STATION: NTPC

SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 1 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

LIST OF CONTENTS
1.

PLANT DETAILS

2.

TESTING OBJECTIVES

3.

TESTING PROPOSALS

4.

SERVICES REQUIRED

5.

SAFETY PRECAUTIONS

6.

EMERGENCY PROCEDURES

7.

STATE OF THE PLANT

8.

COMMISSIONING PROCEDURE

9.

COMPLETION CRITERIA

10. APPENDICES

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 2 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

1. PLANT DETAILS

The Generator transformer steps up the generation voltge of 21 KV to the

nominal grid system voltage of 400 KV. It is connected on the L.V. side to
the generator output terminals through 21 KV isolated phase continuous type
bus ducts. The transformer H.V. terminals are connected to the generator
bay in the switchyard through over head connectors string from the T.G. bay
to generator bay gantry.

THIS SYSTEM CONSISTS OF 3 Nos (ONE FOR EACH PHASE) OF

120/160/200 MVA, SINGLE PHASE,420/1.732/21 KV,824.8/9523.8 A, 50
HZ,YNd11(% of Impedance 13.5%+5% at Normal tap,12-15 % at
Max.,Min. taps,Temp rise: Oil 350C,Winding 400C) TRANSFORMERS,
SURGE PROTECTION AND V.T. CUBICLE, UNIT TRANSFORMERSUT A & B AND ISOLATED PHASE BUSDUCTS

Ring type current transformers are mounted in the bus ducts for metering
and protection of equipment.

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 3 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

OTHER TRANSFORMER PARAMETERS:

MAKE
Insulation Level

: BHEL,BHOPAL
HV : SI 1180 LI 1425-AC 38 CHOPPED LI-1570
LV : LI 125 AC 50

Weights (Kgs)
Core and winding

: 126600

Tank & Fittings(Including

Turrets and Rollers)

: 23515

Bushings

: 2725

Marshalling Box & Wiring

: 820

Coolers

: 15600

Conservator with support

& pipe work

: 1540

oil

: 31900

Total weight including oil

: 202700

Shipping weight(Gas filled)

: 143600

Untanking weight

: 13000

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 4 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

Oil quantity (litres)

Oil in transformer tank,turret &
Bushings

: 33310

Oil in cooler,conservator & Pipe work

: 3340

Total oil quantity

: 36650

Cooling equipment:
No. of compact OFAF coolers : 6- 20 %
No. of fans per cooler

:2

Air delivery per fan

: 24000 cum/hour

No. of oil pump per cooler

:1

Flow rate of each pump

: 900 lpm

21 KV IP BUS DUCT DETAILS

MAKE

: BHEL, JHANSI

MW Rating

: 500

KV Rating

: 24

Current Rating

Main

: 19000 Amps

Delta

: 11000 Amps

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 5 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

Tap off 3000 Amps

Dimensions :
LOCATION

BUSDUCT ENCLOSURE

CONDUCTOR

AL.

(THICKNESS X OUTER DIA.) ALLOY BOX

MAIN RUN
DELTA
TAP OFF

8 mm X 1500 mm
8 mm X 1000 mm
8 mm X 780 mm

(THICKNESS X O/D)
16 mm X 800 mm
16 mm X 426 mm
11.84 mm X 203.2 mm
(65.2 mm Length)

2. TESTING OBJECTIVE

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 6 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

TO TEST THE STABILITY,CHARACTERISTICS OF TRANSFORMER &

BUSDUCT.

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 7 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

3.TESTING PROPOSALS:

The bus duct would be checked and tested as per its standard checklist and test
procedure. High voltage pressure tests would be carried out on bus ducts to prove their
withstand capability.

The Generator transformer would be checked and tested as per its standard checklist and
test procedure. This will include tests on transformer and its cooling system.

Protection tests would be covered in testing schedule for generator protection.

Lightning arrestors and surge capacitors on G.T. H.V. terminals would be tested as per
their standard checklist.

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 8 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

4.SERVICES REQUIRED
5 KV INSULATION TESTER,
3 PHASE 415 AC 50 Hz Supply from relevant MCC,
HT POT AC/DC SOURCE
MEASUREMENT KIT (MULTI METER, TONG TESTER ETC)

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 9 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

5.0

SAFETY PRECAUTIONS

5.1

The engineer incharge of the testing team will inform each member of the test as
to exact nature and extent of his contribution and responsibilities towards tests
carried out.

5.2

Only nominated persons will take part in the tests. All others will remain clear of
the area.

5.3

All persons must acquaint themselves with use and location of fire extinguisher
and first aid posts.

5.4

Each test will be carried out under the control of test team leader.

5.5

A Strict and safe method of applying test leads shall be practiced. Bare wires
should not be used instead proper plugs must be used. All test connection shall be
tight and rechecked.

5.6

A record of any alterations made during the tests, such as shorts or disconnections
shall be made and annexed to relevant test procedure.

5.7

Each test will be carefully planned so that there is no mechanical or electrical

damage to the equipment under test.

5.8

The test area will be kept clear, clearly defined and cardoned off.

5.9

When high voltage tests are being made danger/warning notices shall be fixed at
relevant points to ensure safety and a sanction for test taken. All isolating points
to be manned.

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 10 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

6.

EMERGENCY PROCEDURE

6.1

POWER SUPPLY SHOULD BE ISOLATED from source and load side

6.2

Shock treatment chart & first aid box will be made available.

6.3

Emergency telephone numbers for hospital and fire services shall be prominently
displayed.

6.4

A telephone will be available nearby.

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 11 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

7.

STATE OF THE PLANT

7.1

Bus duct erection completed and flexible connections to the following are
removed.

Generator terminal bushing.

Surge protection and V.T. cubicle.

Unit Transformer A and B

Generator Transformer L.V. terminal.

7.2

Clearance from erection department for carrying out tests as bus duct obtained.

7.3

Generator Transformer erection complete and oil filtration completed.

7.4

Clearance from erection department for carrying out tests on GT obtained.

7.5

400 KV Switchyard is live.

7.6

Generator Transformer isolator 89-GT1 open.

7.7

Earth switches 7-89 AE, 8-89 AE & 9-89 AE closed in generator bay.

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 12 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

8. COMMISSIONING PROCEDURE:
PRE COMMISSIONING CHECKS:
8.1

Check and ensure no temporary earthing or debris any

Transformer No.1/2.

8.2

Check the generator transformer for the following

where in the generator

a.

Adequate oil level in conservator.

b.

Breather colour is blue.

c.

Explosion vent in tact.

d.

Oil temperature indicator in position and shows correct reading.

e.

WTI local and remote (in UCB) are in position.

f.

H.V. bushing free from any damage.

g.

No gas accumulated in bucholz relay.

8.3

Check lightning arrestor on 400 KV side of GT for correct earthing.

8.4

Check surge protection cubicle on 21 KV side bus duct.

8.5

Ensure that the busduct is isolated at the points required for carrying out GT
& Busducts individually.

8.6

Check that generator VT and surge protection cubicle are disconnected from
bus duct.

8.7

Check that all the VT fuses are kept out in VT marshalling box.

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 13 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

8.8

Check and ensure the following generator bay isolators

status as mentioned below:

and earth switches

Horizontal Isolator 8-89A,8-89B open and locked

in F position.

Pantograph Isolator 9-89,9-89A Open and locked

in

F position.

7-89,7-89A open and locked

in F position.
Earth switches :

9-89E,9-89AE open and locked in O position.

7-89E,7-89AE open and locked in O position.
8-89AE,8-89BE Open and locked in O position.
(For GT2 replace 9 by 14,7 by 13 and 8 is inapplicable)
a.

Check air blast circuit breaker is in OFF and Supplies(3 phase drive
supplies,DC control supply) are isolated.

8.9

BUSHING CTs, HV & LV LINE PTs & CTs ARE TO BE

TESTED AT FIRST AS FOLLOWS.

8.9.1

Carry out TANDELTA test for Bushings

8.9.2

Carry out Primary current injection test for CTs

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 14 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

8.9.3

Carry out voltage injection test for PTs

8.10

Check and test the following equipment as per their standard checklist
and test procedure.
Generator 21 KV bus duct
Generator Transformer

8.11

THE FOLLOWING TESTS MUST BE CARRIED OUT IN

TRANSFORMERS ARE
1. TRANSFORMER OIL TEST (BDV)
2. INSULATION RESISTANCE MEASUREMENT
3. WINDING RESISTANCE MEASUREMENT
4. MAGNETIC CORE BALANCE TEST & MAGNITITATION CURRENT TEST
5. VECTOR GROUP TEST
6. STABILITY TEST
7. OPEN & SHORT CIRCUIT TEST (IF POSSIBLE)

8.12

THE FOLLOWING TESTS MUST BE CARRIED OUT FOR BUS DUCT

1. INSULATION RESISTANCE MEASUREMENT
2. BUSBAR RESISTANCE MEASUREMENT
3. LEAKAGE CURRENT/HI POT TEST ( 22 TIMES THE RATED
AC VOLTAGE IN CASE OF DC;2 TIMES IN CASE OF AC)

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 15 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

8.13

THE FOLLOWING PROTECTIONS ARE NORMALLY INCLUDED FROM

LOCAL FOR POWER TRANSFORMER PROTECTION.

PARAMETER
TRANSFORMER OIL TEMP
TRANSFORMER WDG TEMP
FANS ON
PUMP ON

ALARM
TRIP
85 DEG C
90 DEG C
95 DEG C
105 DEG C
60 DEG C OF WDG TEMP
75 DEG C OF WDG TEMP

8.14

BUCHOLTZ TRIP/ALARM TO BE BROUGHT TO CONTROL ROOM &

CHECKED.

8.15

PRESSURE RELIEF VALVE TRIP CONTACT OF TRANSFORMER TO

BE HOOKED UP AND CHECKED .

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 16 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

9. COMPLETION CRETERIA
Check lists and test procedure for generator transformer and bus ducts completed.
Test record for cooling system of generator transformer are noted.
TRANSFORMER & BUSDUCT ARE READY FOR CHARGING.

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 17 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

10. APPENDICES:
DRAWINGS: SLD OF ELECTRICAL SYSTEM AUX POWER DISTRIBUTION
TRANSFORMER YARD LAY OUT (PE-DG-186-100-0501/REV 05)
BUSDUCT CROSS SECTION (Drg. No.45415155059/JHANSI)
LOG SHEETS : I) IR VALUES,WR VALUES OF GENERATOR
TRANSFORMER,UNIT TRANSFORMER
II)

TEST REPORT OF GENERATOR BUS DUCT

III)

UNDERVOLTAGE,OVERCURRENT& EARTHFAULT
SETTINGS KEPT 2 DIFF IF APPLICABLE

STATION: NTPC
SIMHADRI

BHEL REF NO : PS-DC-186-500-111

NTPC REF NO: SIM/1/TS/ 1 / 111

SHEET 18 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : GENERATOR TRANSFORMER & BUSDUCT

I) Insulation

Resistance values of generator & Unit transformer, bus duct.

Megger details :
Rating 5KV

Sl.NO.

Make

Calibration Due on
SlNo

Terminals

1.
2.
3.
4.
5.
6.

RE
YE
BE
RY
YB
BR

Generator Transformer Unit transformer

HV
LV SIDE
HV SIDE LV
SIDE
SIDE

--------------

Bus duct

-------------

II) Winding(Busbar) resistances values of generator, Unit

transformer, Bus duct.

Kelvins Double bridge/Micro Ohm meter details :

Sl.NO.

Make

Calibration Due on

SlNo

Terminals

1.

RY

2.

YB

3.

BR

Generator
Transformer
HV
LV
SIDE
SIDE

Unit transformer
HV
SIDE

LV
SIDE

Bus duct (PH

PH)