TEST - KBL 30aug11

PROJECT: 500 MWe Prototype Fast Breeder Reactor (PFBR)
TITLE: TEST PROCEDURE FOR COMBINED SYSTEM TEST OF

VARIABLE SPEED DRIVE SYSTEM AND MOTOR WITH
PUMP AT KBL
1.0 VARIABLE SPEED DRIVE SYSTEM PERFORMANCE TEST PROCEDURE
1.1 SCOPE:
This procedure is intended to cover the methods and acceptance standards of the
VARIABLE SPEED DRIVE SYSTEM with motor of 2700 KW at KBL works with pump
performance for KIRLOSKAR make SECONDARY SODIUM PUMP for BHARTIYA
NABHIKIYA VIDYUT NIGAM LTD for 500 MWe PFBR PROJECT.
This procedure includes testing of Motor with pump in water for Secondary sodium pump
at 900 rpm and 135 rpm speeds by use of 2700 kW VARIABLE SPEED DRIVE
SYSTEM. To ensure satisfactory overall electrical operation of secondary sodium pump
including motor, transformer, VCB, VARIABLE SPEED DRIVE SYSTEM, control panels
Endurance test of 50 hours will be conducted on all the equipments after completion of
normal performance test.
The VARIABLE SPEED DRIVE SYSTEM is composed of the Input Transformer, Input
VCBs, VSD and motor.
For testing arrangement, please refer Drawing no. 1.
CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED
PROJECT :- PROTOTYPE FAST BREEDER REACTOR

TITLE :- DRG. DATE
PERFORMANCE AND ENDURANCE TEST PROCEDURE FOR APPD. DATE
ELECTRICAL VARIABLE SPEED DRIVE SYSTEM
ORIGINATING AGENCY BHARAT HEAVY ELECTRICALS LIMITED
DRG. NO. SHT.1 OF 14 REV. 00
FILE NAME : KBL TEST PROCEDURE LAST UPDATED:
Drawing no- 1
1.2 EQUIPMENT UNDER TEST:
SL Elements Qty
No.
1 Converter Transformer 1
2 Vacuum Circuit Breaker 3
3 Variable Speed Drive System 1
4 2700 KW Induction motor 1
5 Forced Oil Lubrication System 1
6 Control Panel for Integrated testing 1
2.0 APPLICABLE DOCUMENTS and Standards:
Standards IEC 60146, IEC 61800-4
3.0 TEST PLAN:
i) Uncoupled run
ii) Coupled run
iii) Measurement of P-Q at flow rates and flow adjusted such that motor is at rated
load.
iv) Measurement of vibration and noise level during performance testing. During this
period vibration can be checked.
v) Measurement of speed range, Dynamic response and Speed regulation.
vi) Measurement of power factor and harmonics at grid side.
vii) Measurement of temperature in Variable Speed Drive System.
viii) Ensure smooth and reliable operation up to 50 hrs.

TITLE :- DRG. DATE
3.1 PUMP SPECIFICATION
Pump Data-
Sl. Parameter Value-Unit

No
1 Type SECONDARY SODIUM PUMP FOR
500 MWe PFBR
2 Model SSP 600/90
3 Nozzles SUC – Ø800mm; DEL – Ø600 mm
4 Number of Stages ONE
5 Capacity 3.34 m3/sec through both the discharge
nozzles together
6 Total differential head 65 m
7 Number of revolution 900 rpm (Nominal)
8 Super range 15 to 100%.
9 Pump efficiency 83%.
10 NPSHR3% 16.9 m
11 Direction of rotation Counter clockwise when viewed from
top
12 Liquid Liquid Sodium
13 Liquid temperature 628 K
14 Maximum temperature 819 K
15 Shaft Input Power at D.P. 2564.4 kW (in water)
16 Test Motor rated output 4000 kW
17 Shaft-off head 88 m (Approx)
3.2 MOTOR SPECIFICATION:
MOTOR DATA_ 2700 KW ( 1 No)
Sl. No. Parameter Value-Unit

1 Motor Power 2700 KW
2 Motor Voltage 3150 V
3 Motor Full-load current 593 Amps
4 Motor Frequency 45.18 Hz.
5 Motor Full load speed 900 RPM
6 Motor Max Operating Frequency 47 Hz.

TITLE :- DRG. DATE
3.3 VARIABLE SPEED DRIVE SYSTEM SPECIFICATION:
VARIABLE SPEED DRIVE SYSTEM DATA_2700 KW ( 1 No)

1 Power 2700 KW
2 Rated speed 900 RPM
3 Speed control range 15% to 100% of rated speed
4 Acceleration 45910 N-m2
5 Starting time 0 to 15% rated speed within 10
seconds
6 I/P voltage 2 X 1.85 KV
7 I/P current for rated drive 470 Amps
power o/p
8 I/P current for starting drive 500 Amps
system
9 I/P Frequency 50 Hz.
10 Maximum power 3400 KVA
11 O/P voltage 3300 V
12 Frequency at rated speed 49.37 Hz
3.4 VCB SPECIFICATION: (3 Nos)
VCB DATA –

1 Rated Voltage 6.6 KV
2 Rated normal Current 1250 Amps
3 Power frequency withstand 20 KV
voltage
4 Rated frequency 50 Hz
5 Rated short time (3 Sec) 40 KILOAMPS RMS
current rating
6 Power frequency withstand 20 KV
voltage

TITLE :- DRG. DATE
3.5 TRANSFORMER SPECIFICATION: ( 1 No)
Transformer Data –

1 Primary Voltage 6.6 KV
2 Secondary Voltage 2 X 1.85 KV
3 No load voltage 2 X 1.928 KV
4 Current at rated no load 415.5 A
voltage at principal tap- HV
side
5 Current at rated no load 711.2 / 711.2
voltage at principal tap- LV1
/ LV2 side
6 Incoming voltage variation +10% to -15%
7 Tap range ±5% in steps of 2.5%
8 Vector Group D-7.5°(sec1) yn11 (sec2) d0
9 Frequency 50 Hz
10 Type of cooling ONAN
4.0 TEST LOOP DESCRIPTION
The testing arrangement is designed to enable measurement of performance of all

equipments including pump in a reliable manner. The design of the test set up made in
conformance with the latest edition of IEC 61800-4 and Hydraulic Institute Standards
(HIS). Please refer Drawing no. 2 for testing arrangement.
The pump shall be tested in a closed circuit test loop. The test facility shall consist of 2
closed atanks connected to each other. The pump draws water from tank 2 and pumps it
into the delivery piping which returns the liquid back to another tank 1 after passing
through the 1000Ø value will be used to vary and monitor the pump operating
parameters viz. flow, head, power input and NPSH. The Variable Speed Drive System is
composed of the cascade connection of the I/P transformer, Variable Speed Drive
System and motor with pump. Drawing no.- 2. shows schematic of test setup.

TITLE :- DRG. DATE
The temperature of the liquid in the test loop is controlled by use of cooling tower and
heat exchanger. Required suction pressure will be obtained by provision of compressed
air.
In view of the importance of cavitations performance test, the testing arrangement shall
be provided with an accurate measurement of NPSH. The NPSH control in the testing
arrangement will be carried out by varying the suction pressure by use of compressed
air. The SSP will be loaded so that rated power is drawn from motor.
The Variable Speed Drive System is composed by cascade connection of I/P

Transformer, Inverter and Motor. The entire system is represented in drawing no -1

TITLE :- DRG. DATE
Drawing No-2

TITLE :- DRG. DATE
5.0 PERFORMANCE TESTS –
5.1 Uncoupled run:
All components are connected by proper cables. The Variable Speed Drive System is
fed by power supply Network. Following supplies are available:
 Medium voltage main power supply 6.6 KV, 50 Hz,3ph

 Auxiliary power supply 415 V, 50 Hz. 3ph
 Auxiliary power supply 220 V DC or 240 V, 50 Hz. 3ph
The motor will be uncoupled from the pump and the motor will be run up to 50% speed
and checked for smooth operation.
5.2 Coupled run:
The motor will be coupled to the pump and the motor will be started from zero speed
limiting the starting current to 100 % rated current and run in the speed range of 15%
to 100%. The drive will be run continuously at speed with full power drawn from the
drive system of 2700 KW, measured on drive control panel / Variable Speed Drive
System panel KW meter.
5.2.1 VIBRATION AND NOISE LEVEL TEST
 Vibration test during load characteristics

 Shaft Vibration
Measurement of vibration and noise level will be carried out at 900 RPM at Pump thrust
bearing location. The vibration and noise readings will be recorded.
5.3 MEASUREMENT OF SPEED RANGE, DYNAMIC RESPONSE AND SPEED

REGULATION:
Speed range to be done from 15% to 100% but maximum speed limited by
power rating which can be less than 100% of rated speed.

TITLE :- DRG. DATE
Speed reference and feedback measured in the VARIABLE SPEED DRIVE
SYSTEM panel. The speed regulation will be checked.
For dynamic response- i) Starting current is limited to 100% ii) Starting time will
be measured ,this shall be within 10 secs from 0 to 15% speed.
5.4 MEASUREMENT OF POWER FACTOR AND HARMONICS AT GRID SIDE
This will be shown on the Variable Speed Drive System panel.
5.5 MEASUREMENT OF P-Q
Measurement of P-Q, Eff-Q at various flow rates from 0 to 120 % of rated flow at
900rpm will be carried out. During this testing, motor input power will be
recorded. Measurement of P-Q at flow rates and flow adjusted such that motor is
at rated load.
The calculations of various parameters will be carried out as given below.
 Capacity, Q1 = Actual measurement.

 Total differential head, H1 =Discharge head ± suction head + height difference
of measuring points + differential velocity head.
 Speed, N1 = Actual measurement
 Voltage of Motor = Actual measurement (Display on VARIABLE
SPEED DRIVE SYSTEM panel)
 Current of Motor = Actual measurement (Display on VARIABLE
 Motor input = Actual measurement (Display on VARIABLE
(Motor input X Motor efficiency X Gear box efficiency)
 Motor output (kW) = ------------------------------------------------------------------
10000

TITLE :- DRG. DATE
5.6 TEMPERATURE RISE :
This is a type test carried out to verify the compliance of the VARIABLE SPEED
DRIVE SYSTEM system temperatures within the thermal class limits declared in
nominal data. As the VARIABLE SPEED DRIVE SYSTEM system is of medium
voltage, it is not allowed from safety point of view to take temperature measurement
inside the VARIABLE SPEED DRIVE SYSTEM panel. However we can measure the
inlet and outlet water temperature and the flow indicated on the VARIABLE SPEED
DRIVE SYSTEM panel.
Equipment List:
-Current transducers
-PT100 on Motor windings
-PT100 on motor bearings
-Thermometer in external environment
-Dial type thermometer on transformer
Test Procedure
The test has to be done according to the following specifications:

a) The temperature rise shall be measured in these specified points:
- Motor: windings, bearings;
- Transformer: dial type thermometer;
- External environment.
b) All parameters for the VARIABLE SPEED DRIVE SYSTEM control must be
programmed in the converter control software .
c) The Variable Speed Drive Systems will be switched on in accordance to start-up
logic;
d) Motor is started from zero speed and run up to a maximum speed such that it
draws rated current. Then start monitoring all temperatures at measurement
points. Once the difference between three subsequent measurement (each every
10 minutes) provided in each measurement point is not greater then 2oC, the
system has reached a steady thermal condition. Measurement shall be done for at
least 2 hours.

TITLE :- DRG. DATE
Thermal test
Transformer-
Thermometer Temperature measured
Transformer oil temp
Transformer winding temp
Ambient temperature
Motor-
Over temperature
Measured Maximum
Winding temp (max)
Air IN
Air OUT
Oil in DE
Oil IN NDE
Oil out DE
Oil out NDE
Bearing temperature DE
Bearing temperature NDE
5.7 ENDURANCE TEST AT 900 RPM FOR 50 HOURS AT RATED POWER:
After completion of all above tests, the first pump will be tested at 900 rpm for 50 hours
at rated flow and various parameters like flow, head, input power, speed, noise,
vibration, etc. will be monitored every 2 hours. The flow will be maintained such that
motor draws rated power.
The observations for endurance test will be recorded.
Lub oil circuit performance will be monitored during endurance testing of 50 Hrs.

TITLE :- DRG. DATE
6.0 TESTING EQUIPMENT
The following equipment will be used for measurement of various parameters:

Sl. Measuring Measuring Instruments Unit Accuracy
No Item
1. Capacity/ flow Flow meter M3/sec ±2.0% or better
2. Total head Discharge Pressure transducer m ±1.0% or better
(Mtrs.) Pressure
Suction Differential pressure m ±1.0% or better
Pressure transducer
Distance Linear scale m ±1.0% or better
3. Speed Digital Tachometer rpm ±1 rpm
4. Voltage Voltmeter/ Digital V ±1.0%
Power meter
5. Current Ammeter / Digital A ±1.0%
Power meter
6. Motor input Watt meter / Digital kW ±1.0%
Power meter
7. Vibration Vibrometer Microns ±5.0% or better
8. Noise Noise meter dB(A) ±2dB or better
9. Room Thermometer Deg. C ±1.0 Deg. C
temperature
10 Water RTD/ Thermometer Deg. C ±1.0 Deg. C
. temperature
Measuring instruments to be used for test will be such instruments, which have been
qualified by calibration and are within the term of validity.
This specification establishes the technical requirements for the functional and performance
testing of the Secondary sodium pump Drive system. Variable Speed Drive System shall be
tested at manufacturer’s works up to the test plant capacity and integrated performance
testing on SSP variable speed drive system and drive motor shall be carried out at M/s KBL
works.

TITLE :- DRG. DATE
PERFORMANCE TEST RECORD SHEET OF SECONDARY SODIUM PUMP (SSP 600/90)
O/A No.: Z17G5N8020 O/A Date : 03/06/2005 Item No.:10

PUMP DETAITS DUTY POINT MOTOR DETAILS
Pump type.: SSP 600/90 Flow : 3.34 m3/S Make : BHEL-BPL
Pump No.: 1870809001 Total Head : 65 m Frame:
Suction : 900 mm Pump Input:2564.44kW Rating: 2700 kW
Delivery :600 mm Pump Eff. : 83% Voltage: 3150 V
Imp. Dia. :954 mm Sp. Gravity: 1 Current : 593 A
Imp. Mat. : ST.ST.CF3 NPSHR : 16.9 m Speed : 900 rpm
Direction : clockwise Rec. Motor : 4000 kW
viewed Full Load Speed :
of rotation from motor 900rpm
end
CALCULATIONS
Q1/Q2= N1/N2 Drive input (IP) kW = Meter reading x Meter constant

H1/H2 = (N1/N2)2 Pump Input (BP) kW = ((Drive input (IP) x Drive Efficiency x Gear box
efficiency) /10000)- Bearing & Mechanical seal loss
BP1/BP2 = (N1/N2)3 Pump output (WP) = (Discharge, I/s (Q!) x Total head, m (H!
Pump efficiency = Pump Output/Pump Input = WP/BP1
ENDURANCE TEST
SECONDARY SODIUM PUMP (SSP)
PUMP NO - 1870809001
DATE TIME SPEE FLOW Suc. Del.Hea Del Noie Bearing OilTemp.
Volt Curr Motor Vibrat
D hed d1 .Head2 Input in
rpm I/s mw mwc mwc V Amp kW micro dB(A Inlet Outlet

TITLE :- DRG. DATE
o o
c ns ) C C

TITLE :- DRG. DATE

TEST - KBL 30aug11

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PROJECT: 500 MWe Prototype Fast Breeder Reactor (PFBR)

TITLE: TEST PROCEDURE FOR COMBINED SYSTEM TEST OF

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

1.2 EQUIPMENT UNDER TEST:

2.0 APPLICABLE DOCUMENTS and Standards:

Standards IEC 60146, IEC 61800-4

3.0 TEST PLAN:

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

Sl. Parameter Value-Unit

3.2 MOTOR SPECIFICATION:

MOTOR DATA_ 2700 KW ( 1 No)

Sl. No. Parameter Value-Unit

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

VARIABLE SPEED DRIVE SYSTEM DATA_2700 KW ( 1 No)

Sl. No. Parameter Value-Unit

3.4 VCB SPECIFICATION: (3 Nos)

Sl. No. Parameter Value-Unit

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

Sl. No. Parameter Value-Unit

4.0 TEST LOOP DESCRIPTION

The testing arrangement is designed to enable measurement of performance of all

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

The Variable Speed Drive System is composed by cascade connection of I/P

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

5.1 Uncoupled run:

 Medium voltage main power supply 6.6 KV, 50 Hz,3ph

5.2 Coupled run:

5.2.1 VIBRATION AND NOISE LEVEL TEST

 Vibration test during load characteristics

5.3 MEASUREMENT OF SPEED RANGE, DYNAMIC RESPONSE AND SPEED

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

5.4 MEASUREMENT OF POWER FACTOR AND HARMONICS AT GRID SIDE

This will be shown on the Variable Speed Drive System panel.

5.5 MEASUREMENT OF P-Q

The calculations of various parameters will be carried out as given below.

 Capacity, Q1 = Actual measurement.

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

The test has to be done according to the following specifications:

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

Transformer winding temp

5.7 ENDURANCE TEST AT 900 RPM FOR 50 HOURS AT RATED POWER:

The observations for endurance test will be recorded.

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

The following equipment will be used for measurement of various parameters:

CLIENT :- BHARAT NABHIKIYA VIDYUT NIGAM LIMITED

PROJECT :- PROTOTYPE FAST BREEDER REACTOR

O/A No.: Z17G5N8020 O/A Date : 03/06/2005 Item No.:10