Micro-hydropower Plant Site Completion Test Manualgwweb.jica.go.jp/km/FSubject0901.nsf/3b8a2d403517... · Micro-hydropower Plant Site Completion Test Manual ... Test plan preparation

DEPARTMENT OF ENERGY ENERGY UTILIZATION MANAGEMENT BUREAU

Micro-hydropower Plant

Site Completion Test Manual

June 2009

MHP – 4

This manual was developed by the Department of Energy (DOE) through the technical assistance under the Project on “Sustainability Improvement of Renewable Energy Development for Village Electrification in the Philippines” which was provided by the Japan International Cooperation Agency (JICA).

Table of Contents

1 General......................................................................................................................... 1

2 Scope............................................................................................................................ 1

3 Objectives .................................................................................................................... 1

4 Implementation structure ............................................................................................. 1

4.1 Management structure ...................................................................................... 1

4.2 Roles and responsibilities ................................................................................. 2

5 Test Instruction ............................................................................................................ 3

5.1 Civil and metal structures ................................................................................. 3 5.1.1 Common ....................................................................................................... 3 5.1.2 Gate and stoplog ........................................................................................... 3 5.1.3 Concrete structures ....................................................................................... 4 5.1.4 Operation & maintenance manuals/instructions........................................... 4 5.1.5 Documents to be prepared ............................................................................ 4

5.2 Electro-mechanical equipment ......................................................................... 4 5.2.1 Inlet valve and drain valve for penstock water............................................. 4 5.2.2 Comprehensive test ...................................................................................... 4 5.2.3 Operation & maintenance manuals/instructions........................................... 6 5.2.4 Documents to be prepared ............................................................................ 6

5.3 Transmission and distribution facilities............................................................ 7 5.3.1 Common ....................................................................................................... 7 5.3.2 Operation and maintenance manuals/instructions ........................................ 7 5.3.3 Documents to be provided............................................................................ 7

6 Amendment of the manual........................................................................................... 8

LIST OF ANNEXES

ANNEX 1 : Appearance checklist for civil and metal structures ANNEX 2 : Example procedures of comprehensive test for

electro-mechanical equipment

1

1 General

This manual is intended to specify standardized test items and procedures for the completion test of micro-hydropower plants. Accordingly, an actual on-site test was conducted taking into account the real conditions of the plants which served as the reference basis for the test instructions and record forms shown in this manual.

2 Scope

This manual shall be used for the on-site completion test conducted in conjunction with the new construction of micro-hydropower plants. Users also may utilize this manual for performance tests after the rehabilitation and upgrade of existing micro-hydropower plants by choosing the appropriate test items.

3 Objectives

The objectives of this manual are: (1) to verify if the installed equipment meets the requirements, and (2) to secure the safety of the equipment and people after commissioning through

the precise implementation of a field performance test.

4 Implementation structure

4.1 Management structure

The following figure shows the management structure of the completion test.

Figure 1 Implementation structure of the completion test

Proponent

Contractor Mobilized

Local Residents

Assistance

ReportInstruction/

Advice Implementation of test

Manufacturer/ Supplier

Inspection report/ Drawings

Specifications

2

4.2 Roles and responsibilities

The roles and responsibilities of each component in the planning and implementation of the completion test have been summarized in the following table.

(1) Factory inspection report/drawing collection

The proponent shall collect factory inspection reports and drawings for purchased equipment from manufacturers/suppliers prior to their acceptance. Even in the case of standardized equipment, submission of related documents that show the characteristics of the equipment shall be required for future maintenance.

(2) Test plan preparation

The contractor shall prepare a plan for the completion test and submit it to the proponent in advance for approval. Test items shall be identified according to the composition of the installed equipment and concrete test procedures shall be proposed for each test item.

(3) Test plan approval

The proponent shall review the submitted test plan to be approved after providing necessary instructions to the contractor.

(4) Test implementation

The contractor shall conduct the completion test in accordance with the approved test plan and record the results on the record forms. The local residents shall assist with the implementation of on-site testing. Test records shall be submitted to the proponent for approval.

(5) Approval of test results

The proponent shall review the submitted test record to be approved after providing necessary advice and instruction to the contractor.

(6) Test record maintenance

Test records shall be maintained by the proponent.

Component Role

Proponent

Factory inspection report/drawing collection Test plan approval Test result approval Test record maintenance

Contractor Test plan preparation Test implementation

Local residents Asssistance in implementing the tests

3

5 Test Instruction

5.1 Civil and metal structures

5.1.1 Common

(1) Appearance check

Civil and metal structures shall be inspected visually to identify any defects and/or evidence of water leakage. Examples of checklist items are shown in ANNEX1.

(2) Dimensional test

A dimensions test of civil and metal structures shall be implemented based on the drawings to ensure that these structures possess the required capabilities.

The criteria for evaluation are as follows:

Item Instruments Criteria

Location Within 500 mm

Elevation, Slope Within 100 mm * Penstock shall not be inverse or horizontal

Length, Size

Measuring tape Transit Level gauge

Within smaller value of 5% of design value

(3) Water-filling and dewatering test

A watertight inspection along the waterway shall be executed by means of a water filling and dewatering test. The targets include the weir, the headrace open channel, the settling basin, the spillway, the penstock, the powerhouse, the tailrace, and their auxiliary structures, such as the gate and stoplog. Leakage shall not be observed during this test (10-minute operation under maximum design head and design discharge).

(4) Operation test

An operations test shall be conducted in order to verify that no serious vibrational disturbance of the civil and metal structures will occur when the plant and equipment are in operation.

5.1.2 Gate and stoplog

(1) Running test

A running test shall be carried out to verify the smooth and reliable operation of the gate and stoplogs.

4

5.1.3 Concrete structures

(1) Crack inspection

No cracks larger than 0.4 mm shall be allowed on the concrete structures through which water is run such as the weir, the headrace open channel, the settling basin, the spillway, and the tailrace. Photographs and sketches are useful for monitoring development of the cracks.

5.1.4 Operation & maintenance manuals/instructions

The contractor shall submit operation and maintenance manuals/instructions. Methods and frequency of inspection, repair and maintenance (including painting of penstock, gate and screen, sand flushing valve etc.) shall be described in the manuals/instructions.

5.1.5 Documents to be prepared

The contractor shall provide the following documents one week prior to the completion test.

(1) As-built drawings (layout, major structures)

(2) Head-loss calculation

(3) Maximum output power calculation

5.2 Electro-mechanical equipment

5.2.1 Inlet valve and drain valve for penstock water

After the inlet and drain valve for the penstock have been installed, and before putting the unit into service, the following performance tests shall be carried out by the contractor.

(1) Watertight test

To check water leakage from a closed inlet valve and measure the amount if necessary.

Test item Content

Watertight test To check the water leakage from a closed inlet valve and measure the amount if necessary.

5.2.2 Comprehensive test

After the electro-mechanical equipment, such as the turbine, generator, control panel, and auxiliaries have been installed, and before putting the unit into service, the following tests shall be carried out by the contractor in order to verify comprehensive performance. A series of example procedures for each test are shown in ANNEX2.

5

Test item Content

Visual inspection To check visually the installation conditions of the electro-mechanical equipment in the powerhouse.

Earth resistance measurement

To measure the earth resistance using an earth tester at the grounding electrode, and check that the equipment is connected firmly to the electrode.

Insulation resistance test

To measure the insulation resistance of the generator windings and the dummy load heaters using an insulation tester, and check that they maintain the necessary insulation performance.

Initial run test To check for any abnormal sound, vibration and contact with the stationary parts by rotating the turbine-generator at low rotational speed.

Bearing run test To measure the temperature rise of the bearings and the generator cover by continuously operating the generator-turbine at the rated rotational speed and no load.

Excitation characteristic test

To measure the generator voltage, exciter voltage and exciter current for the frequency stepwise changed in the no load operation, and draw a graph of the excitation characteristic.

Protection function test

To check the characteristics and setting values of protective functions for the ELC panel box by changing the values of the trimmers.

DL governor function test

To check that the frequency is kept constant regardless of a change in the actual load which is substituted by a water resister.

Output vs. guide vane opening test*1

To measure the relationship between the guide vane opening and the generator output.

Load rejection test*2 To check that the frequency is kept constant regardless of a sudden change in the actual load by manually cutting off the parallel-in circuit breaker (MCCB).

Load run test To measure the temperature rise of the bearings and the generator cover by continuously operating the generator-turbine at the rated rotational speed and full output.

Overnight operation data collection

To check that the dummy load governor functions properly during actual operations.

Notes: *1 The total and turbine efficiency can be estimated by measuring the turbine discharge

via utilization of a portable ultrasonic flow meter during the test. *2 The load rejection test is to be used for a system equipped with a governing system

such as a dummy load governor.

6

5.2.3 Operation & maintenance manuals/instructions

The contractor shall submit operation and maintenance manuals/instructions. Assembling and disassembling methods, maintenance period, and the interval of

greasing, etc. for the following equipment and devices is described in the manuals/instructions.

(1) Turbine

(2) Generator

(3) Inlet valve

(4) Driving system

(5) Governing system (Electronic Load Controller: ELC)

(6) Automatic voltage regulator (AVR)

(7) Generator panel

5.2.4 Documents to be prepared

The contractor shall provide the following documents.

(1) Single line diagram – main & control circuits

(2) Power plant equipment layout drawings

(3) Specifications and generator panel drawing

(4) Unit control & protection system diagram

(5) Drawings of the dummy load heater

(6) Drawings of the inlet valve

(7) Drawings of the connecting pipe

(8) Connection diagrams of the generator panel

(9) Connection diagrams of the AVR

(10) Connection diagrams of the governor

(11) Connection diagrams of the control system

(12) Efficiency and output curve of the turbine

(13) Efficiency curves of the generator

(14) Test reports for all equipment/devices

(15) List of tools and spare parts

(16) Operation and maintenance manuals/instructions for all equipment/devices

7

5.3 Transmission and distribution facilities

5.3.1 Common

After the transmission and distribution facilities have been installed, and before putting the unit into service, the following tests shall be carried out by the contractor.

Test item Content

Visual inspection

To check visually that the transmission and distribution line components, such as the pole, cross arm, insulator, guy wire, cable, conductor, switchgear, and arrester are installed adequately, and that offset distances between the conductors and trees are maintained by walking along the route.

Earth resistance measurement

To measure the earth resistance using an earth tester at the grounding electrode, and check that the equipment is connected firmly to the electrode.

Insulation resistance test

To measure the insulation resistance of the cables and conductors using an insulation tester, and check that they maintain the necessary insulation performance.

Power transmission test

To check visually the condition of the transmission and distribution lines energized by operating the generator-turbine, and verify that they are installed adequately without short circuits and grounding.

5.3.2 Operation and maintenance manuals/instructions

The Contractor shall submit operation and maintenance manuals/instructions. Assembling and disassembling methods, and maintenance period, etc, for the

following equipment and devices shall be described in the manuals/instructions.

(1) Transformers

(2) Circuit breaker

(3) Lightning arresters

(4) Fuse cutouts and fuse links

5.3.3 Documents to be provided

The Contractor shall provide the following documents:

(1) Distribution line route drawing

(2) Single line diagram – distribution line

(3) Supporting structure arrangement drawings for the distribution line, including the service wire

(4) Detailed drawings of a fuse cutout

8

(5) Detailed drawings of lightning arresters

(6) Specifications and drawings of conductors/cables

(7) Specifications and drawings of insulators and hardware (cross-arm, strap, u-bolts, bands, etc.)

(8) Test reports for all equipment/devices

(9) List of tools and spare parts

(10) Operation and maintenance manuals/instructions for all equipment/device

6 Amendment of the manual

The DOE shall review this manual annually, and amend it, if necessary, according to the surrounding circumstances in rural electrification of the country. The amended manual shall be fully authorized among the DOE and approved by Director of Energy Utilization Management Bureau of the DOE.

i

Appearance checklist for civil and metal structures (1/2)

Equipment Item Check Method Result Remarks

Weir body Appearance check Visual check with drawings

Water leakage Visual check Sliding timber

Insert condition

Bar screen Appearance check Visual check with drawings

Appearance check Visual check with drawings

Intake weir

Intake Stability of water intake

Visual check


Intake Intake body Stability of water intake

Visual check


Forebay body Checking of variation in WL in operation

Visual check

Visual check with drawings

Screen Appearance check (Pitch, Installation angle) Visual check

with drawings

Appearance check Operational check

Gate operation Visual check

Forebay

Flushing gate

Water leakage Visual check with drawings

Bank protection / Retaining wall

Bank protection / Retaining wall



Leakage from welded area

Visual check

Penstock

Vibrations in operationVisual check and palpation

Expansion pipe Leakage Visual check

Small supporting table


Fixed base Appearance check Visual check with drawings

Air pipe Appearance check Visual check with drawings

Penstock

Other Slope along penstock Visual check

ANNEX1

ii

Appearance checklist for civil and metal structures (2/2)

Equipment Item Check Method Result Remarks

Aqueduct bridge Penstock Appearance check Visual check with drawings

Powerhouse Powerhouse Appearance check Visual check with drawings


Tailrace Tailrace body Condition of water discharge (Positional relation with riverbed)

Visual check

Temporary road Appearance check Visual check with drawings

Temporary road

Other Slope along temporary road

Reconnoitering

Condition of riverbed around intake

Visual check

Others

Disposal of surplus soil

Visual check

Additional comments

i

Test item Visual inspection

Purpose

To verify the installation conditions of the equipment as well as the cable

connection.

Procedure

To inspect visually the installation conditions of the following equipment.

(1) Turbine

(2) Generator

(3) Driving system

(4) ELC panel box

(5) Dummy loads and safety fence

(6) Cable (condition of laying, connection and terminal)

(7) Circuit configuration (consistency with the single line diagram)

Precaution

・ To take note of damage of the control board, faulty wiring, and looseness of

the screws that might be caused by the transportation and installation.

Instrument

Criteria

・ All equipment is properly installed.

・ Cables are properly laid and connected.

・ Main circuit is constructed in accordance with the single line diagram.

ANNEX2

ii

Test item Earth resistance measurement

Purpose

To verify the earth resistance of the grounding electrode and connections

between the electrode and equipment

Procedure

1. Earth resistance measurement

(1) To drive the auxiliary earthing rods P and C deep into the ground, at

intervals of 5 – 10 m (straight line) from the measurement object E

(2) Battery check

(3) Earth voltage check

(4) Auxiliary earthing resistance check

(5) Earth resistance measurement

2. Earthing connection check

(1) To set the tester to “connection check”

(2) To connect the two (2) lead wires to the grounding electrode and the

grounding terminal of the following equipment respectively

・ Generator stator winding

・ Base flame

・ ELC panel box

(3) To verify the connection of the grounding cable by the circuit tester

Precaution

Instrument

・ Earth tester

・ Circuit tester

Criteria

・ Earth resistance of the grounding electrode is at a sufficiently low setting

・ The equipment’s grounding terminal is firmly connected to the grounding

electrode.

iii

Test item Insulation resistance measurement

Purpose

To verify the insulation performance of the equipment by measuring the

insulation resistance.

Procedure

To apply voltage of 500V between the measured circuit and the earth, and

record the value of the insulation resistance after 1 minute. As for a generator,

to continue the measurement for 10 minutes and derive the polarization index

(PI) from the 1-minute value and 10-minute value in order to verify the

moisture absorption of the coils. 10-minute value of insulation resistance (MΩ)

PI = 1-minute value of insulation resistance (MΩ) The measurement is conducted for the following circuit sections.

(1) Generator stator coil (including main circuit)

(2) ELC panel box

(3) Dummy loads including wiring

(4) Distribution lines

Precaution ・ Residual charge must be completely discharged by shorting to earth after the

measurement

Instrument ・ Insulation resistance tester (Digital MΩ HiTester)

Criteria

・ Circuit: Insulation resistance (MΩ)>0.2MΩ

・ Rotating machine (To meet the following conditions)

Rated voltage (V) a. Insulation resistance (MΩ)>

Rated output (kW)+1,000

Rated voltage (V)+Rated speed (min-1)/3 b. Insulation resistance (MΩ)> +0.5

Rated output (kW)+2,000 c. PI > 1.5

* The above criteria should be used as a reference because it is difficult to

estimate progress of insulation deterioration from only the value of the

insulation resistance.

iv

Test item Initial run test

Purpose

To confirm abnormal sound and vibration by rotating the turbine -generator at

low rotational speed

Procedure

Equipment conditions before testing:

(1) Inlet valve: Open

(2) Guide vane: Close

(3) MCB for the main circuit inside the ELC panel box: Open

(4) ON/OFF switch on the ELC panel box: OFF

Test procedure:

(1) To open the guide vane gradually and rotate the turbine-generator at low

rotational speed

(2) To close the guide vane immediately after the turbine-generator starts

rotating

(3) To record the operation data

Precaution

・ The guide vane must be operated carefully to avoid a rapid speed increase of

the turbine-generator

Instrument ・ Tachometer

Criteria

・ Contact between the stationary and rotary part is not observed

・ Abnormal sound and vibration are not observed in each part of the

turbine-generator

ELC panel box

ON/OFF Switch MCB

v

Test item Rated speed run test

Purpose

To confirm the existence of any abnormal sound, odor, vibration and/or

temperature rise in each part of the turbine-generator by rotating the turbine

-generator at the rated speed

Procedure






Test Procedures:

(1) Set the “Clamp on Power Hitester” to the main circuit

(2) Open the guide vane gradually and rotate the turbine-generator at the rated

speed

(3) Record the operation data

(4) Close the guide vane after the bearing temperature is saturated.

Precaution

Instrument

・ Tachometer

・ Infrared thermometer

・ Ultrasonic flow meter

・ Clamp on Power HiTester

Criteria

・ Abnormal sound, odor, vibration and temperature rise are not observed in

each part of the turbine-generator

vi

Test item Excitation characteristic test

Purpose

To measure excitation characteristics of the newly installed generator as the

initial data

Procedure






Test Procedures

(1) Check the connection of the clamp tester set to the main circuit

(2) Set another “Clamp on Power Hitester” to the excitation circuit

(3) Open the guide vane gradually to turn over the turbine-generator

(4) Increase the rotational speed to 110% of the generator rated speed by 10%

(5) Measure the terminal voltage, excitation voltage, and excitation current at

each point

(6) Close the guide vane after testing

(7) Remove the clamp tester for the excitation circuit

Precaution

Instrument

・ Tachometer



・ Clamp meter

Criteria

・ The generator generates the rated voltage at the rated rotational speed

vii

Test item Protection function test

Purpose

To verify the adjustable range for the set point of the protection function that

the ELC is equipped with and to set the operating value

Procedure





(4) ON/OFF switch on the ELC panel box: ON

Test Procedures:


(2) Open the guide vane gradually and operate the turbine-generator at the

rated speed and voltage

(3) Increase/decrease the frequency and voltage by changing the frequency set

point and verifying the adjustable range for the set values of each

protection function

・ Over voltage

・ Under voltage

・ Over speed

・ Under speed

(4) Set the operating point after verifying


Precaution

Instrument


Criteria

・ Each protection function operates at the set value

viii

Test item Dummy load governor function test

Purpose To verify that the frequency is kept constant even during the load change

operation by normal functioning of the ELC

Procedure






Test Procedures:


(3) Set another “Clamp on Power Hitester” to the dummy load circuit

(4) Connect the water resister to the secondary terminal of the MCB after

removing the distribution lines

(5) Close the MCB inside the ELC panel box

(6) Open the guide vane gradually until it is fully opened and increase the

generator output to the maximum

* At this stage, the dummy load consumes all the generator output

(7) Record the operation data at 0% of the actual load

(8) Increase the actual load by inserting electrodes of the water resistor to the

water tank

(9) Record the operation data at 20%, 40%, 60%, 80%, 100% of the actual load


(11) Open the MCB inside the ELC panel box

Precaution ・ Operate the guide vane gradually while monitoring the response of the

frequency and dummy load current in order for the ELC to function properly

Instrument

・ Tachometer




・ Water resister

Criteria

・ Dummy load consumes the generator output from which the actual load is

excluded

・ Frequency is kept constant without hunting for each value of the actual load

ix

Test item Guide vane opening vs. output test

Purpose

To verify the generator output by the guide vane opening

Procedure






Test Procedures:


(2) Open the guide vane gradually to turn over the turbine-generator

(3) Open the guide vane to 10% of its full opening capacity

(4) Record operation data at each point


Precaution

Instrument

・ Tachometer




Criteria

・ To understand the relationship between the guide vane opening and the

generator output

x

Test item Load rejection test

Purpose To verify that the dummy load consumes all the generator output after actual load rejection by normal functioning of the ELC and that the turbine-generator settles at the next equilibrium.

Procedure

Equipment conditions before testing: (1) Inlet valve: Open (2) Guide vane: Close (3) MCB for the main circuit inside the ELC panel box: Open (4) ON/OFF switch on the ELC panel box: ON Test Procedures: (1) Check the connection of the clamp meters set to the main circuit and

dummy load circuit (2) Check the connection of the water resister (3) Set the “Power Meter” to the main circuit to record the transient response

after load rejection (4) Close the MCB inside the ELC panel box (5) Open the guide vane gradually to increase the generator output to 25% of

the maximum * At this stage, the dummy load consumes all the generator output

(6) Increase the actual load to the same as the generator output by inserting electrodes of the water resistor to a water tank * At this stage, the current to the dummy load current becomes zero

(7) Record the operation data before load rejection. (8) Open the MCB inside the ELC panel box manually (9) Observe the transient state of the turbine-generator (10) Record the operation data after load rejection (11) Close the guide vane (12) Repeat the above procedures of (4) – (11) for 50%, 75%, 100% of the

maximum (13) Open the MCB inside the ELC panel box

Precaution ・ Close the guide vane immediately after a rapid increase of rotational speed

occurs subsequent to the opening of the MCB

Instrument

・ Tachometer




・ Water resister

・ Power Meter

Criteria

・ After actual load rejection, the dummy load consumes all the generator

output and the turbine-generator safely settles at the next equilibrium

・ Rotational speed does not exceed the run-away speed

・ Water pressure does not exceed the tolerance of the penstock pressure

・ Abnormal states are not observed in each part of the turbine-generator

xi

Test item Parallel-in run test

Purpose

To energize the newly installed distribution lines by connecting to the turbine-generator and verifying the installation conditions

Procedure






Test Procedures:

(1) Check the connection of the clamp tester set to the main circuit and dummy

load circuit

(2) Connect the disconnected distribution lines to the secondary terminal of the

MCB after removing the water resister


(4) Open the guide vane gradually to its full opening capacity

(5) Monitor the operating conditions of the equipment


Precaution

Instrument

Criteria

・ Abnormal conditions are not observed during operation

xii

Test item Load run test

Purpose

To verify that the turbine-generator can operate normally at the rated conditions

for a long period of time

Procedure






Test Procedures:

(1) Check the connection of the clamp tester set to the main circuit and dummy

load circuit


(3) Open the guide vane gradually to its full opening capacity

(4) Monitor the operating conditions of the equipment and record the data


Precaution

Instrument

・ Tachometer




Criteria

・ Abnormal sound, odor, vibration and temperature rise are not observed

during operation

xiii

Test item Overnight operation data collection

Purpose

To verify the equipment conditions by recording the operation data overnight

which shows the response to actual load fluctuations

Procedure

To acquire the actual load operation data overnight by setting the “Power

Meter” and the AC voltage logger at the power plant and households

respectively

Precaution

Instrument

・ Power Meter with Clamp

・ AC Voltage Logger

Criteria

・ Frequency is kept constant during actual load operation

Department of Energy

Energy Complex Merritt Road, Fort Bonifacio, Taguig City, Metro Manila

TEL: 479-2900 FAX: 840-1817