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ABB INDIA
Commissioning
Test Specification / Report
for
Thyristor Rectifier
PLANT:
NUBERG - FLOUDERS
TYPE:
Order-No:
3100035028
The test procedure and report have been examined. The tested object has functions and
performance according to its specifications with exceptions according to the exception list
and the review comments.
<Date /
>
<Date /
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S.NO
1
2
3
4
5
5.1
5.2
5.3
6
7
8
8.1
9
9.1
10
10.1
10.2
10.3
10.4
10.5
11
12
13
13.1
13.2
13.3
14
15
16
17
18
19
20
21
22
22.1
22.2
23
24
Doc. kind
Title
Description
General
Reference Documents
Preconditions for Commissioning Engineer
Request
List of Tools
Auxiliary Supply
3 Phase Feeder
Light and Heating
DC Control Voltage
Controller Load with PEC View
Analog Signals
Transformer Auxiliaries
Trafo Oil Pump Operations
Rectifier Cooling Unit Auxiliaries
DIW Pump and Rectifier cubicle Fan operation
Rectifier Transformer Switch Gear Interface
Precondition
Status Indications
Main Breaker Interlock
Main Breaker Trip test
Trips/Alarms from Breaker panel
Current of AC motros
Over Current Protection
Fuse Monitoring
Fuse Monitoring +G010
Fuse Monitoring +G020
Fuse Monitoring OverVoltage Protection(Trafo
Sec)
Heat Sink Monitoring (Alarm/trip)
EarthFault Supervison
Signals Test
No Load Test of Rectifier Transformer
Pulse Positioning
Lamp Load Test of Rectifier
Light load test(Using salt water)
Short Circuit Test
Load Test
Curent Readings
Heat Run Test
Exception List
Revision
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3
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4
5
6
6
6
6
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8
9
9
10
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11
11
12
12
12
13
13
15
15
15
16
16
16
17
17
17
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24
27
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28
29
30
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1. GENERAL
2. REFERENCE DOCUMENTS
The following documents are related to the item and to this document.
Identity
Doc. kind
Title
Document kind
Schematic
Schematic
Schematic
Schematic
Schematic
Title
Rectifier Control Panel
Rectifier Panel
AC Distribution Panel
Rectifier Cooling system
Rectifier Transformer
Project
Doc. no.
Lang.
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No. of p.
3
29
Result
OK
-OK
-OK
OK
OK
OK
OK
OK
--
Remark No.
Signature:
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Title
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29
4. LIST OF TOOLS
Which tools should be taken to site?
Communication cables
Mulitmeter FLUKE
Digital Camera
Commissioning Interface ( RCI box)
Osciloscope with 2 voltage probe and 2 current probe
Doc. kind
Title
Project
Doc. no.
Qty
Required
1 Set
1 No
1 No
1 No
1 Set
1 Set
1 No
1 No
1 No
1 Set
Lang.
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5
29
5. AUXILIARY SUPPLY
5.1 3-Phase-Feeder
Incoming Voltage [V]
Nom. Voltage
3* 380 VAC
L1 - L2
380
L1 - L3
381
L2 - L3
380
Current (A)
L1
24.1
L2
24.3
Signature:
L3
24.5
Remark No.
PH N
233.2
PH GND
229.5
N GND
-
Current (A)
PHASE
2.3A
Signature:
Remark No.
Doc. kind
Title
POSNEG
109.1
POS
GND
108
NEG
GND
--
Project
Doc. no.
Current
POS.
Signature:
Remark No.
9A
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29
Doc. kind
Title
System Interrupts
Load in %
3.1
System Tasks
0.7
SCNR
0.2
IRQ_Soft
0.7
SCDT
22
Application Task
SDPT
ECLT
TIME
HSWP
0.1
EXEV
Main
3.2
VCLT
EPEC
BltJb
idle
0.3
idle
21.8
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7. Analog Signals
Signal
LCP PP
AC Current
OK
4-20mA=
0-100deg
OK
4-20mA =
0-100deg
Not OK
4-20mA =
0-20uS
OK
0-1pu=017.5KA
OK
4-20mA =
0-130V
OK
4-20mA =
0-17.23KA
NA
AC Voltage
NA
KAH integrator
NA
DIW COND
UNIT DC Current
DC Voltage
LCP Meters
To DCS
NA
Result
Remark
No.
-OK
NA
-OK
NA
NA
OK
OK
4-20mA = 0-20KA
OK
4-20mA =
0-130V
NA
OK
4-20mA =
0-18KA
OK
4-20mA =
0-130V
NA
OK
OK
OK
Energy meter reading and analog
meter reading OK
Energy meter reading and analog
meter reading OK
Display in KAH integrator (Massibus)
OK
NA
OK
NA
OK
NA
OK
Signature:
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29
8. TRANSFORMER AUXILIARIES
Name of devices
Buchholz Relay for
Main Tank
Oil Temperature
Oil level transformer
Winding temp.
Rectifier Transformer
Pressure Relief
Result
Remark
No.
Alarm
Trip
Settings
OK
OK
OK
OK
OK
OK
NA
NA
A>85DegC
T>98DegC
NA
OK
OK
A>110DegC
T>120DegC
OK
NA
OK
NA
OK
OK
OK
Signature:
8.1 Trafo Oil Pump Operation
Test Case Description
RESULT
Perform Pump ON /OFF COMMAND in manual mode ( From Local Panel located in
Rectifier Room)
Perform all four Fans ON /OFF COMMAND in manual mode ( From Local Panel
located in Rectifier Room)
Status of all pump and Fans in PP846
If anyone Pump / Fan OFF during breaker closed condition alarm generated
Remark
No.
OK
OK
OK
OK
Signature
DIW conductivity
Trip
OK
OK
A>5uS
T>10 uS, 5s
delay
OK
OK
OK
A<50%, T<25%
OK
FM2
OK
OK
FM3
OK
CIC
LS1/LS2
Doc. kind
Title
Result Remark
No.
Alarm
Name of device
Project
Doc. no.
Settings
OK
OK
Lang.
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No. of p.
9
29
TIC1
TIC2
TIC3
TIC4
3 Phase Under
voltage
Monitoring
NA
A > 43 Deg C
T > 47 Deg C
A > 47 Deg C
T > 50 Deg C
A > 35DegC,
A>39 DegC
OK
NA
A > 37 DegC,
A>42 Deg C
OK
230 volt
OK
OK
OK
OK
OK
OK
OK
OK
OK
U1
OK
Signature:
Result
OK
OK
OK
OK
OK
OK
Remark No.
Signature:
Result
OK
OK
Remark No.
Signature:
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Result
OK
OK
OK
Remark No.
Signature:
Result
OK
OK
OK
Remark No.
Signature:
10.4 Main breaker trip test, (few trips to be tested end to end).
Test Case description
Buchholz trip
DIW flow low trip
nd
2 fuse failure trip
Single fuse failure is an alarm and main breaker does not trip
SPAJ 140 overcurrent relay trip
Trip
OK
OK
OK
OK
OK
Remark No.
Signature:
Doc. kind
Title
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29
Y (A)
B (A)
14.3
14.1
15
14.4
14.2
15
1.35
1.34
2.2
3.3
3.2
3.35
3.2
Result
OK
Signature
Un = 23KV,
CTR 85/1A
Rated Current : 71.51
Setting
Actual
I>In
Title
-2
0.9086
K
In>>/In
Doc. kind
-1
0.1
2.523
0.1
2.523
Current
(A)
77.2308
(1.08times)
214.53
Project
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Lang.
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No. of p.
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29
4Sec
-
4Sec
0.05
0.05
Breaker CT
Doc. kind
Title
CT Ratio 750/1A
Project
Doc. no.
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13
29
ALARM
F102
F103
ALARM
OK
2W+
( Leg 3)
F301
OK
F302
OK
OK
F303
OK
F204
OK
F304
OK
Trip
OK
Trip
OK
ALARM
OK
2V+
( Leg 2)
F201
OK
F202
OK
F203
F104
OK
Trip
OK
Remark No.
OK
Signature:
2U( Leg 4)
F401
ALARM
F402
F403
2V( Leg 5)
F501
ALARM
OK
OK
F404
OK
Trip
OK
OK
ALARM
OK
2W( Leg 6)
F601
F502
OK
F602
OK
F503
OK
F603
OK
F504
OK
F604
OK
Trip
OK
Trip
OK
Remark No.
OK
Signature:
+G010
Remark No.
Doc. kind
Title
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Doc. no.
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No. of p.
14
29
Setting
Alarm
Trip
65deg
70deg
Result
OK
OK
Remark No.
Level
Result
7 mA
OK
Signature:
Result
OK
OK
OK
OK
Remark No.
Signature:
Project
Doc. no.
Result
OK
OK
OK
OK
OK
OK
Remark No.
Lang.
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No. of p.
15
29
Signature:
Result
OK
OK
OK
OK
Remark No.
Signature:
Zero crossing of saw tooth waveform generated by AC800 PEC with Phase to phase (Vac)
voltage of Secondary (Dy1)
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Current Probe at 2UVoltage Probe kept between 2U- ( Positive probe) and
2W- ( Negative probe)
Phase Sequence abc
Firing angle = 90Deg
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S.No
Alpha
DC Voltage
Result
OK
OK
OK
OK
OK
OK
Signature:
Remark No.
Tap 1
1
2
3
4
5
6
7
8
Doc. kind
Title
120
110
100
90
80
70
60
50
P-N
44
71
102
126
147
164
172
176
115.1
Project
Doc. no.
115.1
115.1
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No. of p.
19
29
S.No
Alpha
DC Voltage
Tap 2
1
2
3
4
5
6
7
8
120
110
100
90
80
70
60
50
S.No
Alpha
P-N
39
65
90
110
130
145
153
157
103.2
DC Voltage
103.2
103.2
Tap 3
1
2
3
4
5
6
7
8
120
110
100
90
80
70
60
50
S.No
Alpha
P-N
36
61
82
102
117
124
138
141
92.2
DC Voltage
94.2
94.2
Tap 4
1
2
3
4
5
6
7
8
Doc. kind
Title
120
110
100
90
80
70
60
50
P-N
25
49
67
83
99
110
116
119
80.80
Project
Doc. no.
80.8
80.8
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29
S.No
Alpha
DC Voltage
Tap 5
1
2
3
4
5
6
7
8
120
110
100
90
80
70
60
50
P-N
22
40
66
71
84
93
100
102
69.2
69.2
69.2
Result
OK
OK
OK
OK
OK
OK
Signature:
Remark No.
Tap
Doc. kind
Title
Date 26/11/13
S. No.
Alpha
1
120
2
100
3
90
4
80
5
70
6
60
7
50
8
40
VDC
2
8
11
14
19
22
26
32
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29
DC Voltage Waveforms:
Result
OK
OK
OK
OK
OK
Remark No.
Signature:
Readings:
Alpha
90
85
80
75
70
65
60
Doc. kind
Title
DC
current
(KA)
0.1
0.2
0.3
0.1
0.2
0.3
0.4
DC
voltage
(V)
27
35
40
20
30
38
40
AC
Current
(A)
3
5.5
7
2
5
8
10
Project
Doc. no.
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29
Result
OK
OK
OK
OK
OK
OK
Remark No.
Signature:
Readings: Tap 5
Tap
Doc. kind
Title
SP (KA)
0.5
1
2
2.5
3
1
2
3
4
1.1
2
3
5
1
2
3
4
1.2
2.0
3.0
4.0
5.0
Alpha
0.4
1.0
2
2.5
3
1.0
2.0
3.0
4.0
1.1
2.0
3.0
95
90
88
86
84
96
93
90
88
92
90
88
1.0
2.0
3.0
4.0
1.2
2.0
3.0
4.0
5.0
98
94
88
86
98
95
92
89
87
1
2
3.5
6
7
1.0
3.5
7
8
1.5
3.5
7
11
2.2
4.2
7.3
8.2
2.4
4.1
6.0
8.2
11.21
Project
Doc. no.
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No. of p.
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Note: All three phase ac current at the primary was balanced for all 5 taps.
DC waveform: 6 pulses
22 LOAD TEST
22.2 Loading at Electrolizers
Loading started: Date 15 Jan 2014, 18:30 Local Time
S.No.
DC current
actual (KA)
1.0
DC volt
Alpha
AC current (AMP)
Set Point
(KA)
1
2.8
-VDC to
Ground
27.8
+VDC to
Ground
27.5
56.4
66
2.85, 2.9,
2.0
57.3
59
5.6, 5.7,
5.6
28
27.6
3.0
58
56
7.8, 7.99,
7.8
28.3
28
4.0
60
54
29.7
30
5.8
5.79
63
50
31.2
32
8.7
8.69
68
45
33
34
10.1
10.1
69.2
43
27.1, 27.5,
34
35
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29
12
12
70.6
39
34.6
35
13
13
71.4
38
36.1, 36.4,
36.1
35
36
10
14
14
72
36
31
31
11
14.48
14.48
72.6
35
31
31
Date
Time
DC
15 Jan 14
20:00
8.7
34
DMW
Outl
et
Tem
p
Deg
C
37
16 Jan 14
18:00
8.7
35
38
34
47
47.5
40
40
21 Jan 14
20:00
14.
5
37
39.8
35.6
52
54
41
41
KA
DMW
Inlet
Temp
Deg C
Raw
Water
Outlet
Temp
Deg C
Temp
at
Rect
AC
side
DegC
Temp
at
Jn1*
DegC
Temp
at
Jn2*
DegC
33.5
Tem
p
at
Trafo
Sec
Deg
C
45
46
40
40
Temp
at
Jn3*
Deg C
Temp
at
Jn4*
Deg C
Tem
p
at
Balke
n&
DC
bus
Note:
Jn1* Positive DC bus bar flexible junction
Jn2* Negative DC bus bar flexible junction
Jn3* AC flexible between transformer & rectifier
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23 .EXCEPTION LIST
Rem.
No.
Remarks
Decision/Action
1
2
3
4
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24. REVISION
Rev.
ind.
Doc. kind
Title
Page (P)
Chapt.(C)
Description
Date
Dept./Init.
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29