STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 1 OF 30

NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

1. PLANT DETAILS :

The 500 MW generator is coupled to the 500 MW KWU

turbine. The rated parameters of the generator are
listed in plant details (Section-1) of Testing schedule
for generator protection and generator bay. The design
and constructional features are outlined briefly below.
Generator manual supplied by the manufacturer may be
referred for details of above.

STATOR BODY :

The stator body is a totally enclosed gas tight

fabricated structure suitably ribbed internally to ensure
high rigidity. Hydrogen coolers are housed
longitudinally inside the stator body. Rigid end shields
close the casing and support the fan shields.

STATOR CORE :

The stator core is made up of segmental varnish insulated

punchings of cold rolled grain oriented silicon gel and
is assembled in an interleaved manner on core bars.
Steel spacers for ventilating ducts are provided for
radial cooling of core by hydrogen. The core is held
pressed by means of heavy non-magnetic steel press rings
which are bolted to the ends of the core bars.
Additional support is provided to the teeth portion. In
order to isolate the stator body and thus the foundations
from magnetic vibrations, the core bars are designed to
provide elastic suspension of the core in the stator
frame.

STATOR WINDING AND INSULATION:

The stator has a three phase, double layer short corded

bar type windings having two parallel paths. Each coil
side consists of glass insulated solid and hollow
conductors with cooling water passing through the latter.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 2 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

The elementary conductors are Rosbel transposed in the

slot portion to minimize eddy current losses. The coil
sides are firmly held in position by fibrous slot wedges.
The overhang portion of the coil is securely lashed with
glass chord to bondage rings and special brackets of non-
magnetic steel, which are in turn fixed to the core press
rings.

DISTILLATE HEADERS:

Ring type water headers, made of copper are provided

separately for distillate inlet and outlet in the stator
on turbine side. The headers are supported on insulators
and isolated from stator body. The winding ends are
solidly soldered into the coil legs which are then
ultrasonically tested. Individual bars are provided with
water inlet/outlet connections made of P.T.F.E Hoses, The
bar heads are insulated by fiber molded covers.

TERMINAL BUSHINGS:

Water cooled terminal bushings are housed in the lower

part of the stator on the slip ring side, Porcelain
insulators are provided to insulate the terminal bars
from the stator body. Effective sealing is provided
between the terminal bushings and the stator body to
avoid any possible leakage of hydrogen. Terminal bushings
are housed inside a chamber made of non-magnetic steel
plates. Three phase terminals and three neutral terminals
are brought out. The terminal plate of the end terminals,
where bus bar connections are made is silver plated.

ROTOR

The rotor is of cylindrical type; the shaft and body

being forged in one piece from chromium nickel molybdenum
and vanadium steel. The rotor with all the details
assembled is dynamically balanced to a high degree of
accuracy subjected to 20% over speed for 2 minutes.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 3 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

FIELD WINDING:

The field winding is made from hard drawn silver bearing

copper. The winding is held in position and by non-
magnetic rotating ring in the overhang portion. Gap
pickup method is used for direct hydrogen cooling of
rotor.

The main slot insulation is of glass cloth impregnated

with Epoxy resin. The inter turn insulation consists of
layers of prepped glass cloth glued to the bottom of each
conductor. The end windings are packed with blocks of
glass laminates to separate and support the coils and to
restrict their movement under stress. The end windings
are insulated from the retaining rings with the help of
glass epoxy molded segments.

SHAFT MOUNTED FANS

For circulating the cooling gas inside the generator two

propeller type fans are shaft mounted on either end of
the rotor body. Fan hubs are made of alloy steel forging
and are a shrunk fit on the rotor shaft. The alloy steel
cast fan blades are machined in the tail portion to suit
the fan hub and held in position with the help of conical
pins. The blades can be easily removed from or assembled
in the fan hub. Fan shields fixed to the end shields
guide the gas flow.

RETAINING RINGS:

The end windings are held in position by retaining rings

of floating type shrunk fit on the rotor body. The rings
are screwed to prevent axial movement by locking nuts.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 4 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

SLIP RINGS:

The slip rings consists of helically grooved alloy steel

rings shrunk on the rotor shaft and insulated from it.
They are mounted on a single, common steel bush, which
has an insulating jacket pre-molded on it. The complete
bush with sliprings are provided with inclined holes for
self ventilation. The helical grooves cut on the outer
surface help improve the brush performance.

FIELD LEAD:

The slip rings are connected to the field winding through

semi-flexible copper leads and current carrying bolts,
placed radially in the shaft. Two semicircular hard
copper bars insulated from each other and from the rotor
shaft are placed in the central bore or the rotor joining
the two sets of current carrying bolts with special
profiled precision conical threads.

GAS COOLERS

Four longitudinally mounted gas coolers are mounted in

the stator body. They are made out of admiralty brass
with coiled copper wire wound on them staggered form so
as to expose maximum surface area to hydrogen.

BEARINGS:

Generator bearings are of pedestal type with spherical

seating to allow self alignment and are supported on a
separate pedestal on slip ring side and in the L.P casing
on the turbine side, Bearing bush is of cast steel lined
with white metal. Oil catchers and deflectors are
provided to prevent axial leakage of oil. To prevent
shaft currents slip ring side bearing and connecting
pipes are insulated from earth.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 5 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

SHAFT SEALS:

In order to prevent leakage of hydrogen from the

generator casing radial thrust type shaft seals are
provided on either side where the shaft extends out from
the generator. The seal consists of seal liner with
babbit pressing against the shaft caller of the rotor.
Seals are defined in testing schedule of seal oil system.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 6 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

NAME PLATE DETAILS

RATED DATA & O/P TURBO GEN. MAIN EXCITER PILOT EXCITER
APPARENT POWER 588 MVA ------ 65 KVA
ACTIVE POWER 500 MW 3780 KW ------
CURRENT 16166 A 6300 A 195 A
VOLTAGE 21 + 1.05 KV 600 V 220 + 22 V
FREQUENCY 50 HZ ------ 400 HZ
PF 0.85(LAG) ------ ------
STATOR WDG CONN YY ------ ----
HYDROGEN PRESS 3.5 BAR ----- -----
CONT PERM UNBAL 8 % ------ ------
LOAD
RATED FIELD ------ -------
VOLTAGE 340 V
CURRENT 4040 A
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 7 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

2. TESTING OBJECTIVE :

TO TEST THE GENERATOR AND MAKE IT READY FOR SYNCHRONIZATION.

STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 8 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

3.0 PROPOSAL

3.1 Tests as detailed in item-8 shall be carried out on

generator, confirming the manufacturers test reports.

3.2 Generator short circuit test will be carried out and the
values will be recorded.

3.3 The current based relays will be dynamically tested for

their function and the values will be recorded.

3.4 Generator open circuit test will be carried out and the
values will be recorded.

3.5 The voltage based relays will be dynamically tested for

their function and the values will be recorded.

3.6 The synchronizing circuit will be checked and the phasing

out will be carried out.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 9 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

4. SERVICES REQUIRED

4.1 Laboratory equipments/test sets for measurement of

electrical parameters required.

4.2 Illumination at required locations.

4.3 240 V A.C power supply for testing.

4.4 Communication facility at test area.

STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 10 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

5.0 S A F E T Y PRECAUTIONS:

5.1 The test area shall be clearly defined and cordoned

off.

5.2 The test team leader is fully aware of the nature,

location, and probable duration of the tests.

5.3 The other agencies working in the test area are

informed about the test in progress.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 11 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

6. EMERGENCY PROCEDURE :

6.1 Shock treatment chart and first aid box shall be

available.

6.2 Emergency telephone numbers of fire and hospital shall be

prominently displayed near by.

6.3 The test in progress shall immediately be stopped and all

line apparatus disconnected and equipment suitably earthed
in case of a accident or abnormality. Such instruction
will be received from the team leader.

6.4 The test team is fully aware of measures to be taken in

the event of injuries to any personnel / damage to any
machinery.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 12 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

7. STATE OF PLANT :
7.1 Generator Erection complete and satisfactory. All
erection test results/log sheets available for the
following :

- Mounting of embedded parts and foundation plates.

- Erection of stator.
- Gas tightness and Hydraulic tests.
- Measurement of insulation resistances of various
parts of generator, D.C. resistances and impedances.
- Continuity, D.C. resistance and IR checks of RTDs.
- Purge tests of rotor ventilation canals.
- Rotor insertion tests.
- Bearing adjustment tests.
- Alignment or generator rotor.
- Inclination or shaft journal test results.
- Coupling alignment results of generator and LP rotor.
- Magnetic Axis adjustment results.
- Fan and shield clearance results.
- DTI checks on generator rotor.
- Shaft seal adjustment results.
- Temperature monitoring system.
- Centering and offset-setting of brush gear.
- Fixing of brush holder and brushes.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 13 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

7.2 Following Testing/Commissioning schedules completed

satisfactorily and results/records available :

- Generator Gas Tightness Test.

- Hydraulic test and oil flushing of seal oil system.

- Seal Oil System – Circulation

- Hydraulic test and flushing of primary water system.

- Generator test schedule

- Generator, generator bay protection test schedule

7.3 All the systems mentioned in 7.2 are in totally normalised

condition and available for generator testing.

7.4 Fire protection system (CO2 system) is made available.

7.5 For carrying out short circuit test, short generator

transformers HT terminals R,Y,B together at 400 KV side by
earth switch or by the links capable of carrying 1500A
current. Isolate 400 KV supply and earth.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 14 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

1. The following measurement circuits to be made through for

monitoring and taking readings :

a. Generator Voltage – RY, YB, BR

b. Generator Current – R, Y, B
c. Excitation Voltage
d. Excitation Current
e. Active Power
f. Reactive Power
g. Power Factor
h. Energy meter

Synchronising circuits and protection circuits also to be

kept ready alongwith recommended settings set in the
protection relays.

2. Testing / measuring equipments to measure PMG Voltage(3

Phase AC), main exciter Voltage (DC) and PMG’s phase
sequence in AVR are to be kept ready.

3. Excitation Circuit :

 Fuses of PMG input to AVR and main exciter input from AVR
output are to be checked for their healthiness.

 Cables of PMG and main exicter are to be cnfirmed that they

are properly connected and are free from earth short
or any other faults.

 Winding resistances of PMG and main exciter are to be taken

only to check their healthiness.

 Healthiness of stroboscope and DAVR to be checked. No trip

should come from DAVR.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 15 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

4. Ensure that Gen PTS are racked in and Gen bus duct are in
pressurised condition.

5. Systems :

i. Stator water cooling system is to be kept on line.

ii. Rotor cooling is to be confirmed by parameters of H2
temp.
iii. Seal oil circulation in service is to be confirmed.
iv. All RTDs are to be monitored in control room.
v. Busduct pressuring unit must be in service.
vi. Rotor earth fault circuit to be made ready and kept
on line.
vii. Operation of UT-A&B-11KV breakers and GCB are to be
checked and found OK. UT-A & B breakers are to be
put in test position.

6. Following modifications to be carried out and to be

normalised after synchronisation of generator.

i. Excitation system on manual

ii. Auto channel in blocked condition.
iii. Field breaker closing from ATRS inhibited.
iv. Auto synchronised isolated from circuit.
v. Turbine trip from generator trip removed.

GRP TB3 – 9 & 10

GRP TB3 – 11 & 12

7. LBB LINKS to be kept out

8. Interlock between switchyard isolated and field beaker to

be defeated.

9. GT differential protection to be disabled by shorting

input CT Sec. Links.

At 3000 rpm Measure PMG voltage frequency and phase sequence .

STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 16 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

7.6 Excitation system panels are kept in ON condition.

7.7 The steam turbine run to 3000rpm after following the

start-up procedure.

7.8 The spill currents in the CT terminals in the relay

panel,control panel& AVR panels are first checked when the
machine is at 3000rpm.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 17 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

8.0 TEST METHOD :

8.1 Short circuit characteristics test :

8.1.1 AVR in manual mode.
8.1.2 FB is off and no trip from tripping relays and AVR.
Hence, FB close permissive available.
8.1.3 Close GCB in dead circuit.
8.1.4 Measure CT secondary current of GT CT at switchyard.
Control room.
8.1.5 Switch on the excitation
8.1.6 Slowly raise excitation till generator current reaches
500 A and note the readings of field voltage,
current, generator excitation current, terminal
voltage and stator currents in three phases.
8.1.7 Slowly raise excitation and measure the above
parameters at diff. Stator currents till the rated
stator current.
8.1.8 Draw a graph between field current and gen. Current.

S.No Gen.Field Gen. Exciter Exciter Gen. AVR

Current current field field Termina control
(Amps) voltage current l Voltage
Voltage
01. 500 A
02. 1000 A
03. 2000 A
04. 3000 A
05. 4000 A
06. 5000 A
07. 6000 A
08. 7000 A
09. 8000 A
10. 9000 A
11. 10000 A
12. 11000 A
13. 12000 A
14. 13000 A
15. 14000 A
16. 15000 A
17. 16000 A
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 18 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

9 Find overall short circuit ratio of Generator and Generator

Transformer.

8.2 PROTECTION CHECKING:

1. Proving of Rotor Earth Fault protection (64E) :

At machine stand still condition, connect the ground fault

detection brush to earth and ensure that rotor earth fault
relay operates (Refers 3-562-006-0357 / Rev.2, Sheet-37).
Either TE or EE side (TB1-40 OR TB1-41 to be earthed).

2. When GCB closed and , the following checks can be carried

out.

a. Proving of negative phase sequence (46G).

Change the polarity of anyone phase of 3

Phases currents by interchanging relay terminals A5
and A6 or A7 and A8 or A9 and A10 (sheet 36).
i. Ensure that the relays flags are reset.
ii. Close field breaker and slowly raise excitation till
the current is about __________ alarm will appear
after 5 Seconds trip will occur at K1 times operating
time. Operating time depends on the current setting
I23 .
iii. Reduce excitation and switch off FB.
iv. Normalise wires on relays terminals.

b. Proving of Generator field failure protection (40G1 &

40G2).

i. Set K1K5 to the maximum setting.

ii. Check K3 + K4 = K2.
iii. The Voltage across terminals 7 & 8 of the relay and
current through terminal 6.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 19 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

iv. Close FB and slowly raise the excitation. Check

relay operates at Vs = 2I (K1K5 + (K3+K4)
v. Record Vop = Volts

Iop = Apms.

vi. Reduce the excitation and trip FB.

C. Proving of Generator Trasnformer Differential

Protection (87GT R,Y,B)

Keep Relay setting in the minimum value so as to avoid

generator to run in fault condition for a long time and for the
maximum fault current

R phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP 7 TB1-1&4 (wire nos.
A411, A470) and monitor differential current at relay terminal
27. Switch on excitation & slowly raise till generator current
is around 2000A. Record the values of operated current and
Generator current . Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

Y phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP 7 TB1-2&4 (wire nos.
A431,A470) and monitor differential current at relay terminal
27. Switch on excitation & slowly raise till generator current
is around 2000A. Record the values of operated current and
Generator current. Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

PHASE OPERATING CURRENT GENERATOR CURRENT

R
Y
B

D. Proving of Generator Differential Protection (87G1)

STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 20 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

R phase: with machine in de-excited condition, block

contribution of current to differential relay by short-
circuiting CT secondary wires on GRP1 TB1-1&4 (wire nos.
A11,A70) and monitor differential current at relay terminal 6.
Switch on excitation & slowly raise till generator current is
around 2000A. Record the values of operated current and
Generator current . Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

Y phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP1 TB1-2&4 (wire nos.
A31,A70) and monitor differential current at relay terminal 8.
Switch on excitation & slowly raise till generator current is
around 2000A. Record the values of operated current and
Generator current . Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

B phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP1 TB1-3&4 (wire nos.
A51,A70) and monitor differential current at relay terminal 10.
Switch on excitation & slowly raise till generator current is
around 2000A. Record the values of operated current and
Generator current . Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

E. Proving of Gen. Trf HV winding Diff Protection (87HV)

R phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP2 TB1-22&25 (wire nos.
A511,A570) and monitor differential current at relay terminal
6. Switch on excitation & slowly raise till generator current
is around 2000A. Record the values of operated current and
Generator current . Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 21 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

Y phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP2 TB1-23&25(wire nos.
A531, A570) and monitor differential current at relay terminal
8. Switch on excitation & slowly raise till generator current
is around 2000A. Record the values of operated current and
Generator current. Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

B phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP2 TB1-24&25 (wire nos.
A551,A570) and monitor differential current at relay terminal
10. Switch on excitation & slowly raise till generator current
is around 2000A. Record the values of operated current and
Generator current. Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

F. Proving of Generator Differential (87G 2R,Y,B)

R phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP6 TB1-1 & 4 (wire nos.
A111,A170) and monitor differential current at relay terminal
27. Switch on excitation & slowly raise till generator current
is around 2000A. Record the values of operated current and
Generator current. Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

Y phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP6 TB1-2&4 (wire nos.
A131, A170) and monitor differential current at relay terminal
27. Switch on excitation & slowly raise till generator current
is around 2000A. Record the values of operated current and
Generator current . Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.
B phase: with machine in de-excited condition, block
contribution of current to differential relay by
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 22 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

shortcircuiting CT secondary wires on GRP6 TB1-3&4 (wire nos.

A151, A170) and monitor differential current at relay terminal
27. Switch on excitation & slowly raise till generator current
is around 2000A. Record the values of operated current and
Generator current. Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

G. Proving of GT overhead connection Diff (87TL R,Y,B)

R phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP2 either TB1-1 & 4
(A211,A270) or TB1-6&9(A221&A280) or TB1-11&14(A311&A370) or
TB1-16&19 (A321&A380) and measure differential current at relay
terminal 27. Switch on excitation & slowly raise till generator
current is around 2000A. Record the values of operated current
and Generator current. Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

Y phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP2 either TB1-2 & 4
(A231,A270) or TB1-7&9(A241&A280) or TB1-12&14(A331&A370) or
TB1-17&19 (A341&A380) and measure differential current at relay
terminal 27. Switch on excitation & slowly raise till generator
current is around 2000A. Record the values of operated current
and Generator current. Switch off Excitation and trip field
breaker.Normalise TB wirings and relay settings.

B phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP2 either TB1-3 & 4
(A251, A270) or TB1-8&9(A261&A280) or TB1-13&14(A351&A370) or
TB1-18&19 (A361&A380) and measure differential current at relay
terminal 27. Switch on excitation & slowly raise till generator
current is around 2000A. Record the values of operated current
and Generator current . Switch off Excitation and trip field
breaker.Normalise TB wirings and relay settings.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-0020 SHEET 23 OF 30
NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

H. Proving of Unit Transformers Differential (87 UTA

R,Y,B & 87UTB R,Y,B)
UNIT TRANSFORMER - A

R phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP3 either TB1-1 & 4
(A111A, A170A) and measure differential current at relay
terminal 27. Switch on excitation & slowly raise till generator
current is around 2000A. Record the values of operated current
and Generator current. Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

Y phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP3 either TB1-2 & 4
(A131A,A170A) and measure differential current at relay
terminal 27. Switch on excitation & slowly raise till
generator current is around 2000A. Record the values of
operated current and Generator current. Switch off Excitation
and trip field breaker. Normalise TB wirings and relay
settings.

B phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP3 either TB1-3 & 4
(A151A, A170A) and measure differential current at relay
terminal 27. Switch on excitation & slowly raise till generator
current is around 2000A. Record the values of operated current
and Generator current. Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

UNIT TRANSFORMER - B

R phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP3 either TB1-16 & 19
(A111B,A170B) and measure differential current at relay
terminal 27. Switch on excitation & slowly raise till generator
current is around 2000A. Record the values of operated current
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PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

and Generator current. Switch off Excitation and trip field

breaker. Normalise TB wirings and relay settings.

Y phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP3 either TB1-17 & 19
(A131B, A170B) and measure differential current at relay
terminal 27. Switch on excitation & slowly raise till generator
current is around 2000A. Record the values of operated current
and Generator current. Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

B phase: with machine in de-excited condition, block

contribution of current to differential relay by
shortcircuiting CT secondary wires on GRP3 either TB1-18 & 19
(A151B, A170B) and measure differential current at relay
terminal 27. Switch on excitation & slowly raise till generator
current is around 2000A. Record the values of operated current
and Generator current. Switch off Excitation and trip field
breaker. Normalise TB wirings and relay settings.

I. Proving of Backup Impedance(21GRY,YB,BR)

Excite the machine and slowly raise the current till the
relay operates. Measure current at relay terminal 5 & voltage
across 7 & 8. Note the values of Operating current and
Voltage.

iii) Normalise Generator Transformer HT terminals. Open

Generator Circuit Breaker.

8.3 Open Circuit Characteristic Test

1. Keep DAVR in manual

2. Ensure that no trip from protection panel as well as
DAVR are not present.
3. Field breaker close permissive is available
4. Close field breaker
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PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

5. Excite slowly upto Generator Terminal Voltage reaches 2

KV. Note down the values of Field voltage,field
current,Generator field current and Generator current
against Generator terminal voltage.
6. Increase the excitation in steps of stator terminal
voltage 2 KV and note down the above values.
7. Tabulate the values noted and draw a graph between
Generator field current Vs Generator terminal voltage.
8. Find Characteristic impedance of Generator

Gen. Exciter Exciter Gen. S.No. Gen.Fie AVR

Termina field field current ld control
l voltage current Current Voltage
voltage (Amps)
2000 v 01.
4000 v 02.
6000 v 03.
8000 v 04.
10000 v 05.
12000 v 06.
14000 v 07.
16000 v 08.
18000 v 09.
20000 v 10.
21000 v 11.

8.4 Proving of Stator earth fault (64G1 & 96G)

64 G1

1. Earth any one of the phases at 400 KV side.

2. Keep stator Earth fault relay settings at minimum
value.
3. Close FB and slowly raise the excitation. Note the
values of voltage operated and current flown through
earthed phase when relay operates.
4. Normalise the earth and relay setting connection
after reducing excitation and tripping FB.
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NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

96G :

1. Earth the point where neutral grounding

transformers and generator neutral connected
together.
2. Set the relay setting in minimum in order to avoid
over strain of generator.
3. Close FB and slowly raise excitation fill relay
operateds note the values of current operated.
4. Reduce excitation, trip FB and then normalise the
earth connection made for testing as said in point
No.1.

a. Proving of Over voltage(59G) & under voltage (27G1,27G2)

Excite the machine & reach the rated terminal Voltage

across Generator stator terminals i.e.21 KV . Measure the
voltage across 9 & 10 of 27G1 & 27G2. Reduce the voltage to the
set value percentage of the above relays and check that the
relays are operated.

Increase the terminal voltage further above rated voltage

by 5 or 10 %. Check over voltage relay 59 G1 operated

CAUTION: KEEP AS MINIMUM SETTINGS AS POSSIBLE SO THAT

GENERATOR STATOR TERMINALS WILL NOT OVERSTRAIN FOR SUDDEN
VOLTAGE FLUCTUATIONS DURING TESTING.

8.5 Proving of Under frequency Protection(81G1)

1. Short GRP4 TB1-11 &12 to bypass GCB close temporarily.

2. Increase the relay setting above 50 HZ for testing so
that it senses normal frequency as under frequency.
3. Excite the machine and maintain rated terminal voltage
4. Once terminal voltage is reached, underfrequency relay
will operate.
5. Normalise TB shortings and relay settings as
recommended.
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PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

b. Proving of Gen overfluxing (99G)

1. Keep the setting to minimum of 1.o

2. Excite the machine such that the secondary voltge of
PT at the relay terminals is 110V.
3. Relay will operate. After that reduce exdcitation
and trip field breaker.

8.6 SYNCHRONISING:

Now set all the relays as per the recommended values.

The following are the steps for synchronizing the
generator to the Grid:
8.6.1 Excite the generator to the rated voltage.
8.6.2 Switch the synch.selector switch to Manual position
and also switch on the synchroscope.
8.6.3 By monitoring the double voltmeter, match the generator
voltage by raising or lowering the excitation. The
generator in coming voltage to be marginally greater
than the running bus voltage.
8.6.4 No check that the phase sequence of the running bus and
the incoming bus are same.
8.6.5 Now raise or lower the speed such that the
synchroscope pointer rotates in the clockwise
direction at a rate such that the check sync. Relay
operates when the pointer is about 12’ O clock
position.
8.6.6 Close the generator breaker, when the ‘Check sync in’
lamps glows.
8.6.7 Now, manually load the generator to 5 % of the rated
load by giving raise command to the speed reference.
8.6.8 Further loading of the generator is done from the
turbine control panel.
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PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

9. COMPLETION CRITERIA :

9.1 THE RECORD VALUES OF TESTING CARRIED OUT ON GENERATOR

ARE COMPLETED AND KEPT ALONG WITH THIS TESTING

SCHEDULE.

9.2 GENERATOR AUX SYSTEM FOR RUNNING GENERATOR ARE LISTED AND

KEPT ALONG WITH THIS SCHEDULE.

9.3 GENERATOR IS READY FOR SYNCHRONIZATION.

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NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

10. APPENDICES

Drawings :1. Schematic Diagram of Gen, GT & UT protection (3-

562-006-0357) Rev.02
2. Schematic diagram Electrical control panel-1. (3-
659-0050610) Rev.
3. Line 1 & line 2 diameter circuits isolator
interlock (3-562-006-0296) Rev.02.
4. Schematic diagram of 400 KV bus-1&2 protection
(TBDG 1865100101/02)

MANUALS : 1. Relay manuals (Volume – I to Volume IV)

2. 500 MW Turbo Generator O&M manual.
GENERATOR SYNCHRONIZATION CIRCUIT

Sl Source location phases values Phase

No. sequenc

e
1 400 KV ECP1

Bus 1 TBG-23a & 24a R - Y

TBG-24a & 25a Y – B

TBG-25a & 23a B – R

2 400 KV ECP1

Bus 2 TBG-27a & 28a R – Y

TBG-28a & 29a Y – B

TBG-29a & 27a B – R

3 Generator GRP1 VT 2 (LV

VT TB1-23 & 27 SIDE)

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NTPC REF NO: SIM/1/TS/ 2 / 008

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GEN. TESTING PROCEDURE FOR FIRST SYNCHRONISING

TB1-27 & 31 R - Y

TB1-31 & 23 Y – B

GRP8 B - R

TB1-36 & 38 VT 4 (HV

TB1-38 & 40 SIDE)

TB1-40 &36 R – Y

ECP1 Y – B

TBG-31a & 32 a B – R

TBG-32a & 33a

TBG-33a & 31a R – Y

Y – B

B – R
`