.221 8.222 8.221 8.311 8.31 8.313 8.311 [mΩ]





7.98514 7.98611 7.98709 7.98611 7.95236 7.95141 7.95428 7.95268 [mΩ]

OHMIC RESISTANCE PHASE W Test 1 Test 2 Test 3 Average Test 1 Test 2 Test 3 Average

Applied voltage 82.21 82.23 82.28 83.13 83.14 83.15 [mVdc]


Ohmic resistance 8.221 8.223 8.226 8.223 8.313 8.314 8.315 8.314 [mΩ]


7.98611 7.98806 7.99097 7.98838 7.95428 7.95523 7.95619 7.95523 [mΩ]

average winding temperature 27.5 [°C] average winding temperature 31.5 [°C]

ambient temperature 20 [°C]

ambient temperature 29 [°C]

3.4.4 Inside Diameter Stator Wound

3.4.5 Rotor Winding – Ohmic Resistance Measurement

UNIT 1 UNIT 2Average Average

Injected current 10.0 10.0 10.0 10.0 10.0 10.0 [Adc]Voltage 0.5762 0.5763 0.57627 0.5866 0.5869 0.58677 [Vdc]Ohmic resistance 0.05762 0.05763 0.06763 0.05866 0.05869 0.05868 [Ω]Ohmic resistance (at 20°C)

0.05599 0.056 0.066 0.05654 0.05657 0.05655 [Ω]

UNIT 1 UNIT 2Rotor winding temp. 27.4 29.6 [°C] (average all RTDs)Ambient temp. 28 28 [°C

3.4.6 Rotor Winding AC Voltage TestThe complete rotor windings were tested with 1.5 kV AC voltage applied for the duration of one minute. The insulation resistance was measured both before and after the AC test with 500 VDC applied to the winding for the duration of one minute.

3.4.7 Rotor Winding – Insulation Resistance Measurement




GENERATOR 1 GENERATOR 2

Date Measured 12.08.2008 14.11.2008 28.07.2008 18.11.2008

Test Voltage (kVdc) 0.5 0.5 0.5 0.5

Winding Temperature (°C) 27.4 31.5 29.6 31

Ambient Temperature (°C) 26 29 29 31

Relative Humidity (%) 27 39 66 38

Insulation Resistance after 1 min. (R1) MΩ 1.9 3000 43.6 2500

Insulation resistance after 10 min. (R10) MΩ 2.4 4000 51.9 3500

Pol. Index (IP=R10/R1) 1.26 1.33 1.19 1.4

3.4.8 Diameter Rotor Complete

UNIT 1

Position NDT DE AVERAGE Deviation to 3610,00mm

Pole 1-10 3610.98 3609.90 3610.44 +0.44Pole 2-11 3611.03 3609.93 3610.48 +0.48Pole 3-12 3610.73 3610.02 3610.38 +0.38Pole 4-13 3610.78 3609.98 3610.38 +0.38Pole 5-14 3610.80 3610.00 3610.40 +0.40Pole 6-15 3610.75 3609.88 3610.32 +0.32Pole 7-16 3610.78 3609.98 3610.38 +0.38Pole 8-17 3611.00 3609.90 3610.45 +0.45Pole 9-18 3610.95 3609.92 3610.44 +0.44

Total Average 3610.41 +0.41Average Air Gap: 19.98 mm (19.80 - 20.70) 8 measurements

UNIT 2

Position NDT DE AVERAGE Deviation to 3610,00mm

Pole 1-10 3609.37 3,608.85 3609.11 -0.89Pole 2-11 3609.15 3609.14 3609.15 -0.85Pole 3-12 3609.23 3608.60 3608.92 -1.08Pole 4-13 3609.43 3608.80 3609.12 -0.88Pole 5-14 3609.35 3608.80 3609.08 -0.92Pole 6-15 3609.41 3608.69 3609.05 -0.95Pole 7-16 3609.27 3608.77 3609.02 -0.98Pole 8-17 3609.35 3608.77 3609.06 -0.94Pole 9-18 3609.45 3608.77 3609.11 -0.89

Total Average 3609.07 -0.93Average Air Gap: 19.88 mm (19.20 - 20.25) 8 measurements




3.5 EXCITATION SYSTEM

3.6 CO2 GENERATOR FIRE EXTINGUISHING SYSTEMIn addition to the standard commissioning tests a live discharge test was carried out in one generator with 200 kg CO2 (4 bottles)

3.7 UNIT TRANSFORMERS

3.7.1 Insulation Resistance

Transf. SI. No Main winding

IR Value Temperature15 sec 60 Sec 600 sec PI

B-29814 unit 1HV/E 8.27 27.9 117 4.19 32°CHV/LV 7.92 20.8 164 7.89 32°CLV/E 7.44 50.3 69.9 1.38 32°C

B-29816 unit 1HV/E 9.34 36.6 77.4 2.11 32°CHV/LV 5.21 37.9 119 3.13 32°CLV/E 5.42 25.8 66.6 2.58 32°C

B-29820 unit 1HV/E 5.31 13.4 42.4 3.16 32°CHV/LV 4.89 19.7 72.7 3.69 32°CLV/E 5.08 14.4 40.9 2.84 32°C

B-29815 unit 2HV/E 17.3 64.4 128 1.98 32°CHV/LV 10.6 48.9 185 3.78 32°CLV/E 6.84 51.3 115 2.24 32°C



B-29819 SpareHV/E 9.21 14.72 37.8 2.56 32°CHV/LV 7.02 13.9 49.0 3.52 32°CLV/E 4.65 10.5 27.6 2.62 32°C

3.7.2 Ratio Test

Tap No. Connection Measured Ratio Calculated Ratio1 U-N/ u-n 7.64 7.62 U-N/ u-n 7.46 7.43 U-N/ u-n 7.28 7.24 U-N/ u-n 7.09 7.065 U-N/ u-n 6.91 6.88

Same measured ratio in all 7 transformers.

3.7.3 Magnetizing Current Test

Transformer SI. No Side Tap No. Applied Voltage in Volt

Measured Current in mA

B-29814 unit 1 HV 1 223.6 1.13 223.0 1.5




5 222.3 1.1LV 3 224 39.3

B-29816 unit 1 HV1 224 2.53 224 3.35 224 2.4

LV 3 223 39.6

B-29820 unit 1 HV1 224 0.73 222 0.75 223.8 0.9

LV 3 223 40.9

B-29815 unit 2 HV1 226.9 1.83 226.9 1.75 226.9 1.8

LV 3 227 40.4

B-29818 unit 2 HV1 227.2 1.93 227.0 2.35 226.8 2.5

LV 3 226.8 41.2

B-29817 unit 2 HV1 228.2 1.63 227.8 1.75 227.0 1.6

LV 3 227.8 40.6

B-29819 Spare HV1 228.1 1.73 228.3 2.15 227.7 2.2

LV 3 228.3 43.4

3.7.4 Short Circuit Test

Transformer SI. No Tap No. Applied voltage in

VoltMeasured Current in HV

Measured Current in LV

B-29814 unit 11 223.3 2.78 20.33 224.0 3.15 22.95 223.5 3.54 24.3

B-29816 unit 11 223 2.79 20.83 223 3.0 23.05 223.4 3.56 24.5

B-29820 unit 11 223.2 2.6 21.23 223.4 3.0 22.85 223.3 3.4 24.4

B-29815 unit 21 226.5 2.5 20.93 226.6 2.9 22.65 226.6 3.5 24.4

B-29818 unit 21 225.7 2.6 22.03 226.3 3.0 23.25 226 3.5 24.8

B-29817 unit 21 225.6 2.6 21.43 226.3 3.0 22.95 226.4 3.5 24.7

B-29819 Spare1 225.7 2.75 21.33 226.0 3.08 22.85 226.1 3.56 24.6

3.7.5 Winding Resistance




Transformer SI. No Tap No. HV Side in ohms LV Side in milli ohms

B-29814 unit 1

1 0.86

11.522 0.833 0.814 0.785 0.76

B-29816 unit 1

1 0.86

11.532 0.833 0.814 0.785 0.76

B-29820 unit 1

1 0.87

11.592 0.843 0.814 0.795 0.77

B-29815 unit 2

1 0.86

11.462 0.833 0.814 0.785 0.76

B-29818 unit 2

1 0.86

11.582 0.843 0.814 0.795 0.77

B-29817 unit 2

1 0.86

11.632 0.843 0.814 0.795 0.76

B-29819 Spare

1 0.86

11.652 0.843 0.814 0.795 0.77

3.8 110 BATTERIES

3.8.1 Power House Discharge Test 10 Hours 110 A




3.8.2 Headworks Discharge Test 10 Hours 54.6 A

3.9 132 & 33 KV TRANSMISSION LINES

3.9.1 Measurement Insulation Resistance 132 kV Line




3.9.2 Measurement Insulation Resistance 33 kV Line

3.9.3 Attenuation Measurement OPGW 132 kV Line




3.9.4 Attenuation Measurement ADSS 33 kV Line




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




4 RUNNING TESTS

4.1 MAIN INLET VALVE

4.1.1 Closing under Flow

Unit No. 1 Unit No. 2

Test No. MW DP penstock above steady state (bar)

Closing time without end pos. throttling

MW DP penstock above steady state (bar)

Closing time without end pos. throttling

1 9.8 2.2 52 10 51

2 20.2 2.35 38.5 20 40.5

3 30.3 2.4 29.5 30 2.57 31.5

4 41.4 2.8 24 40 2.6 27

During the commissioning tests it was observed that the weight of the counterweights was not sufficient (occasionally the MIVs did not leave the fully open position when close command was given). Additional weights of 1000 kg (500 on each side) were added. Because of these additional weights, the throttles which regulate the closing time had to be adjusted. Because of this some MIV closing tests under flow had to be repeated. Accordingly in the commissioning reports of Voith there are records for following closing tests:

Tests before increasing the size of counterweights

Tests after increasing the size of counterweights

MIV 1 At: 10, 20, 30 and 41.5 MW At: 10 MW

MIV 2 At: 10, 20 and 30 MW At: 10, 20, 30 and 40 MW

Rated closing time at 45 m3/sec is 30 sec.




4.2 TURBINE

4.2.1 Overspeed Test

Unit 1 Unit 2

Overspeed Devices Test setting (%)

Operated at (%)

Max. speed rise (%)

Final setting (%)

Test setting (%)

Operated at (%)

Max. speed rise (%)

Final setting (%)

Mech. (hydraulic) 165 167 171.4 165

Electrical No.1 (digital governor)

105 105 - 167

Electrical No.2 (speed relay )

115 114 -- 165




4.2.2 Load Rejection Tests (LRT) Units 1 and 2The below figures are calculated from the recorded graphs


MW Brutto

Head

Max. SCCL (p_max_SCCL) pressure recorded (bar)

Speed rise (%)

MW Head Max. SCCL (p_max_SCCL) pressure recorded (bar)

Speed rise (%)

9.69 106.01 125.33 10.9

20.49 106.17 122.48 26.0

29.67 106.29 131.98 40.9

41.50 106.49 139.35 54.8




LRT Unit 1 at 41.5 MW

LRT Unit 2 at 41.3 MW




4.2.3 Emergency Shut Down (ESD) TestsThe below figures are calculated from the recorded graphs


MW Brutto

Head

Max. SCCL (p_max_SCCL) pressure recorded (bar)

Speed rise (%)

MW Head Max. SCCL (p_max_SCCL) pressure recorded (bar)

Speed rise (%)

9.85 106 118.44 8.1

20.43 106.13 123.48 22.4

30.41 106.29 139.03 35.0

41.50 106.33 141.20 49.0

ESD Unit 1 at 41.5 MW




ESD Unit 2 at 41.4 MW

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




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




4.2.6 Vibration Measurement




4.3 TURBINE GOVERNOR

4.3.1 Optimization Start-Up Curve




4.3.2 Optimization Speed No-Load




4.3.3 Optimization without Frequency Influence




4.3.4 Synchronization and Step Loading of Unit




4.4 GENERATOR

4.4.1 Balancing

BALANCING OF GENERATOR

Balancing Weights UNIT 1 UNIT 2

Plane NDE NDE DE NDE NDE DE

Angle 120 160 160 80 160 160 [°]

Mass 36 48 8 55 17 7.5 [kg]

MEASUREMNTS

speed 333 332 333 331 333 333 [min -1]




active power 34.8 10.2 20.2 29.5 38.2 34.7 [MW]

reactive power 18.4 1.6 1.96 2.31 3.45 16.6 [Mvar]

stator voltage 11.4 10.8 10.8 10.8 10.8 11 [kV]

stator current 1.95 551 1084 1571 2042 2010 [A]

field current 1339 379 416 473 528 659 [A]

NDE bearing X-45° Overall 0.19 0.6 0.45 0.4 0.4 0.4 [mm/s rms]

1st harm. Ampl. 0.07 0.4 0.4 0.4 0.4 0.4 [mm/s

rms]1st harm. Phase 153 235 223 222 221 220 [°]

DE bearing X Overall 0.34 0.75 0.43 0.22 0.2 0.21 [mm/s rms]

1st harm, Ampl. 0.06 0.12 0.1 0.1 0.1 0.1 [mm/s

rms]1st harm. Phase 318 200 200 207 208 201 [°]

NDE Shaft X Overall 172 141 140 148 155 160 [umpp]

1st harm, Ampl. 58 20 14.5 15 15 17 [umpp]

1st harm. Phase 91 66 43 28 15 10 [°]

Y Overall 185 118 [umpp]

1st harm, Ampl. 75 8 [umpp]

1st harm. Phase 119 293 [°]

DE Shaft X Overall 121 63 60 47 46 47 [umpp]

1st harm, Ampl. 109 40 40 37 38 38 [umpp]

1st harm. Phase 260 188 188 188 190 186 [°]

Y Overall 118 33 [umpp]

1st harm, Ampl. 106 20 [umpp]

1st harm. Phase 267 87 [°]

4.4.2 Shaft Voltage Measurement

Shaft Voltage Measurement

UNIT 1 UNIT 2

Measurements speed Vn Vn Vn Vn Vn [min-1]active power -- 30 -- 4 25 [MW]




reactive power -- 0.8 -- 4.8 1.8 [Mvar]stator voltage Un 10.8 Un 10.8 10.8 [kV]stator current -- 1.65 -- 0.34 1.3 [kA]field current 730 939 732 818 874 [A] NDE Side voltage to earth 0 0 0 0 0 [Vdc] 10.9 11.3 10 10 11.7 [Vac rms] 34 31.6 30 30 34.5 [Vac pp] main frequency 150 150 149 149 150 [Hz]

4.4.3 Characteristic Curves (Short Circuit & Open Circuit)




4.4.4 On-load Characteristics

GENERATOR ON LOAD CHARACTERISTIC

MEASUREM.

UNIT 1 UNIT 2




PF 0.9stator S 38.90 37.43 38.42 42.37 [MVA]

P 35.46 33.80 34.66 38.50 [MW]Q 15.94 16.07 16.57 17.65 [Mvar]PF 0.91 0.90 0.90 0.90 U 11.45 11.46 11.02 11.02 [kV]I 1959 1887 2013 2210 [A]Hz 49.92 49.00 49.90 49.65 [Hz]

rotor Uf 95.10 95.90 88.90 105.00 [V]

PF 1.0

If 1328.00

1318.00

1318.00

1386.00 [A]

stator S 9.98 19.83 29.42 40.99 42.25 43.01 3.95 9.94 10.00 19.94 35.27 [MVA]

P 9.84 19.54 29.37 40.78 40.8 42.85 3.93 9.86 9.98 19.91 35.14 [MW]Q -0.9 -1.8 7.85 4.1 11 6.5 0.42 -1.27 -0.62 -1.02 3.03 [Mvar]PF 0.99 0.99 1.00 1.00 1.00 U 10.78 10.75 11.20 10.55 10.67 10.65 10.67 10.85 10.75 [kV]I 2199 2326 0.21 0.54 0.54 1.06 1.89 [kA]Hz 49.70 49.80 49.60 49.77 50.30 [Hz]

rotor Uf 45 49 81.7 72.3 99.3 54.4 .. .. .. .. 67.9 [V]

If 657.4 732 840 1100 1285 1094 688 683 786.8 952 [A]

4.4.5 Heat Run

GENERATOR HEAT RUN TEST

UNIT 1 UNIT 2

TEST n0:1 Generator short-circuited n0 1 n0 1

n0:2 At rated load n02 n02

n03: Generator overload n03 n03 date 20.01. 03.02.09 05.12.08 14.01.09 14.02.09 duration 3 5 2 4 4 [h] ELECTRICAL DATA stator S 0 38.5 0 35 42.2 [MVA]

P 0 35 0 35 38.8 [MW]Q 0 16 0 3 16.8 [Mvar]cosΦ 0 0.9 NA 0.99 0.92 U 0 11.4 0 10.8 11.1 [kv]I 2.05 1.95 2.05 1.86 2.2 [kA]

rotor Uf 43.6 96 46.3 70 105 [V]

if 666 1309 732 1000 1364 [A]

TEMPERATURE stator winding average 53 70.5 53.1 62 82.3 [°C]

max. 55 74 54 64 84 [°C] stator core average 33 55 33 47.3 60.5 [°C] max. 33 55 33 47.3 61 [°C] rotor winding 36.4 74 27 50 84.9 [°C] cooling air air inlet average 17 22.5 18 18.8 25.5 [°C] max. 17 23 19 20.3 26 [°C]




air outlet average 31.2 45 30 37.2 49 [°C]

max. 32.2 45 30 37.3 49 [°C]cooling water inlet 12 14 12.4 10.8 12 [°C]cooling water outlet 15 21 16.5 17.1 22 [°C]

NDE bearing guide segment 40.4 41.2 52.4 44.6 44.8 [°C]

thrust segment 61.4 65.6 66 65 65.8 [°C]oil 35.9 37 42 36.4 37 [°C]guide bearing oil 36.4 38 42 36.6 38 [°C]oil inlet 30 31 35 32.1 33 [°C]oil outlet 36 38 43 37.8 39 [°C]cooling water outlet 16 21 16.5 17.1 [°C]

DE bearing guide segment 46.7 45.8 53 51.9 50.4 [°C]

oil 37.9 39 41 43.4 44 [°C]guide bearing oil 38.1 39 41 43.5 44 [°C]oil inlet

35 36 37 37.3 38 [°C]

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

TEMPERATURE RISE

stator winding max. 38 48 35 45.2 58.5 [K]

(above cold air) stator core max. 16 32.5 14 28.5 36.5 [K]

rotor winding 19.4 51.6 11 31.2 59.4 [K]

cooling air 15.2 22.5 11 18.5 23.5 [K]

air cooler cooling water

12 14 [K]

4.4.6 Load RejectionsRefer Sub-section 4.2.2




4.5 EXCITATION

4.5.1 Automatic Voltage Build-up Curve with the Automatic Channel (unit 1)

4.5.2 De-excitation Curve with the Automatic Channel by Field Breaker Opening (unit 1)




4.5.3 De-excitation Curve by Protection Trip with the Automatic Channel (unit 1)

4.5.4 +10% Stator Voltage Step with the Automatic Channel in Operation (unit 1)




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




4.5.6 Transmission Line Charging with Unit 2




4.6 UNIT TRANSFORMERS

4.6.1 Heat RunThe transformer temperatures of unit 2 transformers were verified during generator heat run test at overload (refer to clause 4.4.5 above). The unit was operated with approximately 42.2 MVA (38.8 MW and 16.8 Mvar) for about 4 hours. The winding/oil temperatures in the three single phase transformers reached the following values by an ambient temperature of approx. 26 °C:

Transformer winding: 74 – 78 – 79 °C; Temp. rise over ambient of 26 °C: 48 – 52 – 53 °C;

Transformer Oil: 64 – 61 – 66 °C; Temp. rise over ambient of 26 °C: 38 – 35 – 40 °C;

These figures can be compared with the limit values spelled out in the contract as follows:

Max. temperature rise over ambient of 35 °C: Top oil/average winding (°C): 50/55;

Although the generator was operated at overload (rated output 39 MVA overload capability 47 MVA), the load at which the test was conducted (42.2 MVA) represented less than the rated power of the transformers (3x14.5 = 43.5 MVA).

4.7 PENSTOCK BUTTERFLY VALVE Closure of the penstock butterfly valve was tested against 25, 50, 75 and 100% of the maximum flow. The tests were successful and the pressure rise in the tunnel remained well below the permissible limits. The test data at the 100% flow are shown in the table below:

Penstock butterfly valve closure under flow:

Unit U1 U2 Limit

Power MW 37,5 36.9

Q total m3/s 85

HWL masl 625.2

H stat. PBV m 26.17

H max PBV m 43.1 74.9

The test confirmed safe functioning of the penstock valve.

The test was carried out with total flow of 85 m3/s, this being the design flow for the valve. But with both units operating at maximum opening and maximum head, approx. 2x41 MW can be produced at the turbine shafts with a total flow of about 92 m3/s.




5 GENERATOR PERFORMANCE TESTSPerformance tests (type tests) were carried out on generator No. 2. The below data are extracted from the test records submitted by Alstom.

For details, reference is made to Alstom O&M manual W01-06, Index 12.

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

5.2 OHMIC RESISTANCE OF THE STATOR WINDINGMeasured: 8.3083 average per phase mOhm at 31.5 °C; Calculated: 9.6645 mOhm at 75.0 °C

5.3 OPEN-CIRCUIT CHARACTERISTIC For result, see item 4.4 below.

5.4 THREE-PHASE SHORT-CIRCUIT CHARACTERISTIC




5.5 DIRECT AXIS SYNCHRONOUS REACTANCE AND SHORT-CIRCUIT RATIO Calculated from Open-Circuit and Three-Phase Short-Circuit Characteristic

Measured Field Current Air-gap field current Ifg = 612 A Excitation current at rated armature voltage Ifo = 718 A Excitation current at rated armature current Ifk = 662 A Synchronous Reactance in Directional Axis xd Unsaturated value xd (measured) xd = Ifk / Ifg = 662 / 612 = 1.082 p. u. Design value xd = 1.043 p. u. Saturated value xd (measured) xd = Ifk / Ifo = 662 / 718 = 0.922 p.u. Design value xd = 0.977 p. u. Short - Circuit Ration Kc (Standard: IEC 60034-4 (1985) SECT. 27) Field current at rated armature voltage Ifo = 718 A Field current at rated armature current Ifk = 662 A

Measured ValueKc = Ifo / Ifk = 718 / 662 = 1.08

Design value Kc = 1.06

5.6 DETERMINATION OF MOMENT OF INERTIAThe moment of inertia was determined by recording the essentially linear rate of speed rise (63.5 rpm) during the first 1.04 sec. immediately following a load rejection at nominal load (Standard: IEC 60034 – 4 (1985) Cl. 70, 71).

Result: Moment of Inertia (J) = 157 tm2; (Design value 156 tm2 (without turbine shaft and runner).

Acceleration Time Constant: 5.46 sec.

5.7 WAVE FORM DEVIATION FACTORMeasured deviation factor: 1.261%; Guaranteed value: ± 5%




5.8 DETERMINATION OF RATED EXCITATION CURRENTThe determination was done according standard IEEE 115 -1995 Cl. 5.3.

Measured Value: 1296 A; Calculated: 1288 A.

5.9 DETERMINATION OF GENERATOR EFFICIENCY

LOAD % 100 75 50

GENERATOR DATA

APPARENT POWER MVA 39.00 29.25 19.50ACTIVE POWER MW 35.10 26.33 17.55REACTIVE POWER MVAr 17.00 12.74 8.50

POWER FACTOR (overexcited) 0.90 0.90 0.90

ARMATURE VOLTAGE kV 11.00 11.00 11.00ARMATURE CURRENT A 2046.97 1535.23 1023.48ROTOR VOLTAGE V 88.62 76.45 65.65

ROTOR CURRENT A 1296.00 1118 960

MEASURED LOSSES WINDAGE LOSSES P (windage)* kW 92.45 92.45 92.45LOWER GUIDE BEARING LOSSES kW 10.31 10.31 10.31COMBINED THRUST - GUIDE BEARING LOSSES kW 54.40 54.40 54.40

TOTAL MECHANICAL BRUSH LOSSES PB mech kW 1.30 1.30 1.30TOTAL ELECTRICAL BRUSH LOSSES PB EL kW 5.18 4.47 3.84ARMATURE COPPER LOSSES PCU 75* kW 121.48 68.34 30.37ARMATURE STRAY LOSSES PSL* kW 62.71 35.27 15.68CORE LOSSES PFE* kW 119.58 119.58 119.58ROTOR LOSSES Pt75* kW 114.86 85.47 63.02EXCITATION LOSSES PEX (Excit. Transformer and converters) kW 10.00 8.00 6.00

TOTAL MEASURED LOSSES kW 592.27 479.60 396.95

TEST DATA GENERATOR ACTIVE kW 35100.00 26325.00 17550.00




POWERGENERATOR ACTIVE INPUT POWER kW 35692.27 26804.60 17946.95 MEASURED EFFICIENCY % 98.34 98.21 97.79 GUARANTEED VALUES GUARANTEED EFFICIENCY (CONTRACT) % 98.420 98.320 97.950

TOTAL GUARANTEED LOSSES kW 563.483 449.817 367.305TOTAL GUARANTEED LOSSES (Maximum)* kW 619.831 494.799 404.035DIFFERENCE TOTAL GUARANTEED kW 27.56 15.20 7.080LOSSES - TOTAL MEASURED LOSSES

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

6 COMMISSIONING SCHEDULE

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


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