A Report on Commissioning

Checks on Generator

Prepared by: Guided by& Submitted to:

Shubhendu Raghav Sh. A K Ghildiyal

Sr. Engineer Dy. General Manager

QA-EM OMS, QA & Safety

Introduction:

A Generator is the prime equipment of a hydro power plant which converts

Mechanical Energy of Runner(Turbine) into Electrical Energy which is then fed
into Electric Grid at a particular frequency. The major components of Generator
include:

1. Stator which includes Stator Winding Bars, Circulating Terminals, Stator

Frame etc.
2. Rotor which includes Rotor Spider & Hub, Rotor Poles or Laminations
(in Reversible Pump-Turbine)

The Erection, Testing and Commissioning of hydro generating unit is a very

complicated and specialized job. This has to be carried by expert and
experienced team of engineers, technicians and helpers.The erection
technologies of hydro machines are tailor made, hence the technologies may
differ for a particular machine which has to be obtained from the manufacture.

The entire process of erection, testing and commissioning may be divided into
three main categories:

o Pre-erection activities to be completed before starting of erection of the

plant.
o Erection of built in parts of the plant.
o Erection of main operating components of hydro set.
Pre-erection Activities Mainly Covers following:

- Preparation of a plan to carry out erection work and sequence of different

activities.

- Preparation for site storage and pre assembly of the equipment, construction of
roads, accesses for delivery of plant to assembly area.

- Erection of temporary structures, living quarters necessary for carrying out site
work smoothly and speedily.

- Arrangement of construction power water, compressed air for the erection

activities.

- Arrangement of lighting of erection site and nearby area - Setting lay out of
erection bay as shown in fig. 1. -

FIG.-1 [Goncharov]

- Ensuring delivery of equipment and materials necessary for continuity of

erection work as per charts and plan.

- Providing hoisting, handling mechanisms, tools and devices for erection as

also making arrangement of transportation of material to the site.
- Arrangement of safety measures protection of workers and equipment during
handling, shifting and installing different components of plant.

- Arrangement of first aid and health checkups for workers.

Erection of built in Turbine Parts:

Erection of these items starts as soon as the underwater concrete structure has
reached the required elevation below the lining of DT cone. At this stage
permanent crane is not available as such temporary gantry crane has to be
installed whose lifting capacity, travel upward, downward, forward and
backward is decided by the size andweight of heaviest and largest part to be
handled by the crane.

Erection of main operating components:

Erection of main components of unit is started only after permanent crane is

made available. As such civil works are planned in such a way that availability
of maincrane matches with the start of assembly and erection of main plant.

Planning

Erection work usually is planned in two stages: -

- The first stage is to prepare a well-coordinated over all plans for

construction of civil activities and activities related to erection of hydro
mechanical items and hydro generating units.
- The second stage is the detailed planning stage and it should include
following information concerning erection of main equipment.

The amount of installation work by years according to overall constructionof

the project. Sequence, speed and technologies for erection activities.
Requirement as regards workers, engineers, and technicians. Basic material and
their expected deliveries to the site. The second stage planning consists in
preparing special plan for erection of main

equipment based on overall coordinated construction plan, delivery schedule of

main plant and availability of funds. This plan should contain following
information:

- The technical features of main equipment, weight and size of parts and
subassemblies.
- A time schedule for carrying out erection work matching with delivery
schedule and civil construction activities for each generating set and for
all sets together. This should give sequence and duration of all critical as
well as parallel activities for completion of erection work as per overall
schedule.
- The technological process of assembling and erection of unit.
- Preparation of a chart showing labor requirement and their movement.
- All relevant plan, assembly and erection drawings and details of required
- technologies. - Requirement of hoisting, requirement of each part,
subassembly and assemblies. - Requirement of tools, material equipment,
electrical energy, compressed air. - Requirement of special tools devices
essential for erection work. - Requirement and arrangement of safety and
industrial health measures.
- A general layout plan showing location of equipment, dumps, assembly
areas, temporary structures for erection activities, hoisting gear track etc.
- Erection work should not be carried out without a plan. - Erection work is
generally planned through MIS/PERT/CPM Project Management
Softwares etc.
Recording of Erection Work and Technical Review

A record of the work carried out must be kept during erection. This record
shouldcontain:-

- Brief technical details of equipment with the name of supplier.

- Names, surnames and position of the technical personnel in charge of
erection work and personnel in charge of erection work and personnel in
charge of suppliers erection team and the owners erection manager.
- Descriptions of the main stages of works and date when they are begun
and finished.
- Records of shortcomings in the equipment noticed during erection and of
the action taken.
- Records of form checking and other log sheets recorded during erection
works. Records of quality checks during erection works. All instructions
passed on to the technicians during process of progress of erectionwork.
- Alternations, deviation made in various erection drawings during
progress of erection work.
- Photographs of various important erection activities with dates.
- Sketches and drawings of innovative techniques, tools or devices used
during erection work with material details.

The main purpose of technical performance documentation of erection of a

hydro set is to determine qualitative indicators of the work done and the state of
equipment. This data is checked with the technical specifications for erection
and manufacturer’s instructions.

The technical evaluation of erection of main equipment is compiled from the

original documentation for each generating set separately after it has been put in
service. The evaluation must indicate the conditions, process of erection
accompanied by explanatory records with diagrams and photographs. The
explanatory records should contain following:-

- Brief power and design characteristics of the equipment with data.

- Data on the weights of generating set, separate mechanisms, sub
assemblies and main parts.
- Remarks concerning completeness of equipment supplied.
- Availability and quality of manufacturers’ technical documentation, plans
for installing of equipments etc.
- Details of hoisting devices, innovative devices used during erection.
Technological processes used during erection (planned actual).
Description of new advanced work procedures used during erection. The
nature of simultaneous construction and erection work. Number of
engineers, technicians and workers employed during various assemblyand
erection activities (total and by qualification).
- A summary of manufacturing defects in the equipment, the amount of
work and cost involved in action taken.
- A summary of cost in installing each hydro set.
- Measured operating characteristics of generating set (power, governor
response) during acceptance test when the equipment is put into
operation.
- General conclusion in installing of the hydro generating set in the plant.
- Drawings of generating set (sections) charts of installation work
(directive and performance) photographs and plans of typical operations
during assembly and erection.
- Sketches and drawings of innovative tools and devices for assembly and
erection of generating set.
 TESTING, INSTALLATION & COMMISSIONING
CHECKS OF HYDRO GENERATOR

Every major equipment is installed with the erection guidelines of the

manufacturer. During installation of any major equipment, there shall be various
test and check to verify the installation procedures. After installation before
operation, testing & commissioning is conducted in every machine. Testing and
commissioning is meant for to ensure that the equipment, or more generally the
plant or device or system or software is installed and tested to confirm
compliance with technical specifications and operational requirements. This
includes visual inspection, tests and measurements, verification of correct
equipment and verification of correct operation.

Testing is defined as performing tests, inspections and adjustments on the

equipment in the field.

Commissioning is defined as the process in which the equipment, facility or

plant is verified and validated in accordance with design objectives,
specifications and factory tests.

Generator is one of the major equipment of any Hydro Electric Project. During
erection and before start-up the Generator there are various tests and checks
which confirm that it was erected properly. Following measurements and tests
shall be performed as a minimum which deemed to be necessary for any Hydro
Generator:-

SITE TEST BEFORE STARTUP

a) Visual inspection and dimensional check.

b) Check of stator bore for exact roundness at the upper, middle and lower edges
of the iron core.

c) Checking of the uniformity of the air gap.

d) Checking of the alignment of the ready assembled turbine and generator shaft.

e) Checking of all the bearing clearances.

f) Checking of all the bearing oil cooling installation for complete and correct
assembly.

g) Checking of the entire generator cooling system for complete and correct
assembly.

h) 2 hours’ hydrostatic pressure and tightness tests of all equipment containing /

carrying water, oil and compressed air.

i) Checking of jacks in braking and lifting operation respectively

j) Measurement of the DC resistance of the field winding.

k) Measurement of stator winding DC resistance per phase.

l) Megger test and HV test of the field winding.

m) Meggar test (1 min. and 10 min. value) of stator winding and determination of
polarization factor.

n) Performance of operational tests on all generator auxiliary equipment,

including calibration of related electric control instruments, and checks for
correctness of wiring and piping.

o) Checking of alarm and protection devices.

p) Performance tests on the excitation system.

 COMMISSIONING TESTS-

The following tests shall be performed on each generator during commissioning

check:

a) Test of shaft movement, bearing run and shaft eccentricity.

b) Checking of start-up and shut- down sequence including mechanical braking.

c) Dry-out run.

d) Measurement of short circuit and no load curves.

e) Meggar test and HV withstand test of the stator winding.

f) Performance test of excitation system during no load running.

g) Functional test of generator protection relays.

h) Determination of reactances and time constants as derived from specified

measurements / tests.

i) Measurements of shaft voltages.

j) Balancing, overspeed test and vibration measurement.

k) Synchronization with the Grid.

l) Load rejection tests at different loads steps, including at 110 % in order to

check turbine governor and AVR.

m) Rated output test of the unit including temperature run.

n) Measurement of individual losses and determination of efficiency in

accordance with IEC 34-2.
DESCRIPTION OF VARIOUS TESTS ON HYDRO
GENERATOR
1. CHECKING OF SHAFT CURRENT AND MEASUREMENT OF
BEARING INSULATION RESISTANCE
1.1 Origin of Shaft Currents - Irregularities in the magnetic circuit may cause a
small amount of flux to link with the shaft, with the shaft, with the result that an
electromotive force is generated between shaft ends. This electromotive force is
generated between shaft ends. This electromotive force may cause a current to
flow through the shaft, bearings, bearing supports and machine framework and
back to the other end of the shaft, unless this circuit is interrupted by insulation.
(While other causes may produce a shaft to the other, no special tests are
provided for the resulting effects because each of these sources would require
specially adapted methods of tests, essentially of a research nature).

The shaft currents are normally prevented by insulating one or more bearing
pedestals in the case of horizontal machines. In the case of vertical water wheel
generators with a combined thrust and guide bearing at the top of the rotor and a
guide bearing below the rotor, all parts likely to come into contact with the
stationary parts shall be insulated to prevent flow of shaft currents.

1.2 Checking of Shaft Current

The machine is run at rated speed on open-circuit at rated voltage. A low

resistance conductor is connected between the shaft and the uninsulated bearing
to short-circuit the oil film. A low range at voltmeter (or high range ac
ammeter) is then connected between the shaft and the frame at each insulated
bearing successively. Defection of the meter indicates the presence of an
electromotive force that would produce shaft currents in the absence of bearing
insulations. If there is no deflection of the meter, either the insulation of bearing
is defective or there is no electromotive force present. It is then necessary to
check up the bearing insulation resistance.
1.3 Measurement of Bearing Insulation Resistance: -

In case of bearings insulated from the frame by a single layer of insulation and
with the rotor not in the bearings the insulation resistance is measured between
the bearings and frame by means of a 500-volts insulation tester. The insulation
resistance measured shall be not less than one megohm.

2. HIGH VOLTAGE TESTS:

Before carrying out the high voltage tests, the insulation resistance of the
windings shall be measured in accordance with the. The measured insulation
resistance values shall be at least equal to the minimum values specified;
otherwise it is necessary to dry out the windings. The high voltage tests are
carried out when the machine is at rest. Generally, the high voltage tests are the
last one in the serial order of tests carried out on the machine.

In case of polyphase windings, where both the terminals of each phase are not
brought out, the tests shall be carried out on all the phases simultaneously.

All the terminals of polyphase winding under test are joined together and
connected to the high voltage terminals of the source and all terminals of other
windings as well as the other terminal and the frame of the source of tests
equipment are connected to the machine frame which is solidly earthed.

In case of polyphase winding where both the terminals of each phase are
brought out, the high voltage test may be carried out on each phase separately, if
desired.

The two terminals of the phase under test are joined together and connected to
the high voltage terminals of the sources and all the terminals of the other
phases and all the other windings as well as other terminal and the frame of the
source of the test equipment are connected to the machine frame which is
solidly earthed.
During testing of the field windings of large machines the brushes normally
should be lifted so that no excessive voltage stress will be imposed on the field
winding if some part of the brush rigging or the leads fails. The brush rigging
and station leads should be tested separately from the field. If it is desired to
test the brush rigging of a machine at the same time the field is being tested, the
exciter leads should be disconnected unless it is intended that the exciter be
tested simultaneously. In any case the permanent instrumentation leads should
be disconnected. They may be tested separately, if desired.

The test voltage shall be in accordance with the values specified in IS:4722-
1968 and IS: 5422-1969.

Precautions should be taken to prevent anyone from coming in contact with any
part of the circuit or apparatus while the high voltage test is being conducted.

2.1 Method of Testing- The usual method of testing is with AC voltage.

2.1.1 Testing with AC Voltage- The test shall be performed with AC voltage of
any convenient power frequency, preferably between 40 and 60 Hz. The test
voltage shall be of particularly sine-wave from so that the peak value as
determined by the spark gap or oscillograph of any other approved method shall
not be more than 1:45 times the rms value. The rms value of the applied
voltage shall be measured by means of a volt-meter and a suitably calibrated
potential transformer or by means of a voltmeter used in connection with a
special calibrated voltmeter winding of testing transformers, or by means of a
voltmeter used in connection with a special calibrated voltmeter winding of
testing transformers, or by any other suitable voltmeter connected to the output
side of the testing transformer.

2.1.2 Duration of High Voltage Test: - The test shall be commenced at a

voltage of about one-third of the tests voltage which shall be increased to the
full test voltage in accordance with IS:4722-1968 as rapidly as is consistent with
its value being indicated by the measuring instrument. The full tests voltage
shall be rapidly diminished to one-third or less of its full value before switching
off. Precaution should be taken to earth the high voltage terminal after the tests.

2.2 Test with dc Voltage

This method is employed as an alternative to ac high voltage tests method.

Unless otherwise agreed upon between the manufacturer and the purchaser, the
dc tests voltage shall be obtained by multiplying the respective ac test voltage
by 1.6. This voltage shall be maintained for one minute. The dc test voltage may
be measured by means of a voltmeter and a voltage divider or by resistor
ammeter method.

Precaution should be taken to earth the winding for at least 30 minutes after the
test; otherwise if the windings are earthed only momentarily, a voltage may
build up following the removal of the earth.

Insulation resistance of winding shall be measured at the end of the high

voltage test. The test is considered satisfactory if neither flashover nor
breakdown of insulation takes place and also the insulation resistance of the
winding under test is in accordance with the specified values. Corona discharges
shall not be considered as an indication of defect.

2.3 Supplementary High Voltage Test: The test made on the windings on
acceptance shall as far as possible not be repeated. If, however, a
second test is made at the special request of the purchaser, after further
drying if considered necessary, the test voltage shall be 80 percent of the
voltage as a specified in IS:4722-1968 and IS:5422-1969.
 3. PHASE-SEQUENCE TEST
The phase-sequence test is made to check the agreement of the machine with
the terminal markings and phase rotation that have been specified, or with the
relevant standards. The results are used when connecting line leads to the
armature terminals to obtain correct phasing of a generator to the bus, or the
correct direction of rotation for motors. The phase sequence on three-phase
machines can be reversed by interchanging the line connections to any two
armature terminals. The phase sequence on two-phase machines can be reversed
by interchanging the two leads of either phase.

3.1 Method 1: Phase - Sequence Indicators - Phase sequence is determined by

running the machine as a generator in the direction of rotation for which it was
designed and by connecting to the terminals a phase-sequence indicator or an
induction motor, whose direction of rotation is known when a given phase
sequence is applied to its terminals.

Figure 5 shows one type of phase - sequence indicator which consists of

windings placed on a laminated iron core with a steel bar mounted in centre.
The terminals of the machine under tests, whether three-phase or two-phase,
should be connected to the corresponding terminals of the indicator. The
indicator will operate clockwise if the phase sequence is 1,2,4 and counter-
clockwise if the phase sequence is 1,3,2.

Another type of phase-sequence indicator without moving parts is also available

for three-phase machines and is shown schematically in. The indicator makes
use of a small capacitor and two neon lamps connected in ϒ across the three-
phase circuit to be test. For phase sequence 1,2,3 the lamp connected to terminal
I will glow. For phase sequence 1,3,2 the lamp connected to terminal 3 will
glow.
To check the indicator, the switch shown in should be closed. If operating
correctly both lamps will glow with equal intensity.

When it is necessary to connect a phase-sequence indicator to the machine

terminals through potential transformers, extreme are is required because the
reversal of polarity of any transformer win will alter the phase relations
between the voltages applied to the indicator. If a ϒϒ connection is used,
selected terminals of the high-voltage windings of the transformers should be
connected to form the primary neutral. Corresponding terminals of the low-
voltage windings should be connected to form the secondary neutral.

If a delta-delta or open-delta connection is to be used, similar care is required to

ensure proper phasing of the secondary.

For any of the above cases, it is important to retain the identification of the
proper phase sequence in the secondary network.

3.2 Method 2: Indication of Differential Voltage - A convenient check of the

phase-sequence of a synchronous generator compared to the system to which it
is to be connected can be obtained as follows: -
Four potential transformers should be connected as shown in for three-phase
machines. Great care is necessary to maintain the correct polarity of the
transformer connections. The asterisks (*) show the corresponding terminals of
the primary and secondary windings. This connection effectively places
indicating lamps across open disconnecting switches between the generator and
the system. The generator should be brought up to speed and excitation applied
corresponding to normal voltage. When it is near synchronous speed, lamps
connected to the potential transformer secondary’s will brighten or dim
simultaneously if the generator has the same phase sequence as the system,
whereas they will brighten or dim one after the other if the phase sequence is
opposite.

3.3 Method 3: Comparison with System Voltage - This method provides an

absolute check of the phase sequence of a synchronous generator compared
with the system to which it is to be connected. It is necessary that the generator
be separated from the system by a circuit-breaker, and means should be
provided for disconnecting the generator from the circuit-breaker. A phase-
sequence indicator should be connected to the generator side of the circuit-
breaker through suitable potential transformers. With the generator
disconnected, the circuit-breaker should be closed and the indication of the
phase-sequence indicator noted. With the generator connected to the circuit-
breaker, but with the latter open, the indication of the phase-sequence indicator
should be noted when the generator is operating at normal speed and is excited
to produce normal voltage. If the two indication of the phase-sequence are the
same, the generator is known to have the same phase sequence as the system.

3.4 Method 4: Direction of Rotation for Motors: - In the case of a motor, the
phase sequence can be checked by starting it from its normal source of power
and observing its direction of rotation. If damage can result from improper
rotation, the motor should be used so as not to damage the apparatus; or another
procedure such as Method 1 or an adaptation of Method 2 or Method 3 should
be used.

4. INSTANTANEOUS SHORT-CIRCUIT WITHSTAND TEST

Sudden short-circuit tests are made to show that the mechanical design of the
machine is adequate to withstand the stresses due to short-circuits and related
abnormal operating conditions and also to determine certain characteristics such
as reactance’s and time constants.

This test is carried out on synchronous generators only at the express request of
the Owner made at the time of the order. The test is carried out when the
machine is running at rated speed and on no-load with rated terminal voltage
unless otherwise agreed upon but in no case the terminal voltage shall exceed
105 percent of rated voltage. The voltage at which the instantaneous short-
circuit is to be carried out may be reduced, by agreement between the
manufactures and the purchaser, to take into account the impedance of the
transformer which may be placed between the generator and the system. The
test may be carried out at site by between the manufacturer and the purchaser.
The short-circuit shall be maintained for a period of 3 seconds.
Before making this test the machine shall be carefully inspected to see that the
bracings of stator end windings are satisfactory, the foundation is in good
condition and foundation bolts are tight. The rotor shall be inspected to see that
all the keys and bolts are in place and properly tightened.

Certain precautions are required in preparing the electric connections because of

the abnormal conditions which attend a sudden short-circuit test. Very heavy
currents flow, particularly, on large machines, resulting in great forces on the
test conductors. To prevent damaging by movement, test conductors should be
securely braced.

The armature circuit should be solidly grounded at a single point, using a

conductor of size comparable to the leads from the machine terminals. There are
two choices for the location of this ground connection: the neutral of a Y-
connected armature winding or the point’s common to the three contacts of the
shorting circuit breaker. If shunts are used in measuring the currents, there
common point should be where the ground connection is made, to avoid
hazardous voltage the oscillograph in case of a mishap. If current transformers
are used in measuring armature current the point common to their primaries
should be where the ground connection is made, unless they are insulated to
withstand full line-to-line armature voltage.

All protective relays which could cause the field circuit-be-eaker to trip should
be made inoperative. A discharge resistor of sufficiently low value should be
used so that if the field circuit breaker where to trip, the voltage across the field
winding would not be excessively high.

The three phases are to be short-circuited practically simultaneously. The phase

contacts should close within 15 electrical degrees of each other. This value may
be exceeded on test when the armature dc component is not importance.
When the machine is running at rated speed and no-load and at the terminal
voltage agreed upon between the manufacturer and the Owner all the three
phases are instantaneously short-circuited.

5. MEASUREMENT OF OPEN-CIRCUIT AND SHORT-CIRCUIT

CHARACTERISTICS
5.1 No-Load Saturation Test (Open-Circuit) - The no-load saturation test is
conducted:

a) By driving the machine under test as a generator by some prime mover,

b) By running the machine under test as a motor without shaft load from a
source of alternating symmetrical three-phase voltage, and
c) During retardation of the machine under test.
Readings of no-load saturation curve (Fig 10) should always be taken with
increasing excitation. If it ever becomes necessary to decrease the field current,
it should be reduced to zero and then increased carefully to the desired value.

The machine should be allowed to run for several minutes at each voltage point
to allow the speed to stabilize at the rated value so that there will be no error
caused by variation in speed and excitation.

At rated voltage, readings should be taken of the terminal voltage (line-to-line)

of all the three phases to check the phase balance. These readings should be
made under constant conditions of excitation and speed, and with the same
voltmeter.

The open-circuit saturation curve is obtained by driving the machine under test
at rated speed, open-circuited and recording its armature terminal voltage and
field current.

During this test, excitation current, line voltage and frequency (speed) should be
measured simultaneously, Excitation changes should be made in gradual steps
from zero to a value corresponding to at least 130 percent of the rated voltage of
the machine under test with the excitation current equal to zero, the residual
voltage of the machine under test is measured.

If the no-load saturation test is conducted when the synchronous machine is

running as an unloaded motor, then in addition to the measured values
mentioned in it is necessary to measure armature current. At each voltage step,
readings should be taken for minimum armature current which corresponds to
unity power factor. The no-load saturation test during retardation of the machine
under test may be performed with due precession provided its retardation is not
more than 4 percent of the rated speed per second.

If the machine under test has retardation above 2 percent of rated speed per
second, excitation from a separate source is required in order to have more
stable excitation during the test. Before disconnecting from the line, the
machine is excited to the highest required value, but not below 130 percent of
the rated voltage of the machine. The excitation is lowered in steps and at each
steps, readings of armature voltage and speed (frequency) are taken
simultaneously with constant excitation current. The retardation test may be
repeated to obtain all the steps required.

The no-load saturation (open-circuit) characteristic that is the relationship

between the armature open-circuit winding voltage at the terminals and the
excitation current at rated speed (frequency) is drawn from the data of the no-
load test. If, due to high residual voltage, the no-load characteristic cuts the axis
above the origin a correction shall be introduced. To determine this, the straight
portion of the no-load curve, which is usually called the air-gap line, projected
to the point of intersection with the abscissa. The length on the abscissa axis cut
by this projected curve represents the correction value which shall be added to
all the measured values of the excitation current

If the frequency while conducting the test differs from the rated value, all the
measured voltage value shall be referred to the rated frequency.
5.2 Measurement of Three Phase sustained Short Circuit Characteristic

The sustained three-phase short-circuit test is conducted by:

a) Driving the machine under test as a generator by prime mover,

b) By a retardation test on the machine and
c) By running the machine under test as an unloaded synchronous motor at a
very low voltage.
The short-circuit should be made as close to the machine terminals as possible,
the excitation current being applied after short-circuiting the armature windings.

The machine under test is driven at its rated speed and is excited to get the
required armature current. The armature current in each phase and the
corresponding exciting current are recorded. The measurement shall be made
preferably for armature currents of 125, 100, 75, 50 and 25 percent of the rated
current.
The test is carried out starting from largest value of the armature current on
short-circuit so that the winding temperature is as nearly constant as possible
during the run.

For each measurement the average value of all the armature currents shall be
taken as the armature current on short-circuit for obtaining the short-circuit
characteristics. The speed of rotation (or frequency of the machine) under test
may differ if required from its rated value, but should not fall below 20 percent
of its rated speed.

The sustained three-phase short-circuit test may be carried out during

retardation with due precision provided the retardation of machine under test is
not more than 10 percent of its rated speed per second. It the machine under test
has retardation above 4 percent of its rated speed per second, excitation from a
separate source is required in order to have more stable excitation during the
test.

The machine under test is driven by an electric motor at its rated speed and is
excited to get the required armature current on short-circuit. The machine under
test is then retarded by switching off the supply to the driving motor. The
armature current in each phase and corresponding field current are recorded.

The relationship between the armature current on short-circuit and the

corresponding excitation current is drawn from the data of the three-phase
sustained short- circuit characteristic.

Short-circuit characteristic may be obtained by running the machine under test

as an unloaded motor and at an input voltage just sufficient to keep the machine
running stable (about 20 percent of rated voltage). Varying the armature current
up to 150 percent for various field currents, a number of readings are taken of
field current and armature current and a curve is plotted to get the overexcited
part of no-load V curve. A straight line passing through origin and parallel to
this part of V curve is a approximately the same as short-circuit characteristic.
7. DETERMINATION OF IRREGULARITES OF VOLTAGE WAVE-
FORM

7.1 Wave Deviation Factor - The deviation factor of a wave is the ratio of the
maximum difference between corresponding ordinates of the wave and of the
equal sine-wave, to the maximum ordinate of the equivalent sine-wave the
waves are superpost in such a way as to make this maximum difference as small
as possible. The equivalent sine-wave referred to in the definition is a sine-wave
having the same frequency and rms value as the wave being tested.

7.2 Wave Distortion Factor - The distortion factor of a voltage wave is the ratio
of the effective value of the residue after the elimination of the fundamental to
the effective value of the original wave.

8. Telephone Harmonic Factor: -

The telephone harmonic factor of a three phase synchronous machine is the

ratio of the square root of the sum of the squares of the weighted rms values of
the fundamental and all the series of harmonics voltage of the machine on no
load.

The telephone harmonic factor (t.h.f.) of the line-to-line terminal voltage shall
be measured when the synchronous generator is run at rated speed on open-
circuit at rated voltage. The range of the frequencies measured shall cover all
harmonics from rated frequency up to 5000 Hz.

By measuring each harmonic by a frequency analyser, the t.h.f. may be

determined from the following formula:
9. OVERSPEED TEST AND CHECKING OF VIBRATIONS

Before making the over speed test, rotor should be carefully inspected making
sure that all the holding-down bolts and parts are tight and in good condition.
The rotor should be in as good mechanical balance as possible before starting
the test. The speed should be read by means of a tachometer or other indicating
device. The tachometer should be calibrated with the leads used in the test and
the reading checked at normal speed before starting the test. In case of turbine
type generators; the test is carried out in a special safety tunnel on the unexcited
rotor to ascertain its mechanical strength.

Unless otherwise agreed upon, rotors of all the synchronous machines other
than water wheel generators shall be tested at 120 percent of the rated speed for
a period of 2 minutes.

The rotors of the water wheel generators shall be tested at their runway speed
for 2 minutes at site if specially agreed between the manufactures and the
purchaser.

When making the test the rotor should be run at rated speed for a period long
enough to reach approximately steady conditions and to ascertain that the rotor
is running satisfactorily. The insulation resistance of the rotor winding is
checked at the rated speed or at rest. The vibrations are also checked at the rated
speed.

The rotor is then accelerated with reasonable promptness to the specified over
speed. For speeds greater than 120 percent, it is desirable to pause briefly at
various speeds during acceleration to check such operating conditions as
vibration, run out of the rotor, and behaviour of the oil in the bearings.
Following the operation at the specified over speed for the specified period the
rotor shall be brought promptly and smoothly back to rated speed and run until
the bearing temperatures come to normal. Vibrations are again checked at the
rated speed and the rotor is balanced if necessary. The rotor is brought to rest
 and the insulation resistance of rotor windings is again checked. An ac high
voltage in accordance with 9 is then applied to the rotor windings for a period of
one minute. The rotor is then carefully inspected.

The test is considered satisfactory if:

a) There are no evident deformations of the rotor,

b) The rotor windings passes the high voltage test, and
c) The vibrations after the test are well within the limits specified in IS :
4729-1968

9. INSULATION RESISTANCE TESTING AND DRYOUT

The insulation resistance of a winding is a function of the type and assembly
of insulating material. In general, it varies directly with the thickness of
insulation and inversely with the conductor surface area. The value of
insulation resistance also varies inversely with the amount of moisture in the
insulation and the amount of solvent left in the bonding varnish of the winding
connections. Insulation tests are carried out normally using a megger. Where
polarization index values are required, the megger must be capable of
supplying a steady voltage for 10 minutes. The results obtained using D.C. test
methods are affected by the general conditions of the surface of the windings as
well as by the leakage through the main insulation. Interpretation of the results
may be difficult if contamination is present; for this reason, before carrying out
the test, the surface of the winding should be examined to make sure that they
are clean and dry, and not contaminated by moisture, oil, salt, carbon dust or
other foreign matter.
INSULATION RESISTANCE TESTING
SAFETY PRECAUTIONS FOR TESTING
Before attempting any insulation resistance test, it is essential to earth the
frame of the machine and parts of the winding not being tested. Dry
insulation resistance is capable of holding an electrical charge for several
 hours after the removal of the applied voltage. For reasons of both safety and
accuracy, it is essential that the winding, or section under test is adequately
earthed both before and after the application of the test potential. For large
machines a period of 30 minutes should be allowed.

METHOD OF TEST

Initial test may be carried out without disconnecting the supply cables, but if
unsatisfactory result is obtained, then the windings should be isolated from all
externals cables and connections before repeating the measurement of
insulation resistance. Insulation resistance should be measured between each
individual phase and earth with the remaining phase earthed. The insulation
resistance (Rph) of one phase to earth on a 3-phase winding is approximately
twice that of the complete winding; therefore, the measured value must be
divided by two to obtain a value for comparison with the value
recommended. In practice each test is carried out by conductor or terminal of
the winding under test and the other lead to the frame. The instrument is then
switched on and the test voltage maintained for one minute at which stage the
insulation resistance reading (R1) is noted. The test is continued and an
additional reading (R10) after 10 minutes is noted for calculation of the PI-
value.

POLARISATION INDEX

The measured insulation resistance of a winding normally increases with the

time of application of the D.C. test voltage. The increase is usually rapid for
the first one to two minutes and thereafter the slope of the curve steadies of
with time; for the next 10 to 30 minutes, the increase is a function of the
absorption characteristics of the insulation and hence of its general condition.
On majority of the winding, the value reached in 10 minutes will be greater
than 90% of the final steady state reading. The polarisation index of a
 winding is defined as the ratio of the insulation resistance after 10 minutes
(R10) to the insulation resistance after 1 minute (R1) i.e.
Polarisation Index (P.I.) = R10/R1
On a clean dry winding, the polarisation index value should not be less than
2.0. If a value below this is obtained, then a dry out should be carried out.
DRY OUT
Methods of dry out
(a) Space Heaters
Electric space heaters may be used for drying windings where the moisture is
on or close to the surface of the outer layer of insulation. However, if the
moisture has penetrated the winding insulation, then the method is unlikely to
be successful on its own. If used in conjunction with direct heating, it can
prove useful in keeping the overall temperature upto the specified dry out
value.

(b) Short Circuit Running

The stator terminals should be short circuited by connecting the three main
terminals together. Connections must be made with cable or copper strip of
adequate section to carry the full load current of the machine. Approximately
equal current should flow in each phase during the dry out. The stator frame
must be solidly earthed. The machine should be run up using the prime
mover. As a first part of the dry out schedule, the machine should be run
without excitation as the windage losses will generate sufficient heat to raise
the temperature of the winding to an acceptable rate. Initially excitation
should be applied to cause approximately 15% of the full load current to flow.
As the temperature goes up, the excitation should be varied to follow the
heating rate specified in Para 2.4. In general, the circulating current must not
be allowed to exceed the full rated value, otherwise overheating of the stator
may occur.
 (c) Direct current heating
Where the controllable low voltage direct current supply is available from a
motor generator set or rectifier equipment, then this may be used for dry out
of the A.C. stator windings (with or without the rotor in position) and DC
field Circuit.
A.C. Stator
All the phases should be connected in series using copper strip or cable of
adequate section to carry the full load current. Initially the value of current
should be set at approximately 15% of the full load rating and adjusted as the
temperature rises to follow the heating schedule. The direct current supply
and any external cables must be disconnected before any insulation
resistance reading are taken. Usually, about 50-60% of rated current may be
sufficient to maintain dry out temperature. The end windings must be
properly covered by suitable non hygroscopic covers to contain the heat
within, and the direct heating can be supplemented by use of space heaters
located below the winding for quick results. Asbestos sheets are not
recommended for covering the end windings as these are hygroscopic and
may hinder satisfactory dry out.

DC Field circuits
For drying out the DC field windings all the coils should be connected in
series and current passed through the circuit so as to follow the rate of
temperature rise specified below. In general the value of current used should
not exceed the maximum value specified for the machine field circuit. As
field circuits are inductive, it is essential when breaking the circuit (to take
insulation readings) that the current is brought down to a low value by either
having a resistance in series with the supply or by reducing the voltage to as
near zero as practicable.
Dry out temperature
In general when using direct heating of the winding by passing current the
temperature should be raised to approximate 800 C as measured by
thermometers attached to the end windings are 900C when measured by
embedded temperature detectors (ETD’S). The rate of temperature rise for a
winding which has been allowed to get damp due to moisture pick up from
highly humid atmosphere should be limited to 5 to 60 C per hour, where a
winding has been soaked with water than the rate of temperature rise should
be limited to 2 to 30 C per hour, otherwise damage to the insulation is likely
to occur. Once the maximum temperature is reached it should be maintained
through out the dry out period. To ensure that the moisture is effectively
removed there must be free circulation of air around the windings. The
generators covers must be opened occasionally to allow continuous
interchange of air as otherwise the air may become saturated and there by
slow down the rate at witch moisture comes out from the windings. A
convenient method of following the progress of dry out is to take insulation
resistance reading (R1 & R10) at regular intervals of say 6 hour and to plot
them, along with the calculated value of polarization index and winding
temperature. For damp windings readings should be taken every 1 to 2 hours.
On grossly contaminated windings the dry out will be slower and the
intervals may be increased to 4 to 8 hours. During the initial period of the
dry out the insulation values tend to decrease appreciable as the temperature
rises but over a period of time they will rise again. Once the maximum
temperature has been reached, it should be maintained as constant as
practicable so that the measured changes in insulation resistance reflect
accurately the progress of the dry out. The dry out process should be
continued beyond the time at which the insulation resistance has started to
increase and heat should be maintained until the insulation resistance is
above the minimum acceptable value. Polarization index is not substantially
affected by temperature and hence a value of minimum to should be
 achieved. Since the winding will cool off slightly during the time that the
insulation resistance and polarization index tests are carried out, two points
should be observed.

(a) When individual phases are being checked, the order in which readings
are taken should be kept the same during each test period.
AND
(b) If the cooling is significant (e.g. on small machines) then the polarisation
index value will be slightly optimistic unless the insulation resistance
values are related to the same temperature.

Completion of dry out

The dry out should be terminated, and the source of heat removed, after the
minimum levels of insulation resistance and nearly constant (but not less
than two) polarisation index have been reached and maintained for at least
another 24 hours based on 6 hourly readings.

NOTE : If PI value tends to increase with successive readings the dry

out should be continued till nearly constant value is reached.

RECOMMENDED MINIMUM INSULATION RESISTANCE

Stator winding
(i) Insulation resistance of stator winding varies considerable for different
insulation systems, atmospheric condition and service life, but for practical
purposes a recommended minimum one minute value for each phase of the
winding may be obtained from the following equation:

IR min = 2.Ft (2kV + 1) Mega ohms

where kV = line voltage in Kilovolts.
 ‘Ft’ is a factor dependent on winding condition and winding temperature at
which the test is carried out. Values of Ft are given below:

Values of ‘Ft’
Winding New machine Machine after Machine after service for
Temperature Dry, unaged Service, clean Several years with normal
0
C and clean and uncontaminated Industrial Contamination

10 32 16 8
20 16 8 4
30 8 4 2
40 4 2 1
50 2 1 0.5
60 1 0.5 0.25
70 0.5 0.25 0.125
80 0.25 0.125 0.0625

(ii) Polarisation Index

The PI value shall be recorded in addition to IR. It is not uncommon on a
clean, dry winding to achieve a PI value of 2.0 & more after proper dry out.
However, this may not be achievable in some cases due to adverse
atmospheric conditions such as presence of moisture, dirt or dust etc. The
minimum PI value acceptable for satisfactory operation in such cases shall be
taken as 1.5.

NOTE : It is recommended that a dry out shall be carried out

irrespective of IR/PI value before H.V. test or building up
voltage during commissioning.
ROTOR WINDING
(i) Insulation Resistance
The values normally achieved for a new and clean individual pole assembly
is 200 M.Ohm at room temperature. The minimum acceptable limit for
satisfactory operation is 50 M.Ohm below which dry out is recommended.
It is expected that on a newly assembled machine with clean, dry and
uncontaminated winding, the IR value shall not be less than 2 M.Ohm,
measured between collector and earth. However, for satisfactory operation
under any condition, minimum IR value of total rotor winding measured
between collector and earth shall be not less than 1M.Ohm. However, in
such cases, it is recommended that the generator be run for several hours on
light load to improve the IR value such that mal-operation of earth fault
relay caused by low IR is avoided.
(ii) Polarisation – Index
PI value is not required or recommended for rotor winding circuits.

COLLECTOR ASSEMBLY AND BRUSHGEAR

Normal expected value for a new machine is 5 M-Ohm, but minimum
acceptable value for satisfactory operation is 2 M-Ohm.

General Note:
The IR values recommended are for guidance. As stated in IEEE-43, it is
impractical to specify a definite minimum value of IR or PI of a rotating
machine below which the machine cannot be operated. It is recognized that
it is sometimes possible to operate a machine with value lower than the
recommended minimum value, but it is not considered a good practice in
the majority of the cases.
 10. STATOR FORM AND ROTOR FORM (AIR GAP)

GENERAL

The purpose of checking stator and rotor forms is to minimize the

inequalities in the air gap all-round the circumference. This will ensure
minimum possible unbalanced magnetic pull with the built up stator and
rotor, which will have a beneficial effect on vibration performance of
generator.
The stator and rotor must be built as circularly as possible, ensuring
that the difference in radius of diametrically opposite poles is within 0.2
mm. This can be achieved by building the rim concentric to the spider (i.e.
ensuring uniform gap on all key bars) and properly grinding the pole seating
surface and T-Slot groove in rim while assembling the rotor poles.
NOTE: BEFORE TAKING STATOR AND ROTOR FORMS MEASUREMENTS,
IT IS NECESSARY TO CENTRALISE THE GENERATOR SHAFT
WITH RESPECT TO INNER DIA.METER OF GUIDE BEARING
SUPPORT RING. NEXT, FIT FOUR DIAMETRICALLY OPPOSITE
CENTRALISING BLOCKS WITH JUST SUFFICIENT CLEARANCE
(0.02 TO 0.03 MM) TO ENABLE ROTATION OF ROTOR. THE
ROTOR SHOULD REMAIN IN THIS POSITION THROUGHOUT
THIS PHASE OF WORK.

STATOR FORM
• Mark equivalent peripheral position, equal to no of poles, on the stator bore
I.D.
ƒ Using any one pole as a datum; bring centerline of this pole tip opposite to the
mark point on stator bore.
ƒ Measure the air gap at top and bottom ends of stator bore, approximately 200
mms from the ends.
ƒ Rotate the datum pole successively to remaining marked position on stator
bore and take readings.
ƒ Draw a reference circle of known diameter on a graph. Its diameter shall be
kept a little smaller than the air gap readings.
ƒ Mark the points as per air gap readings outside the reference circle and join them
to obtain stator form. This plot represent the profile of stator bore and is
indicative of its circularity.

ROTOR FORM
• Mark a datum point on stator bore, which can correspond to the erection
mark location on stator frame.
• Bring center of each pole successively opposite this datum mark on stator
bore.
• Measure the air gap at top and bottom ends, approximately 200 mms from
the ends of stator core.
• Study the air gap readings taken for rotor form and orient so as to obtain
the positionof largest difference in air gap between stator and rotor. Plot
air gap readings of rotor form to the same scale on a different transparent
paper, but inside the reference circle. This represents the profile of pole
tip.
• The air gap variation between stator and rotor form represent the
inequality in built up generator. The purpose of this exercise is to reduce
this inequality.

SHIFTING OF STATOR
• Examine the stator and rotor form plotted for top and bottom ends of
generator. Superimpose the two forms, and by rotating the rotor form,
identify the pole corresponding to maximum air gap variation.
• Take the difference of air gap readings on the stator form
corresponding to maximum air gap and the opposite pole. Half of this
difference is the shift of the stator required.
• The shifting of stator will be in a direction opposite to the maximum
air gap. For this fine shifting of stator; radial screw jacks are to be
 used and fine movement of stator along with its lateral shifting, if any
shall be monitored by means of four dial gauges fixed at 900.
• After above adjustment, stator form and rotor form are to be checked
again. If required, further adjustment of the stator position has to be
done. Since, the core is long, separate plots are to be drawn for top air
gap readings and bottom air gap readings. It has to be checked that
there is not much difference between top and bottom air gap readings
corresponding to each pole. If the difference between top and bottom
air gap readings at any pole is large, the mounting of pole has to be
checked.

CHECKING ROUNDNESS OF ROTOR

• It is necessary to check the roundness of the rotor in order to minimise

the variation in air gap. For this, radius of pole face shall be measured
and it should be ensured that the difference in the radii between any
two diametrically opposite poles is in the range of 0.2 to 0.3 mm.
• The checking of rotor diameter shall be done on both rim A/F and
pole O.D. where the difference in radii is beyond permissible limits,
the relevant poles shall be taken out and rim-seating surface shall be
ground to remove the high spots/protruding punching and the poles re-
assembled.
• The measurement of pole face radius can also be carried out with the
help of stick micrometer. Readings are taken between the centralized
piano wire and a straight edge which is firmly pressed against the pole
face at its tip center.
• Minimizing the radii difference to reduce the air gap variation will
reduce the UNBALANCED MAGNETIC PULL in operation and
will result in low vibration of the rotor shaft system and bearing
brackets.
 • While re-assembling the poles on the rotor after correcting the
roundness, it is necessary to ensure that the centre lines of all poles
are matching for proper checking of the magnetic center of the unit at
a later stage. For this purpose, refer to the detailed procedure on
magnetic Centering.
• After grinding operations are over, utmost care must be taken to clean
all surfaces free of iron filings, dirt and dust. Otherwise this may lead
to a possible earth fault at a later date.
NOTE :

It is necessary to check the pole face radius at top and bottom of each
pole. The verticality of each individual pole shall be within 0.3 mm, when
measured after assembly on rim. Any large variation could be due to

(i) Rim face not being vertical,

(ii) seating surface of pole on rim not being flat, and

(iii) protrusion of rim punchings or pole punchings.

The verticality can be corrected by grinding of the rim surface and/or seating
surface of pole body which will be in contact which rim.

LEVELS, CENTERING AND ALIGNMENT

(INCLUDING DOWELLING AND GROUTING)

Levelling and alignment along with centralizing are the most important
operation in the erection of a Hydro generator. Trouble free operation of a
machine depends on satisfactory achievement of level, alignment and
centralizing of rotor. These operations must ensure that:
• The thrust bearing is horizontal
• The thrust bearing elevation is set to give correct turbine runner elevation
during normal operation
• The axis of turbine shaft, generator main shaft, top shaft and collector
shaft are in one vertical line.
• The turbine runner centre and generator rotor center coincide with centre
line of stay ring and stator bore respectively during normal operation.
• The guide bearing clearances are set as per drawing.

11. STARTING, TESTING AND COMMISSIONING

11.1 GENERAL
• Clean the hydro generator of dust and dirt with the help of dry
compressed air and vacuum cleaner. Rub with cloth to clean internal
surfaces of frame and air baffles with cloth.
• Remove foreign objects, if any from inner parts of hydro generator,
specially the core ducts, air gaps, inter polar gaps etc.
• Check installation of dowels and tightening of fixing bolts of stator,
bottom bracket, top bracket, brake-jack assemblies etc. Check the locking of
all the nuts, particularly in rotating parts of generator and air baffles.
• Check air guides and air baffles to ensure that they do not touch the
rotating parts of generator and the variation in air guide/baffle clearances
are within limits specified in the drawings.
• Check that all cover plates are closed tightly.
• The oil pot and pipelines are to be flushed by circulating oil for twelve
hours. The bearing housing shall then be filled with fresh oil up to the level
shown in the drawing. Again use the oil purifier for twenty-four hours for
purification. Check for any oil leakage.
• In order to prevent entry of dirt and dust into the oil bath during first
starting, disconnect air piping from air baffle to vapour seal. HOWEVER,
THE AIR PIPELINE MUST BE CONNENCTED BACK AFTER FEW
DAYS OF RUNNING.
11.2 PRE-START CHECKS
• Check that cooling water circulation is normal through the air coolers and
bearing oil coolers. Open the valves of the coolers for releasing the trapped
air.
• Oil circulation through inter pad cooling system shall be checked.
• The fire extinguishing system of generator should be checked for
operational readiness.
• The brake shall be applied and released a number of times with
compressed air to check their performance to ensure that they are not
sticking.
• Disconnect the generator excitation system and disconnect the generator
main terminals from bus bars. Start Interpad Cooling System and
Hydrostatic Lubrication System.
• Check that all the thermal indicators are installed at the required places
and the instruments are functioning normally.
• Check that fire extinguishing system for generator functions normally.

11.3 BUMP START

The machine is given a start and allowed to rotate so that it makes few
rotations. The aim is to ensure that rotor rotates freely without any fouling
or abnormal noise.
11.4 FIRST RUN
In the first run, the machine is run without excitation and hence ensure that
generator excitation system is switched off. Start the hydro set and run it at
low speed and make sure that there is no jamming, unwanted noise/run-out
of shaft and collector. If any abnormal vibration is noticed at lower speed,
balancing shall be done at that speed before taking the machine to the next
higher speed and upto finally rated speed. OTHERWISE THE SHAFT
MAY RUB THE OIL VAPOUR SEAL AND POSSIBLY DAMAGE THE
SEAL.
Provision is made on the rotor spider for fixing of the balance weight. By
choosing the proper size and location of balance weights, as required, the
generator should be balanced within allowable limits.

11.4.1 After first start

After the first start, the machine is to be shut down for inspection. The
generator shall be thoroughly inspected and mechanical fastenings shall be
checked for looseness. Check whether the brushes are properly bedded on
the collector.
11.4.2 Bearing run
Run the machine at rated speed (at no load). The thrust and guide bearing
temperatures are to be carefully observed when the set is spun. The
temperature should increase gradually without sharp kicks, with uniform
increment and within 2-3 hours of operation, it should practically stabilize.
If the temperature indicated by any thermometer in thrust and guide
bearings increases sharply even if the absolute temp. is not very high, the
machine should be stopped and the reason for the same is ascertained. The
bearing run can be continued for about 12 hours.

Observe the oil level in thrust bearing oil bath. After starting, the oil level
rises due to centrifugal forces, heating and aeration. Check that the oil does
not leak through the bearing housing and oil retaining sleeves.

11.5 SETTING OF OVERSPEED DEVICE

CHECK THE SETTING OF OVERSPEED DEVICE BY SPEEDING-UP
THE UNIT TO SPECIFIED OVERSPEED SETTING. IT SHOULD BE
LITTLE HIGHER THAN MAXIMUM LOAD THROW-OFF SPEED.
KEEP A WATCH ON ABNORMAL KNOCKING AND NOISE DURING
SPEEDING UP. UNIT SHALL NOT BE MAINTAINED AT OVER
SPEED FOR A LONG TIME. INPECT GENERATOR COMPONENTS
AFTER OVERSPEED TEST, INCLUDING TIGHTENING OF ALL
HARDWARES, POLE/RIM KEYS ETC.

11.6 VOLTAGE BUILD-UP

Before building-up the voltage, generator shall be run for dry out of
windings by short circuiting the three-phase terminals and by circulating the
current through windings. For supplying excitation to the generator field
windings, the static excitation equipment can be used under manual control,
by giving 11 kV station supply to the HV terminals of excitation
transformer.

The voltage shall be built-up only after satisfactory condition of winding

insulation achieved by dry out. In order to build-up the voltage in stator
winding, switch on the excitation system and increase field current.
Generator terminal voltage shall be increased in steps of 2 kV and the unit
shall be allowed to run for about 5 minutes every time before increasing the
voltage. Check the brushes for any sparking. Over voltage protection check
can also be done at this stage.

During the process of voltage build-up, monitor the vibration of shaft and
bearing brackets and if necessary, rebalance the machine before proceeding
to the next higher voltage. In this way, balance the machine under excited
condition upto rated voltage.

11.7 SYNCHRONISATION AND LOADING

Stop the unit and connect the generator terminals to transformer terminals
through bus bars. Restart the unit and build-up voltage as explained above.
Synchronize and load the unit. Load shall be increased in steps of 10 MW
and sufficient time shall be allowed at every stage to watch the
performance. Check for abnormal noise, vibration etc. and keep a watch on
winding, core and bearing temperatures. Collector brushes shall also be
checked for smooth function.

Measure the vibration of the bracket and the shaft at top bracket and bottom
bracket with and without excitation and no load. If necessary, rebalance the
machine before proceeding to the next higher load. In this way, balance the
machine under excited condition upto rated load.

Conduct partial, full load and max. load throw off tests and check for
satisfactory voltage and speed rise.

11.8 PUTTING INTO OPERATION

Before putting the generator on commercial load, following final checks
should be made:
(a) All balance weights are permanently welded/locked as per
drawing, after removal of temporary locking provided during balancing of a
unit.
(b) Check carefully the tightness of fixing details of poles and keys,
fan, rotor, air baffles, stator, brackets, cover plates etc.
(c) Check carefully the stator winding for absence of any bulging of
insulation or flow of varnish.
(d) Check the interpolar joints of the rotor field winding. If necessary,
tighten the holding down nuts etc.
(e) Check the sealing of oil baths and vapour seal clearances.
(f) Check water and oil pipe lines for any leakage.
(g) Check working of braking system.
(h) Check the connections of current carrying leads and cables.
(i)Measure the insulation resistance of all the windings of the generator and
compare them with the measurements carried out earlier.
(j)Check the welding of rotor spider, top and bottom brackets, stator and
other details.
(k) Blow the collector with dry compressed air as during starting
period the most sensitive wear of the brushes is observed.
(l)Check the oil levels in the bearing housings.

11.9 STOPPING
Following sequence shall be followed for stopping the unit when running
on load.
(a) Reduce the output of generator till it is almost zero.
(b) Trip line circuit breaker.
(c) Reduce the field current till the terminal voltage is almost zero.
(d) Trip field circuit breaker.
(e) Allow the machine to decelerate to braking speed and apply brakes.
(f) Shut off cooling water supply to air/oil coolers, after machine
comes to stand still. .
(g) Shut off H.S. Lubrication system and interpad cooling system.
(h) Release and reset brakes.

11.10 HANDING OVER

After successful running of the machine as per contractual requirement,
same will be handed over to Owner for operation as per grid demand.
Reference:

o “IEEE Guide for commissioning of Electrical systems in Hydro-electrical

Power Plants”, IEEE Standard 1248, IEEE, 1998.
o “Guide for commissioning, operation and maintenance of Hydraulic
Turbines”, International Electro-technical Commission (IEC) Standard
545, IEC, 1976.
o “Installation of Vertical Hydraulic Turbine – Driven Generator &
Reversible G/M for Pumped Storage Installation”, National Electrical
Manufacturer’s Association (NEMA) Guide 5.2, NEMA, 1989.
o Hydro Power Station – Generating Equipment and its Installation by A.N.
Goncharov.
o Shodhganga