ANNEXURE 4

FIELD ACCEPTANCE TEST FOR GENERATORS

1.1 Field acceptance tests (all units). These tests consist of:

(i) Stator dielectric tests. These tests consist of: Insulation resistance and polarization
index, Corona probe test, Corona visibility test, Final AC high potential test, Partial
discharge analysis (PDA) test, and Ozone detection (optional).
(ii) Rotor dielectric tests.
(iii) Stator and rotor resistance tests.
(iv) Noise and vibration measurements.

1.2 Special field test (one unit of series). These tests consist of:

(i) Efficiency tests.

(ii) Heat run tests.
(iii) Machine parameter tests.
(iv) Excitation test.
(v) Over speed tests (optional).

1.3 Temperature rise test. This test should include

(i) Oil and babit material of guide and thrust bearing.

(ii) Magnetic core.
(iii) Stator winding, rotor poles.
(iv) Air and cooling system.

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 ANNEXURE 5

LIST OF TESTS/ CHECKINGS OF HYDRO GENERATING UNIT

(During Pre-commissioning AND Commissioning)

NOTE: 1. Guide lines indicated here under are general and may vary from manufacturer
to manufacturer.
2. Items not applicable for particular turbine can be indicated as NA.

Serial Activity Remarks.

No. Results/test
values obtained
A Erection

1 Checking the position /Alignment with respect to center line and

axis of components
a Turbine
b Generator
c Gear box
2 Individual & combined alignment of above.
3 Positioning of Oil Pumping Unit with Accumulator
4 Positioning of Cooling water
5 Positioning of Drainage and Dewatering system
6 Positioning of LAVT, NGT/NGR, Excitation transformer, local
control panels, AC/DC distribution boards, etc
7 Positioning of Control & protection, metering, battery chargers,
LTAC, 11KV switchgear, Governor, SEE, Synchronizing Panels
etc;
8 Outdoor equipments like Transformers, Breakers, Isolators, LAs,
CTs, PTs, MOM & Marshalling boxes, etc;
9 Stringing of outdoor bus bars & equipments,
10 Checking Grounding of all equipments
11 Checking Comprehensive cabling & termination as per cable
schedule
B Testing & Commissioning
1 Testing of DG set & or start-up power source
2 Commissioning of charger panels & extension of DC supply to
various panels etc.
3 Testing of fire protection systems
4 Commission DG set in all respect
6 (i). Test LTAC panels for good IR values.
(ii). Operation of individual breakers, interlocks.
(iii). Checking of change-over of incoming breakers
preferential -wise by simulation etc.
(iv). Charging of panels with start-up source.
7 (i). IR & PI values of generator stator windings (1 000 v
megger, min. 50 M-ohms for 1 KV, PI- min.2); dry-out if
necessary.

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 Serial Activity Remarks.
No. Results/test
values obtained
(ii). Measurement of stator & field winding resistances, IR &
impedance values of field winding (500 V megger, value
in M-ohm & impedance as per design), healthiness of
heaters.
(iii). Proper operation of brakes, HP lubrication system, etc.
(iv). Tan delta measurements, if contemplated.
8 (i). Hot-oil circulation of unit & auxiliary transformers,
Checking of BDV & PPM content.
(ii). Measurement of winding resistances, IR & PI values
(iii). (HV-E, LV-E, HV-LV: 2.5kV megger, results
comparable to factory tests).
(iv). Magnetic balance, proper operation of buccholtz relay,
oil-level switches, PDV, temperature high & too-high
alarm/ trips, local/remote operation of oil pumps,
change-over, airing-out, adjustment of proper oil/water
pressure & flow rates, differential pressure & its relay
setting, healthiness of silica-gel, etc.
9 (i). HT- side breakers: Filling of SF6 gas.
(ii). Operational Checking, pole discrepancy, trip circuit
supervision circuits, chronograph Checking, alarm, lock-
out & inter-lock Checking, remote operations, protection
tripping etc.
10 (i). Alignment of isolators.
(ii). Motorized operation, remote operation, inter-locks etc.

11 Checking & ensuring Line -Line & Line -Earth clearances for
all bus wires & equipments at ODY
12 Checking & ensuring grounding of all equipment
13 Measuring earth-mat resistance for proper value. Checking its
value with the design calculations
14 Protection relays- soft-ware loading, Checking for proper
operation of all protections, adopt recommended settings
15 Extending power supply to various auxiliary systems like OPU
sets, Lube-oil systems, cooling water system, etc; adjust for
required flow at recommended pressures, ensuring proper
change-overs, alarm/trip settings of various associated limit/
pressure/ level/flow switches & commissioning each as per
schemes.
16 Checking all individual CTs, PTs (415V/1 1kV/220kV) for
proper PI -P2 positioning, ratio & polarity; IR values.
17 Checking the synchronising scheme
18 Dry stroking of MIV/butterfly valve/pen stock gate as the case
may be; adjust for proper opening/closing times, adjust correct
settings of limit & pressure settings, Checking for proper
indications, alarms, trips etc. as per scheme.
19 Dry stroking of turbine, ensure proper beddings, achieve

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 Serial Activity Remarks.
No. Results/test
values obtained
recommended conjugation of guide vane vs. blade incase of
Kaplan, nozzle vs. deflector in case of Pelton runner, box-up,
assemble accessories , keeping ready for initial spinning
20 Checking of individual schemes for proper wiring, correct inter-
locks as per approved drawings.
21 Checking all protection & annunciation circuits by actual
simulation of devices wherever feasible & ensure operation of
trip relays, opening of associated breakers, correct alarm &
annunciations as per approved logic diagrams
22 Checking operation of MIV under dry and as well as in wet
conditions
23 Filling of penstock gradually and observe for leakage in MIV,
by pass and air release valves etc
24 Filling of draft tube in case of reaction turbines from D/S &
testing of DT gates.
C Initial Spinning, Pre -commissioning Tests
1 Re Checking & ensuring all components of unit are boxed-up -
properly, & the brakes are released
2 Starting all auxiliaries like
(i). Cooling water pumps,
(ii). OPUs, GLOP, etc; & ensuring requisite pressure and
flow rates at different points as per scheme.
3 Opening MIV/Penstock gate/ Butterfly/Spherical valve as the
case may be.
4 Starting Lube oil pump & ensure requisite oil pressure buildup
5 Open slowly the GVs/Needles just enough to start rotation of
rotating parts. Observing closely for absence of rubbing sounds
& ensure rotation is smooth
6 Increasing speed gradually while closely monitoring smooth
running & that temperatures & vibrations are normal - locking
the governor position at no-load/ rated speed condition,
allowing the machine to run at rated speed till all temperatures
stabilize ( not more than 1 degree C in an hour ) - recording
stabilized temperatures & vibrations. With the unit now running
@ rated speed; there will be a slight voltage of around 100 to
200 volts on the stator terminals & corresponding milivolts on
the secondaries of 11 KV PTs. Measuring and recording this
voltages at PT cubicle & further at all relays, meters, excitation
& other equipments as per scheme. Stopping the unit & ensure
proper application of brakes.
7 Tripping the unit with emergency push button and Checking for
closure of BFV etc
8 Braking test for verification of stopping time of the unit
D Short Circuit Characteristics
1 (i). Shorting the generator line terminals at XLPE terminal
and cables shall be adequately rated to withstand

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 Serial Activity Remarks.
No. Results/test
values obtained
continuous over-load rating current of the unit.
(ii). Ensuring NGT isolator is closed. Start the unit & bring
the unit to rated speed.
(iii). Slowly & gradually increase field current to achieve
around 1 to 2% of stator rated current.
(iv). Measuring and recording the presence of
corresponding secondary currents at all CTs, meters,
relays & other equipments fed by them.
2. (i). Shorting the secondary side terminals of neutral side
CTs of Overall Differential protection at 87GT relay
terminals.
(ii). Measuring the differential (87 G) CTs current at
corresponding relay terminals of 87G which should be
equal. Assuming shorting is made after the line side
CTS of 87G, the spill current in the operating coil
circuit of the 87G relay should be zero or minimal.
(iii). Increasing the field current gradually while
continuously monitoring the spill current (which should
continue to be zero) till 50% of rated current is
achieved. The relay should be stable with negligible
spill current. This establishes the stability requirement
of the relay.
(iv). Reducing excitation to zero & reverse the polarity of
any one set of CTs feeding 87G relay ( for numerical
relays just shorting of one set CTs may be sufficient) &
slowly increase the field current while monitoring the
spill current in the 87G relay. The relay should operate
at the set current (normally 10%) & trip the master trip
relays.
(v). Unit should be shut-down & excitation should be
switched off.
3 (i). Restoring the normalcy of reversed polarity of CTs (or
remove the short as the case may be) & restart the
unit. At rated speed, gradually increase the field
current. At every 20% of rated stator current (In) & at
continuous overload rating current of the stator; note
down associated field current (If) & field voltage (Vf).
(ii). Reducing excitation to zero, open field breaker &
shut- down the unit. Plot the SCC graph of measured
If vs. In values; If being plotted on x-axis. Compare
with factory test results.
(iii). Reducing excitation to around 50% of rated current &
reverse polarity of one or two CTs of Negative phase
sequence relay & ensure its operation.
(iv). Restoring reversed polities of CTs. Remove the
shorting arrangement after the unit completely comes
to rest.
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 Serial Activity Remarks.
No. Results/test
values obtained
(v). Do not interconnect the unit transformer.
4 (i). Checking of Stator Earth Fault Relay (DGF) 95%:-
Create a Line to Ground fault by connecting a 7/20
gauge wire from any of the R-Y-B phase terminal to
the earth.
(ii). Restarting the unit & bring it to rated speed. Checking
for the presence of a small voltage across NGR. & then
at the relay terminals. Setting of the relay may be
reduced to the minimum possible. While closely
monitoring this voltage, increase field current slowly
till the relay setting voltage appears across the relay &
causes the relay to operate & trip the unit.
(iii). Allow for the unit to come to standstill before removing
the simulated ground fault
5 (i). Repeating the process by grounding one phase on
neutral side to ensure 95 to 100 % E/F relay function.
(ii). Disabling of starting inter-lock could be necessary.
E Open circuit characteristics
1 (i). Restarting the unit & bring it to rated speed. Sufficient
voltage must be available now due to residual
magnetism.
(ii). Checking & ensure correct PHASE SEQUENCE
directly at the generator terminals.
(iii). Slowly increase the field current & ensure uniform
build-up of voltage on all three phases.
(iv). Measure presence of PT secondary voltages at all PTs &
at all meters, relays & other terminations as per scheme.
At every 20% rated voltage; record Vf, If & generator
voltage Vn. At 100% Vn, measure PT secondary
voltages again.
(v). Checking the PHASE SEQUENCE & ensure it is as per
scheme for all the sets of PT secondary.
2 (i). Reducing the setting of V/Hz relay to least possible
value & ensure the operation of the relay. Slight
increasing of voltage & reducing of speed may be
required for this.
(ii). Tripping of the unit may be blocked for this protection.
Restore normal setting.
3 (i). Reducing the setting of Over Voltage relays.
(ii). Increase the voltage suitably to ensure proper operation
of same.
4 (i). Regularize transformer connections. For small units,
closing of 11 KV breaker may be sufficient. Short the
HT terminals after the HT CTs using same size
conductors as used for regular connections. Remove the
earlier shorting made on the secondaries of neutral side
CTS.
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 Serial Activity Remarks.
No. Results/test
values obtained
(ii). Restarting the unit & bring it to rated speed. Slowly
increase field current & monitor currents in 89GT
Overall Differential relay. Currents from two sets of
CTs from neutral & HT side should be equal and that in
the spill circuit should be zero.
(iii). Raise field current till 50 % of rated current is passing.
The relay should not operate & be stable. Reduce
excitation to zero. Reverse polarity of one set of CTs.
Slowly increase excitation while continuously
monitoring relay currents. The current in the spill circuit
should be double of individual CT currents. Increase
excitation till the relay operates at the set value;
normally 20 % of rated current.
5 (i). Remove the short on HV terminals. Ground any one HV
terminal after the CT using a 50 mm-square cable or
thereabouts.
(ii). Slowly raise excitation till around 5% of rated current is
passing in the grounded phase. Measure currents in the
CT circuits and spill circuit of transformer
(iii). Restricted Earth Fault relay terminals. CT currents
should be equal & spill current should be zero. Reduce
current to zero & reverse the polarity of neutral CT.
Increase excitation slowly. Spill current equal to double
the value of CT currents should manifest. Increase
current till relay setting is reached & the relay operates,
(iv). Restore correct polarity of the NCT.
6 Measurement of bearing current/shaft voltage
F Over-Speed Test
1 (i). Governor is as yet under manual control. Start the unit
& slowly bring it to rated speed; ensuring picking-up of
various speed relays.
(ii). Set the electrical over speed relay at the guaranteed over
speed value. Raise the unit speed steadily till that speed
& ensure operation of the relay
G Excitation & Governing
1 Removing the soft-start arrangements made in the Excitation
system, run the unit at rated voltage & commission auto-
operation of AVR.
Removing excitation & re-excite by field flashing.
2 Commission Auto synchronizer
3 Commission AUTO-OPERATION of Governor
Unit is now ready for Synchronizing
H Phasing -Out Checking & Synchronizing
1 By this time the transmission line would have been ready &
charged up to the out going gantry.
Checking for healthy IR values of HT BUS. Associate
transmission engineers to ensure correct settings are made for
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 Serial Activity Remarks.
No. Results/test
values obtained
Line protection relays & charge the station HT bus by closing
the line breaker/s. Ensure that the PHASE SEQUENCE is
proper as per the station switch-yard layout
2 Open the line breakers & render the HT bus dead. Start the unit,
excite and charge the HT bus from the unit's supply. Checking
again for correct phase-sequence. Switch on the Synchroscope.
It should be point at 12'O clock position, the guard relay in
the Checking-synchronising relay should have picked-up &
'ready for synchronising' lamp should be glowing, Depending
on 'bright' or 'dark' lamp method adopted; corresponding lamps
should glow brightly or completely dark as the case may be.
3 Open the synchronizing breaker. Charge the bus from lines'
end. Keep 89G isolator open. Switch on the synchronizing
scheme & match unit voltage & then its speed/frequency to that
of bus voltage & carry-out 'dummy' synchronizing.
Open the synchronizing breaker, close 89G isolator & carryout
regular synchronizing. Load the unit in 10 to 15 steps up to 25
% of rated load. Ensure all parameters are normal &
temperatures are synchronizing.
I Load throw of Tests
1 Loading of the unit to 25%, 50%, 75%, 100% and 115%
gradually subject to hydraulic conditions as required along with
balancing at different load conditions, if required.
2 Measurement of bracket and shaft vibrations with excitation
and at loads of 25%, 50%. 75%, 100% and maximum
continuous rating. Adjust the governor timings, if warranted
3 Load throw off test at each of the above loads to ensure that
speed and pressure rises are within the guaranteed limits.
Record the finally set guide vane or needle opening/ closing
times.
4 All functional Checking and fine-tuning of governor controls,
conjugation etc., and prove the performance.
All functional Checking and fine-tuning of AVR including
proper setting of all the limiters etc., and prove the performance
J Reliability tests
1 After commissioning the unit shall be run for 72 hours
continuously at the maximum continuous rating (MCR) that
could be achieved at the available head and discharge to prove
its capacity (Output) and performance guarantee figures of
temperatures of stator / rotor etc.
2 72 hours capacity demonstration test is to be conducted to
prove the guaranteed continuous over-load capability by
running the unit as for as possible at that MVA loading.
Temperatures rises shall not exceed the guaranteed values.
The Reliability test shall be considered successful, provided
that each item of the plant can operate continuously at the
specified operating condition during this period. Minor
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 Serial Activity Remarks.
No. Results/test
values obtained
interruptions not exceeding four (4) hours during the
Reliability tests shall not affect the total duration of Reliability
tests
K Field Acceptance tests
Field acceptance tests shall be conducted to meet the functional
guarantees specified for Turbine and Generator. The tests shall
be conducted as per IEC-60041. The measurement so made
will be the basis for the assessment of values guaranteed.

L Taking over:
After the successful completion of the "Reliability test" the
unit will be taken over by the 'Owner' for 'commercial
operation'. In case the rated head or discharge is not available
to operate the unit at full capacity, the unit shall be
provisionally taken over after completion of Reliability tests at
available head or discharge. The Contractor shall prove the
unit at full capacity immediately when the rated head and /or
the discharge is available after which the unit will be 'Taken
over' by the 'Owner'
M Protocol on Tests
A protocol on tests carried out at site including acceptance tests
shall be prepared and supplied.

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