We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © Copyright 2008 ABB. All rights reserved
Procedure and Report for Test and Commissioning of Excitation System ® UNITROL 6800 Plant:
P.H. SOGAMOSO
Type:
A6T-O/U5H1-F2500
Unit:
2
ABB Order No.:
600182
ID No.:
3BBR520311D0042
Serial No.:
P15392Z
Approval signatures YES NO The test procedure and report have been examined. The functions and performance of the t he tested object are according to its specifications with exceptions according to the exception list and the review comments.
The object has been tested in accordance with the conditions stipulated in the t he contract and observing relevant safety rules. No findings were recorded The following findings were recorded Follow up inspection:
*) Rev. Ind.
Not needed
Needed
FAT:
Site:
Site:
A
B
3BHS223093 E31 Rev. D
Prep.
Alisson Cruz Rodrigo Reis
C
Doc. kind Title
Date/Place:
FAT:
Based on
Appr.
”Exception List” sheet no:
Test and Commissioning Report UNITROL 6800
D
E Project
F
P.H. SOGAMOSO
07-2011 Doc.
Item
Des.
Des.
Resp. Dept.
ATPE
Doc. no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
en
Rev. Ind. Page
1
No. of p.
1 30
TABLE OF CONTENTS 1.
GENERAL ..................... ................................. ....................... ....................... ....................... ...................... ...................... ...................... ..................... ..................... ...................... .................... ......... 3
2.
REFERENCE REFERENCE DOCUMENTS............... DOCUMENTS.......................... ...................... ..................... ..................... ....................... ....................... ....................... ........................ .................... ........ 6
3.
8.
MAIN SIGNAL DATA ....................... ................................... ....................... ....................... ....................... ....................... ........................ ....................... ....................... .................... ........ 7 3.1 General General Data .................... ................................ ....................... ....................... ....................... ...................... ..................... ..................... ...................... ...................... ................ ..... 7 3.2 Identification Plate of Excitation. ............. ............ .............. ............. ............ .............. ............. ..... 7 HARDWARE-SETTINGS HARDWARE-SETTINGS ..................... ................................. ....................... ...................... ...................... ...................... ..................... ..................... ....................... .................... ........ 8 4.1 Non Linear Linear Resistors Resistors .................... ............................... ....................... ....................... ....................... ........................ ....................... ...................... ...................... ............. .. 8 4.2 Linear Linear Resistors, Resistors, Type: Type: GINO (-R02) (-R02) ...................... ................................. ....................... ....................... ....................... ........................ .................... ........ 8 4.3 Overvoltage Protection / Crowbar: Firing Print UNS 0017a-P, 0017a-P, Var. 1 (-A02) (-A02) .............. ............ ... 8 4.4 Advanced Power Distribution (APD) ............. ............. .............. ............. ............ .............. ........... 8 4.5 Settings for Converter Fans.... ............. .............. ............ .............. ............. ............ .............. ....... 9 4.6 Settings Settings for AVR Cubicle Cubicle Fans ...................... ................................ ..................... ....................... ........................ ....................... ....................... .................. ...... 10 4.7 Transducer Transducer Settings Settings ..................... ................................ ....................... ....................... ....................... ........................ ....................... ...................... ...................... ........... 10 4.8 Rotor Earth Fault Relay UNS 3020a-Z (-F40)............... ............ ............. .............. ............. ....... 11 4.9 Additional Additional Hardware Hardware Modificatio Modifications ns ...................... ................................. ...................... ..................... ..................... ...................... ...................... .............. ... 11 FACTORY TESTS AND PRECOMMISSIONING PRECOMMISSIONING ....................... ................................... ........................ ....................... ...................... ...................... ........... 12 5.1 Visual and Mechanical Checks.. ............. ............ .............. ............. ............ .............. .............. .. 12 5.2 High Voltage Test (See Additional Report) ............ ............ .............. ............. .............. ............ . 12 5.3 Check of Supplies...... Supplies................. ....................... ....................... ....................... ....................... ....................... ....................... ....................... ........................ .................. ...... 13 5.4 Adjust Adjust Device and IP Addresses Addresses ..................... ................................ ...................... ...................... ..................... ..................... ...................... .................. ....... 14 5.5 Converter Control Panel (CCP) AF D242 ........... .............. ............. .............. ............ .............. .. 15 5.6 Excitation Control Terminal (ECT) ............ ............. ............ .............. ............. .............. ............ . 15 5.7 Device firmware download download and project-specific programming......... programming......... ............. .............. ............ . 15 5.8 Downloadin Downloading g Applicatio Application n ...................... ................................. ...................... ...................... ...................... ..................... ..................... ....................... .................. ...... 16 5.9 Field Flashing Flashing (-A03) (-A03) .................... ............................... ....................... ....................... ....................... ........................ ....................... ...................... ...................... ........... 16 5.10 Function Function Test of Protection Protection Devices Devices ..................... ................................ ...................... ....................... ....................... ...................... ...................... ........... 17 5.11 Analog Signals 17 5.12 Control Control Functions Functions Test ..................... ................................ ....................... ....................... ....................... ........................ ....................... ...................... .................. ....... 17 5.13 Function Tests of the Regulator........... .............. ............ .............. ............. ............ .............. ..... 18 5.14 Excitation Monitoring Monitoring and Protection (Standard-SW, (Standard-SW, Option for FAT).. ............ .............. ......... 18 5.15 Water Circuit Circuit Tests............................. Tests........................................ ..................... ..................... ....................... ........................ ....................... ...................... .................. ....... 18 5.16 Final Works 19 TESTS DURIN DURING G COMMISSIONING COMMISSIONING ....................... ................................... ....................... ....................... ....................... ....................... ........................ .................. ...... 20 6.1 Pre-Tests Pre-Tests (Standing (Standing Machine) Machine) ..................... ................................. ....................... ....................... ........................ ....................... ....................... .................. ...... 20 6.2 No Load Tests (Machine (Machine at Rated Speed).............. .............. ............. .............. ............ ............ 22 6.3 On Line Functions (Machine Synchronized). ............. .............. ............. ............ .............. ......... 24 6.4 Final Works................ Works........................... ....................... ....................... ....................... ....................... ....................... ....................... ....................... ....................... .................. ....... 26 USED INSTRUMENTS INSTRUMENTS ..................... ................................. ....................... ....................... ........................ ....................... ....................... ....................... ...................... .................. ....... 27 7.1 Factoy Test....................... Test................................... ........................ ....................... ...................... ....................... ........................ ....................... ...................... ...................... ........... 27 7.2 Commissioni Commissioning ng ..................... ................................. ....................... ....................... ........................ ....................... ....................... ....................... ...................... .................. ....... 27 APPENDIX............ APPENDIX...................... ..................... ...................... ....................... ....................... ...................... ...................... ...................... ..................... ..................... ...................... .................. ....... 28
9.
OPEN ISSUES............... ISSUES........................... ....................... ....................... ....................... ...................... ...................... ...................... ..................... ..................... ...................... .................. ....... 29
10.
MODIFICATIONS MODIFICATIONS AFTER COMMISSIONING..... COMMISSIONING................. ....................... ...................... ..................... ..................... ...................... ...................... .............. ... 30
4.
5.
6.
7.
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
en
Rev. ind. Pages
1
No. of p.
2 30
TABLE OF CONTENTS 1.
GENERAL ..................... ................................. ....................... ....................... ....................... ...................... ...................... ...................... ..................... ..................... ...................... .................... ......... 3
2.
REFERENCE REFERENCE DOCUMENTS............... DOCUMENTS.......................... ...................... ..................... ..................... ....................... ....................... ....................... ........................ .................... ........ 6
3.
8.
MAIN SIGNAL DATA ....................... ................................... ....................... ....................... ....................... ....................... ........................ ....................... ....................... .................... ........ 7 3.1 General General Data .................... ................................ ....................... ....................... ....................... ...................... ..................... ..................... ...................... ...................... ................ ..... 7 3.2 Identification Plate of Excitation. ............. ............ .............. ............. ............ .............. ............. ..... 7 HARDWARE-SETTINGS HARDWARE-SETTINGS ..................... ................................. ....................... ...................... ...................... ...................... ..................... ..................... ....................... .................... ........ 8 4.1 Non Linear Linear Resistors Resistors .................... ............................... ....................... ....................... ....................... ........................ ....................... ...................... ...................... ............. .. 8 4.2 Linear Linear Resistors, Resistors, Type: Type: GINO (-R02) (-R02) ...................... ................................. ....................... ....................... ....................... ........................ .................... ........ 8 4.3 Overvoltage Protection / Crowbar: Firing Print UNS 0017a-P, 0017a-P, Var. 1 (-A02) (-A02) .............. ............ ... 8 4.4 Advanced Power Distribution (APD) ............. ............. .............. ............. ............ .............. ........... 8 4.5 Settings for Converter Fans.... ............. .............. ............ .............. ............. ............ .............. ....... 9 4.6 Settings Settings for AVR Cubicle Cubicle Fans ...................... ................................ ..................... ....................... ........................ ....................... ....................... .................. ...... 10 4.7 Transducer Transducer Settings Settings ..................... ................................ ....................... ....................... ....................... ........................ ....................... ...................... ...................... ........... 10 4.8 Rotor Earth Fault Relay UNS 3020a-Z (-F40)............... ............ ............. .............. ............. ....... 11 4.9 Additional Additional Hardware Hardware Modificatio Modifications ns ...................... ................................. ...................... ..................... ..................... ...................... ...................... .............. ... 11 FACTORY TESTS AND PRECOMMISSIONING PRECOMMISSIONING ....................... ................................... ........................ ....................... ...................... ...................... ........... 12 5.1 Visual and Mechanical Checks.. ............. ............ .............. ............. ............ .............. .............. .. 12 5.2 High Voltage Test (See Additional Report) ............ ............ .............. ............. .............. ............ . 12 5.3 Check of Supplies...... Supplies................. ....................... ....................... ....................... ....................... ....................... ....................... ....................... ........................ .................. ...... 13 5.4 Adjust Adjust Device and IP Addresses Addresses ..................... ................................ ...................... ...................... ..................... ..................... ...................... .................. ....... 14 5.5 Converter Control Panel (CCP) AF D242 ........... .............. ............. .............. ............ .............. .. 15 5.6 Excitation Control Terminal (ECT) ............ ............. ............ .............. ............. .............. ............ . 15 5.7 Device firmware download download and project-specific programming......... programming......... ............. .............. ............ . 15 5.8 Downloadin Downloading g Applicatio Application n ...................... ................................. ...................... ...................... ...................... ..................... ..................... ....................... .................. ...... 16 5.9 Field Flashing Flashing (-A03) (-A03) .................... ............................... ....................... ....................... ....................... ........................ ....................... ...................... ...................... ........... 16 5.10 Function Function Test of Protection Protection Devices Devices ..................... ................................ ...................... ....................... ....................... ...................... ...................... ........... 17 5.11 Analog Signals 17 5.12 Control Control Functions Functions Test ..................... ................................ ....................... ....................... ....................... ........................ ....................... ...................... .................. ....... 17 5.13 Function Tests of the Regulator........... .............. ............ .............. ............. ............ .............. ..... 18 5.14 Excitation Monitoring Monitoring and Protection (Standard-SW, (Standard-SW, Option for FAT).. ............ .............. ......... 18 5.15 Water Circuit Circuit Tests............................. Tests........................................ ..................... ..................... ....................... ........................ ....................... ...................... .................. ....... 18 5.16 Final Works 19 TESTS DURIN DURING G COMMISSIONING COMMISSIONING ....................... ................................... ....................... ....................... ....................... ....................... ........................ .................. ...... 20 6.1 Pre-Tests Pre-Tests (Standing (Standing Machine) Machine) ..................... ................................. ....................... ....................... ........................ ....................... ....................... .................. ...... 20 6.2 No Load Tests (Machine (Machine at Rated Speed).............. .............. ............. .............. ............ ............ 22 6.3 On Line Functions (Machine Synchronized). ............. .............. ............. ............ .............. ......... 24 6.4 Final Works................ Works........................... ....................... ....................... ....................... ....................... ....................... ....................... ....................... ....................... .................. ....... 26 USED INSTRUMENTS INSTRUMENTS ..................... ................................. ....................... ....................... ........................ ....................... ....................... ....................... ...................... .................. ....... 27 7.1 Factoy Test....................... Test................................... ........................ ....................... ...................... ....................... ........................ ....................... ...................... ...................... ........... 27 7.2 Commissioni Commissioning ng ..................... ................................. ....................... ....................... ........................ ....................... ....................... ....................... ...................... .................. ....... 27 APPENDIX............ APPENDIX...................... ..................... ...................... ....................... ....................... ...................... ...................... ...................... ..................... ..................... ...................... .................. ....... 28
9.
OPEN ISSUES............... ISSUES........................... ....................... ....................... ....................... ...................... ...................... ...................... ..................... ..................... ...................... .................. ....... 29
10.
MODIFICATIONS MODIFICATIONS AFTER COMMISSIONING..... COMMISSIONING................. ....................... ...................... ..................... ..................... ...................... ...................... .............. ... 30
4.
5.
6.
7.
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
en
Rev. ind. Pages
1
No. of p.
2 30
1. GENERAL The test sections refer to t he Test Instructions (TI) 3BHS210837 E31: Example: TI Chapter 5.8 see Chapter 5ff.
Test Specification:
20.01.2012 Date of the factory test:
< Date > DMSESS / Carlos Mello Factory test carried out by:
< Dept./initials of first name, family name >
Date of the site test:
< Date >
Site test carried out by:
< Dept./initials of first name, family name >
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
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Rev. ind. Pages
1
No. of p.
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Abbreviations used in this document Abbreviation UT2o Usyn UC UTestmax Upower ICT1 IfDC IDC RL
Signal Secondary no-load voltage of excitation transformer Synchronous voltage Control voltage Test voltage Converter supply during the test Current transformer primary current (CT) Current Field current measurement Current Excitation current measurement Load of the excitation systems during the test
Abbreviation AC AI AO APD AVR BOD BU CB CCI CCM CCM BU CCP CH1 CH2 CIO COMM. CT CtrlBuilder DC ECT EDS EMC FAT FW HW ICU IP MCB OPC PC PI PID PQ PSS PT RTM SW TI TL USB
Signal Alternating Current Analog Input Analog Output Advanced Power Distributor Automatic Voltage Regulation Break-over Diode Backup Channel Control Builder Converter Control Interface Communication Control Measurement Device Communication Control Measurement Device (Backup Channel, BU) Converter Control Panel Channel 1 of the Automatic Voltage Regulator Channel 2 of the Automatic Voltage Regulator (Dual channel system) Combined Input/Output Device Commissioning Current Transformer Internal Software for PEC80-devices Direct Current Excitation Control Terminal Ethernet Device Switch Electromagnetic Compatibility Factory Acceptance Test Firmware Hardware Input Coupling Unit International Protection Miniature Circuit Breaker OLE for Process Control Personal Computer Proportional Integral Proportional Integral Differential Power and Reactive Power Power System Stabilizer Potential Transformer Rotor Temperature Measurement Software Test Instruction Test Lab Universal Serial Bus
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
en
Rev. ind. Pages
1
No. of p.
4 30
V/Hz
Volt per Hertz
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
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Rev. ind. Pages
1
No. of p.
5 30
2. REFERENCE DOCUMENTS The following documents are related to the item and to this document. Identity
Document kind
Title HW-Schematic
3BBR520311D0002 3BBR520311D0004 3BBR520311S0007
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
Layout Drawing Test Instructions (TI)
C
D Project
E
F
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
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Rev. ind. Pages
1
No. of p.
6 30
3. MAIN SIGNAL DATA 3.1 General Data Generator Apparent Power SN [MVA] Rated machine voltage U [V ac] Rated machine current I [A ac] Rated machine frequency f [Hz] Synchronous d-axis reactance Xd [p.u.] Synchronous q-axis reactance Xq [p.u.] No-load field current Ifo [A dc] Rated field current IfN [A dc] Ceiling current Ip [A dc] No-load field voltage Ufo [V dc] Rated field voltage UfN [V dc] Ceiling voltage Up [V dc]
Nominal Value 324 16500 11337 60 0.953 0.675 1030 1830
Transducer -16500 / 120
Remarks
-----
For systems with rotating exciter, the values are valid for exciter field
--
For systems with rotating exciter, the values are valid for exciter field
--
Auxiliary only temporarily for test
---
Phase to phase
356.1
Excitation System Supply mode Excitation transformer U1 / U2 [V ac] Converter supply voltage [V ac] (*) Converter supply frequency [Hz] Excitation system rated current IEN [A dc]
Shunt Supply 16500 / 899 899 60 2112
Auxiliaries Auxiliary Supply Uaux [V ac / Hz] 120 / 480 / 60 -Battery Supply 1 Ubatt [V dc] 125 -Battery Supply 2 Ubatt [V dc] 125 (*) No load, Excitation transformer secondary [Volt]
3.2 Identification Plate of Excitation Description TYPE: ABB ORDER NO.: SERIAL NO. YEAR OF DELIVERY: RATED CONT. DC-CURRENT: CEILING VOLTAGE: CONVERTER SUPPLY: SUPPLY FREQUENCY: PROTECTION DEGREE: MAX. AMBIENT TEMPERATURE: DIAGRAM: OPERATION INSTRUCTION:
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
Nominal Value A6T-O/U5H1-F2500 3BBR520311D0005 P15392Z 2011 2112 A
Language: English
900 V 60 Hz IP54 40°C
3BBR520311D0002
C
D Project
E
F
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
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Rev. ind. Pages
1
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4.
HARDWARE-SETTINGS
4.1 Non Linear Resistors TI Chapter 5.8 Doc. Ref.: HIER 466876 / 466877 / 464797 ABB-Order-No.
Pos.
[kWs]
Project
Manufacturer Label
Test
Comm. Rem.
HIER 466876
P.…..
550
HIER 466877
P…...
800
HIER 464797
P0002
1100
4.2 Linear Resistors, Type: GINO (-R02) TI Chapter 5.8 ABB-Order-No.
Rubr.
Type
Resistor value R20°C [Ω]
No. of elements in series
Project
Tester
Comm.
3BHE025009
R2315
690.0
0.02
15
Rem.
4.3 Overvoltage Protection / Crowbar: Firing Print UNS 0017a-P, Var. 1 (-A02) Doc. Ref.: HIEE 422032 Datasheet Name Function Voltage 24V 110V 125V 220V 1001 K1-Coil IN OUT IN OUT 1002 K1-Coil IN IN OUT OUT 1003 K1-Coil IN IN IN IN 1004 K2-Coil IN OUT IN OUT 1005 K2-Coil IN IN OUT OUT 1006 K2-Coil IN IN IN IN R1001 K3-Coil 0Ω 4.7kΩ /3W 5.6kΩ /3W 10kΩ /6W K3 Free wheeling relay (IN for 2 ch. type A5T) 1007 Free wheeling function (closed for 2 ch. type A5T) 1011 Closed for non redundant de-excitation (UNS 4017/4023 Var. 612, 622, 632, xx) V1000 Break over diode
250V IN OUT OUT IN OUT OUT 12kΩ /7W
Default Project Test Comm. Rem 110 V 125V OUT IN IN OUT IN IN OUT IN IN OUT IN IN OUT OUT --OUT OUT --OUT OUT -- OUT OUT OUT
2400V
4.4 Advanced Power Distribution (APD) Doc. Ref: 1333787 ZAE 000 Datasheet Name APD #1 CH APD #1 CH APD #1 CH APD #1 CH
*) Rev. Ind. Based on Title
#1 (+ER-Q801) #2 #3 #4
B 3BHS223093 E31 Rev. D A
Current Setting 2A 2A 2A 6A
C
Project 2A 2A 2A 6A
D Project
E
F
Test
Comm.
Rem.
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
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Rev. ind. Pages
1
No. of p.
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APD #2 CH APD #2 CH APD #2 CH APD #2 CH
#1 (+ER-Q802) #2 #3 #4
1A 1A 1A 1A
1A 1A 1A 1A
APD #1 CH APD #1 CH APD #1 CH APD #1 CH APD #2 CH APD #2 CH APD #2 CH APD #2 CH
#1 (+ER-Q811) #2 #3 #4 #1 (+ER-Q812) #2 #3 #4
2A 2A 2A 6A 1A 1A 1A 1A
2A 2A 2A 6A 1A 1A 1A 1A
Project 1A 2A 1A 2A 2A 2A 1A 1A
Tester
Comm.
1A 2A 1A 2A 2A 2A 1A 1A
Name APD #1 CH #1 (+EE-Q801) APD #1 CH #2 APD #1 CH #3 APD #1 CH #4 APD #2 CH #1 (+EE-Q802) APD #2 CH #2 APD #2 CH #3 APD #2 CH #4
Current Setting 1A 2A 1A 1A 1A 1A 1A 1A
APD #1 CH #1 (+EE-Q811) APD #1 CH #2 APD #1 CH #3 APD #1 CH #4 APD #2 CH #1 (+EE-Q812) APD #2 CH #2 APD #2 CH #3 APD #2 CH #4
1A 2A 1A 1A 1A 1A 1A 1A
Rem.
4.5 Settings for Converter Fans Fan M.C.B. for UNL 14300-Converter (n) = number of converter 1 to 8 M.C.B. +EG.1 -Q10, -Q20 +EG.2 -Q10, -Q20
Project 2.0A 2.0A
Tester
Pressure Measuring +EG.1 Pressure Measuring +EG.2 Pressure Measuring
Value 450Pa 450Pa
Tester
Notice:
*) Rev. Ind. Based on Title
Comm.
Witness
Comm.
Rem.
Rem.
The test report of the single converter module UNL14300 is not part of this document. Please refer to the test report of the individual converter.
B 3BHS223093 E31 Rev. D A
Witness
C
D Project
E
F
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Test and Commissioning Report UNITROL 6800 Document no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
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Rev. ind. Pages
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4.6 Settings for AVR Cubicle Fans Thermostat for AVR Cubicle Fan Thermostat +ER -F96
Project 30°C
Tester
Witness
Comm.
Rem.
4.7 Transducer Settings TI Chapter 5.12 PHOENIX-CONTACT: 3 way isolation amplifier, configurable, type MINI MCR-SL-UI-UI Combination table for In- and Output signals and settings with DIP-switch S1 and S2 (see Phoenix-Contact User Manual) Output Transducer connected to CCM: -U501 (AO) Setting Project [Field Current] Range (o: open / C: closed) Input 0...10 V S1 – o o Output 0…20 mA S2 – o o o o o c -U502 (AO) […] Input Output
Setting Range 0...10 V 0…20 mA
Project (o: open / C: closed) S1 – o o S2 – o o o o o c
Output Transducer connected to CIO: -U534 (AO) Setting Project […] Range (o: open / C: closed) Input 0...10 V S1 – o o Output 0…20 mA S2 – o o o o o c
Test
Comm.
Signal Range
2...10 V 4…20 mA (Measuring range)
Test
Comm.
Signal Range
2...10 V 4…20 mA (Measuring range)
Test
Comm.
Signal Range
2...10 V 4…20 mA (Measuring range)
-U535 (AO) […] Input Output
Setting Range 0...10 V 0…20 mA
Project (o: open / C: closed) S1 – o o S2 – o o o o o c
Test
Comm.
Signal Range
2...10 V 4…20 mA (Measuring range)
-U536 (AO) […] Input Output
Setting Range 0...10 V 0…20 mA
Project (o: open / C: closed) S1 – o o S2 – o o o o o c
Test
Comm.
Signal Range
2...10 V 4…20 mA (Measuring range)
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
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P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
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Rev. ind. Pages
1
No. of p.
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4.8 Rotor Earth Fault Relay UNS 3020a-Z (-F40) TI Chapter 5.9 Name Function S1 Measuring bridge to shaft earth (terminal 1-01) S2 Measuring bridge to coupling cap.(terminal 1-02) S3 24 V DC-supply to earth (terminal 3-12) S103 Operation frequency selection S104 Operation frequency selection S1201 Output relays active during test S1202 Output relays not active during test R1101 Matching resistor for shaft voltage filter * R1401 Setting range stage 1 R1402 stage 2 C1101 Compensation capacitor C1102 Compensation capacitor C1103 Compensation capacitor C1104 Compensation capacitor * Without shaft filter 120Ω, with shaft filter 1kΩ
Default IN IN OUT 50 Hz 50 Hz OUT IN 120 Ω 820Ω 820Ω 1 µF 1 µF ---
Project IN IN OUT 60 Hz 60 Hz OUT IN 1kΩ 820Ω 820Ω 1 µF 1 µF ---
Test
Comm. Remarks
µF µF µF µF
---
4.9 Additional Hardware Modifications Device
Element
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
Value
C
Modification Descriptions
D Project
E
F
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Test and Commissioning Report UNITROL 6800 Document no.
ABB Switzerland Ltd
3BBR520311D0042
Lang.
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Rev. ind. Pages
1
No. of p.
11 30
5.
FACTORY TESTS AND PRECOMMISSIONING
5.1 Visual and Mechanical Checks Action • • • • • • • • • •
Test
Witness
Remarks
Ensure checklist 3BHS298272_D03 is filled out completely Arrange components, quality and safety Affix identification and name of the cubicles, components and system cables Affix identification plate sticker, according to the data in chapter 3.2 Affix 24h Hotline sticker beside the plant name plate Ground the devices and components, interface boards, doors, ground bars etc. Check power cables and bus bars according to schematic diagram Check according to Manufacturing Guideline Fill out correct SW-Release on relevant sticker at panel door Put the documents in the document case
5.2 High Voltage Test (See Additional Report) TI Chapter 5.5 Action • Power Circuits • Auxiliary Circuits 230 V ac •
Auxiliary Circuits 400 V ac
• • • •
Auxiliary Circuits 1 DC Auxiliary Circuits 2 DC PT 1 CT 1
• •
PT 2 CT 2
•
Fan and Heaters circuits
•
Fans, UNL14300 Measuring transducers (analog signals)
•
Project 3500 V, 60 Hz; 1 Min. 1500 V; 60 Hz; 1 Min. 2500 V; 60 Hz; 1 Min. 2500 V; 60 Hz; 1 Min.
Max Values < 20 mA
2000 V; 60 Hz; 1 Min.
< 10 mA
2000 V; 60 Hz; 1 Min.
< 10 mA
2000 V; 60 Hz; 1 Min.
< 10 mA
Based on Title
B 3BHS223093 E31 Rev. D A
2500 V; 60 Hz; 1 Min.
500 V; 60 Hz; 1 Min.
D Project
< 20 mA
2000 V; 60 Hz; 1 Min.
C
< 10 mA
< 10 mA
Converter Type D5 converter, Type UNS7915 Var. V5…, D5 converter, Type UNS7915 Var. V7…, UNL13300 converter, UNL14300 conv., Input Volt. between 460V and 1340V acc. to appl. UNL14300 conv., Input Volt. between 1080V and 1500V acc. to appl.
*) Rev. Ind.
Remark
Test
E
Test Voltage power circuits 2500 V; 50 Hz; 1 Min. 3500 V; 50 Hz; 1 Min. 5000 V; 50 Hz; 1 Min. 5000 V; 50 Hz; 1 Min. 7500 V; 50 Hz; 1 Min.
F
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Notice
The high voltage test must not be repeated on the plant with the values specified above.
5.3 Check of Supplies TI Chapter 5.6 Action • • • •
Auxiliary supply AC (light, heating, fans) AC shunt supply (fans, converter supply, AC supply transformer) Auxiliary supply DC (Battery 1 and 2) Control voltage 24 V dc
Test
Comm.
Remarks
5.3.1 DC/DC Supply (-G80) TI Chapter 5.6 Function Input voltage to the supply unit Adjust output voltage to 25 VDC
Test 124,8 V dc 25,00 V dc
Comm. ………. V dc …..….. V dc
Remarks
Test 124,8 V dc 25,00 V dc
Comm. ………. V dc …..….. V dc
Remarks
Test 124,8 V dc 25,00 V dc
Comm. ………. V dc …..….. V dc
Remarks
5.3.2 DC/DC Supply (-G81) TI Chapter 5.6 Function Input voltage to the supply unit Adjust output voltage to 25 VDC
5.3.3 DC/DC Supply (-G100) TI Chapter 5.6 Function Input voltage to the supply unit Adjust output voltage to 25 VDC
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
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5.4 Adjust Device and IP Addresses TI Chapter 5.8 Adjustment of IP Addresses is only necessary with PC D232. The PC D235 does not feature any Ethernet connections. Name
Device Addresses S 200 Code Switch CIO #1 (-A51) Device Address 1 PC D235
IP Addresses Subnet Mask
Project
Test
Comm.
CIO #2 (-A52) Device Address 2 PC D235
CIO #3 (-A53) Device Address 3 PC D235
CIO #4 (-A54) Device Address 4 PC D235
CIO #5 (-A55) Device Address 5 PC D235
CIO #6 (-A56) Device Address 6 PC D235
ECT (-H100)
Not Available
172.16.0.61 255.255.0.0 172.16.0.63
Comm. PC
Not Available
CCM #CH1 (-A11)
Device Address 1
CCM #CH2 (-A21)
Device Address 2
CCI #1 pos Converter 1
Device Address 1
CCI #2 pos Converter 2
Device Address 2
255.255.0.0 172.16.0.21 255.255.0.0 172.16.0.22 255.255.0.0 172.16.0.31 255.255.0.0 172.16.0.32 255.255.0.0
Configuration
Positive Bridge
Remarks
Negative Bridge
Remarks
Converter #8 DI Input 12 on CCI: Link between X300:23 and –X300:24 Project Tester Comm.
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
No
Yes
No
C
D Project
E
F
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5.5 Converter Control Panel (CCP) AF D242 Doc. Ref.: 3BHS233287 E80 Operating Instructions Name CCP Converter #1 connected to -X66 CCP Converter #2 connected to -X66
Project
Tester
Comm.
Rem.
5.6 Excitation Control Terminal (ECT) Doc. Ref.: 3BHS233935 E80 Operating Instructions Function Supply ECT EDS (Ethernet Device Switch) –U100 USB-Dongle installed
Default 24VDC USED
Project 24VDC USED YES
Tester
Comm.
Rem.
5.7 Device firmware download and project-specific programming TI Chapter 5.7 Check the firmware ident-Nr. and download the specified version if necessary. Check conformity of the serial numbers of the following converters against the delivered converter test reports and add these reports to the test and commissioning report. Project El. Desig.
Project
Test
SW Release Firmware Version.
Compare the enlisted installer software to Release Track List 3BHS261662 E01
v.3.0.00
AC 800 PEC Main Controller CH #2 PC D230 CCM CH #1
PC D230 CCM CH #2
PC D235 CIO #1
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
Compare Serial-No. with test report
-A20
Compare Serial-No. with test report
-A11
Compare Serial-No. with test report
-A21
Compare Serial-No. with test report
-A51
C
D Project
v.3.0.01
-A10
Compare Serial-No. with test report
All Software Tools must be up to date and be checked before testing or commissioning by means of the database (Softw. General) AC 800 PEC Main Controller CH #1
Comm.
SG1290772019
v.3.0.01
SG1591011018
v.1.5.09
113230S0005
v.1.5.09
113230S0047
v.1.1.06
110235S0063
E
F
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Compare Serial-No. with test report
-A52
Compare Serial-No. with test report
-A53
Compare Serial-No. with test report
-A54
Compare Serial-No. with test report
-A55
Compare Serial-No. with test report
-A56
Compare Serial-No. with test report
-A01
Compare Serial-No. with test report
-A02
Converter Control Panel CCP #1
Compare Serial-No. with test report
-H101
v.1.1.02
Converter Control Panel CCP #2
Compare Serial-No. with test report
-H101
v.1.1.02
Excitation Control Terminal ECT
Compare Serial-No. with test report
-H100
1.4.0.15986
PC D235 CIO #2
PC D235 CIO #3
PC D235 CIO #4
PC D235 CIO #5
PC D235 CIO #6
PC D231 CCI #1
PC D231 CCI #2
v.1.1.06
110235S0032
v.1.1.06
110235S0066
v.1.1.06
110235S0065
v.1.1.06
110235S0107
v.1.1.06
110235S0060
v.1.5.05
134231S0010
v.1.5.05
111231S0017
Check: All boards of the same type inside an excitation unit must have the identical firmware release.
--
5.8 Downloading Application Action Configure IP of used downloading PC to: Download software package Application software (.zip file) Set IP-Addresses to devices Set time synchronizing
Project 172.16.0.63
Tester
Comm.
Rem.
-
-
5.9 Field Flashing (-A03) TI Chapter 5.10 Check the appropriate field flashing assembly AC or DC Field Flashing Supply [V] AC
M.C.B -Q03 [A]
Transformer -T03
16
---
Field Flashing Assembly [20A, 40A, 60A, 80A] 20A
Action
Title
Tester
125Vdc
Comm.
Rem.
Tester
*) Rev. Ind. Based on
Control voltage [V]
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
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No. of p.
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Check field-flashing current
20A
5.10 Function Test of Protection Devices Action • • • •
Function of the transformer overtemperature protection Function of the overvoltage protection / Crowbar Function of the rotor earth fault relay (Option) Additional protective relay (Option)
Test
Witness
Remarks
5.11 Analog Signals Action • • •
Check the local measuring devices and indications (CCP/ECT) Check the measuring of the actual value for the excitation Check analog signals for external indications
Test
Witness
Test
Witness
Test
Witness
Remarks
5.12 Control Functions Test 5.12.1 Local and Remote Operation TI Chapter 5.14 Action • • • • • • • •
Changeover between remote and local operation Field Breaker ON/OFF, status indication Excitation ON/OFF orders, status indication Setpoint RAISE / LOWER orders, MIN / MAX position indication Transfer between AUTO and MAN operation modes, status indication Transfer between channels 1 and 2, status indication Transfer between channels 1, 2 and Back-up channel, status indication (for T6x systems) Check additional application programming
Remarks
5.12.2 Self Acting Control Functions TI Chapter 5.9 Action • • • • •
Control of the field-flashing Protective transfer to alternate channel (only applicable for two channel systems) Protective transfer to manual operation Protective blocking of thyristor bridges (only applicable with N-1 redundancy of the converter bridges) Protective transfer to the stand-by converter bridge (only applicable for TWIN converter arrangement)
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
Remarks
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
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Rev. ind. Pages
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No. of p.
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5.12.3 Converter Control TI Chapter 5.11 Action • Test of the converter with temporary supply and base load • Check firing orders • Check the converter and inverter end position • Shape of the converter output voltage over the full range of control
Test
Witness
Remarks
5.13 Function Tests of the Regulator TI Chapter 5.13
5.13.1 Tests in Open Loop Mode Tests with simulated actual values and regulators in open loop condition Action • Variation of setpoints • Measurement of actual values
Test
Witness
Remarks
5.14 Excitation Monitoring and Protection (Standard-SW, Option for FAT) TI Chapter 5.17
5.14.1 Excitation Monitoring Action • Monitoring of the actual values • Rectifier Monitoring
Test
Witness
Test
Witness
---
Test
Witness
Tester
Witness
Test
Witness
Remarks
5.14.2 Protection Functions Action • Overcurrent Protection • P/Q- protection • V/Hz-protection
Remarks
5.14.3 Alarms and Trips Action • Hardware Trips and Alarms • Software Trips and Alarms
Remarks
5.14.4 Software Compliance Action • With closed field breaker download the application software in each channel, no trip allowed
Remarks
5.15 Water Circuit Tests Action *) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
Remarks
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
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No. of p.
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• • • • • • • •
Apply water to the system and check for leakage (Pressure 6 bar) Verify Pressure switch indication (P> tags: F10 / F20) Verify Leakage detector (PDIT tags: U10 / U20) Verify Pressure indicator transmitters (Pit tags: U01 / U03) Verify Flow Indicator (Fit tag: U02) Verify temperature sensor (Te tag R02) Verify temperature indicator (TI tag: P02) Check Valve position indications (Y01, Y02, Y21, Y22, Y11, Y12)
5.16 Final Works Action • Thermo strip necessary according to 3BHS288505 E01 yes/no • Disconnect system and prepare for delivery • Disconnect connections between transportation units • Plug protection covers on optical transmitters/receivers
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
Test
Witness
Remarks
E
F
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6. TESTS DURING COMMISSIONING 6.1 Pre-Tests (Standing Machine) 6.1.1 Visual Checks Action • • • •
Result
Remarks
Cubicles mounted properly, no visible damages External wiring, bus bar connections, external grounding Field breaker, field-flashing and de-excitation circuits Remove protection covers on optical receivers/transmitters and connect optical fibers
6.1.2 Field Resistance Action •
Result
Remarks
Field resistance including cables at 20 ºC
6.1.3 InsulationTest Action • Insulation test of main circuit
Result
Remarks
6.1.4 Supplies Action • • • • • • •
Result
Remarks V V V V
AC main supply for converter and supply transformer AC supply for light and heating DC supply for electronic circuits Second DC supply (option) Field flashing supply 24V supply Function of electronic devices okay / Internal power supplies okay
V
6.1.5 Field Flashing Action
Comm.
Measured field flashing supply voltage
Remarks V
6.1.6 Software Action • • • •
Result
Based on Title
Make sure that the tools on the comm. PC are up-to-date Download the most recent project software to the PC (to both channels of a 2 or 3 channel system) if there were changes in the TL after testing. Firmware-Version updated and added to the list in case of changes Adjustment of project-specific parameters
*) Rev. Ind.
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
Remarks
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
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No. of p.
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6.1.7 Transducer Action • • •
Result
Remarks
Programming of the transducer Definition setpoint range and Pre-sel for the manual channel Definition setpoint range and Pre-sel for the auto channel
6.1.8 Control Circuits Action • • • • • • • • •
Result
Remarks
Check all command inputs Check all signalization outputs Check alarm circuits Check trip circuits Field breaker control circuits Field-flashing control circuits Check fan control circuits Check PTs and CTs Check analog inputs and outputs
6.1.9 Protection Devices Action • • •
Result
Remarks
Adjustment of rotor ground fault relay Test temperature supervision of excitation transformer Visual inspection of crowbar (correct BOD-elements)
6.1.10 Converter Test with Base Load Action • • •
Result
Remarks
All firing pulses present Characteristic UE = f(UC) with base load, polarity of voltage Check limits of firing angle
6.1.11 Current Tests on Standing Machine Action • Optimization of manual channel with ref. value jumps
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
Result
Remarks
E
F
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6.2 No Load Tests (Machine at Rated Speed) 6.2.1 Manual Channel Action • • • • • • • • • • •
Result
Remarks %
Field-flashing with blocked converter, measuring of Ug Check actual value measuring (U, Usyn, If, Uf), adapt resp rescale if necessary Define limits of reference value and preset-value Adaptation of PI-Filter in MAN (with reference value jumps) Converter supply voltage at rated voltage / phases correct Check of de-excitation with field breaker off (de-excitation via resistance) Deexcitation with inverter operation (Field breaker remains closed) Check of de-excitation without field breaker off (de-excitation via converter) Adjustment Diode monitoring at IEmin Setpoint adjustment with +/-buttons Setpoint adjustment via analog input
V
6.2.2 Automatic channel Action • • • • • • • •
Result
Remarks
Field-flashing and Softstart Define limits of reference value and preset-value Optimization of PID-Filter Settings and check of V/Hz-limiter Check de-excitation circuits (normal de-excitation and trip field breaker) Definition of P/Q-droop resp. P/Q-compensation Setpoint adjustment with +/-buttons Setpoint adjustment via analog input
6.2.3 Channel Changeover Action • Check changeover from CH1, CH2 and Backup-channel; smooth changeover • Check changeover from AUTOMAN and vice versa; smooth changeover
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
Result
Remarks
F
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6.2.4 Monitoring / Protection Action • • • •
Result
Based on Title
Check emergency changeover AUTOMAN with missing U-measuring Check emergency changeover CH1CH2 CH3 (only A6x or T6x systems) Adjust and check rotor ground fault relay Bridge voltage after calibration u+(no load) …… Veff Desired resistor for alarm level Rf1 ……. k Stage 1: u+ (=Uref1) …… V Delay time …… s Desired resistor for trip level Rf2 …… Stage 2: u+ (Uref2) …… V Delay time …… s
*) Rev. Ind.
B 3BHS223093 E31 Rev. D A
C
D Project
E
Remarks
F
P.H. SOGAMOSO
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1
No. of p.
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6.3 On Line Functions (Machine Synchronized) 6.3.1 General Tests after Synchronization Action • • • • • • • •
Result
Remarks
Adjust generator current measurement / check P- and Q-measuring Auto channel setpoint step on the grid to optimize the dynamic behavior Manual channel setpoint step on the grid to optimize the dynamic behavior Load rejections with P0; Q positive Load rejections with P0; Q negative Adjust diode monitoring at IEN Adjust manual restrict Trip of the generator breaker through the excitation
6.3.2 IE- Limiter Action • •
Result
Remarks
Define and check IE-limitation overexcited Jump into limitation to optimize dynamic behavior
6.3.3 I- Limiter Action • •
Result
Remarks
Define and check I-limitation over- and underexcited Jump into limitation to optimize dynamic behavior
6.3.4 P/Q – Limiter Action • • •
Result
Remarks
Define P/Q-characteristic Check P/Q-limitation underexcited Jump into limitation to optimize dynamic behavior
6.3.5 IEmin – Limiter Test No./ Test description • •
Result
Remarks
Define and check IEmin-limitation underexcited Jump into limitation to optimize dynamic behavior
6.3.6 Superimposed cos phi-Regulator Action • • • • •
Result
Based on Title
Check stability and dynamic behavior of cos phi-regulator Check limits of cos phi-reference value Check reference value settings by +/-buttons Check reference value setting by analog input Check follow up between analog reference value and +/-reference
*) Rev. Ind.
B 3BHS223093 E31 Rev. D A
C
D Project
E
Remarks
F
P.H. SOGAMOSO
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No. of p.
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6.3.7 Superimposed Q-Regulator Action • • • • •
Result
Remarks
Check stability and dynamic behavior of Q-regulator Check limits of Q-reference value Check reference value settings by +/-buttons Check reference value setting by analog input Check follow up between analog reference value and +/-reference
6.3.8 Rotor Temperature Measurement (Optional) Action • Setting of RTM-parameters • Measurement of rotor temperature
Result
Remarks
Deg.
6.3.9 Excitation Transformer Measurement Action • Setting of excitation transformer parameters • Measurement of transformer temperature
Result
Remarks
Deg.
6.3.10 Power System Stabilizer Action • Define parameters of PSS (K1 and K2) • Verification of correct behavior of PSS
Result
Remarks
6.3.11 Special Tests Action • Time synchronization with ECT • Time synchronization with Time Server
Result
• • • • • • •
*) Rev. Ind. Based on Title
Remarks
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
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No. of p.
25 30
6.4 Final Works Action • • • • •
Result
Remarks
All screws fixed Clear fault logger Reset all temporary parameter settings Save parameters in both channels Save the following files to a CD for the customer and make a copy for ABB home documentation: Project archive: - Installer Archive files, *.zip from all channels - Snapshot files from all channels - CIT Software, *.zip
ECT archive:
•
• • • • •
•
- OPC files, *.*Xml (if no ECT present, copy from PC) - ECT configuration files, *.xml - ECT database file, *.fdb - ECT single line diagram, *.dll (if applicable) - Trendings (not on customer CD) Hand over the CD called "as Commissioned" with the above files to the customer (Use and complete the labeling of the ABB pre-labeled CD) All modifications must be registered in a schematic diagram and a commissioning protocol Client signature must be marked in commissioning protocol Provisional acceptance report filled out and signed Restart Data Logger Temperature registration according to 3BHS288505 E01 and values in excel file (3BHSxxxxxx E02). Only when 5.13 temperature strip present and already powered
Check and correct (if necessary) SW-Release on sticker at panel door
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
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7. USED INSTRUMENTS 7.1 Factoy Test Name / Type
Identification
Last Calibration
Identification
Last Calibration
7.2 Commissioning Name / Type
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
C
D Project
E
F
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8. APPENDIX
Upower
CONTROLS
CONVERTER
V/A
V
Digital output
Digital input
U
Generator Model
I If Uc
Uaux
*) Rev. Ind. Based on Title
B 3BHS223093 E31 Rev. D A
Ubatt
C
D Project
E
RL
F
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No. of p.
28 30
9. OPEN ISSUES Rem. No.
Remarks
*) Rev. Ind. Based on Title
Date/ Signature
B 3BHS223093 E31 Rev. D A
C
D Project
Decision/Action
E
F
Cleared: (Date)
P.H. SOGAMOSO
Test and Commissioning Report UNITROL 6800 Document no.
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No. of p.
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