Statut de transmission: Statut retour d'approbation:

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A Nom JI. Rodriguez B. Bieli J. Mignan 11.11.13 First Issue GFE

Rev. Etabli par Vérifié par Approuvé par Date Modifications Statut

Owner:

REPUBLIC OF ZIMBABWE
ZIMBABWE POWER COMPANY

KARIBA SOUTH HEPP

Modernization of DC Distribution Panels

Contractor:

ALSTOM POWER HYDRO

Consultant:

Document Title:

30BTM10, 30BTB10, 30BRB10, 30BUB

Commisioning Protocols
Echelle Issu par: Sous-contractant:
1 : 50 ALSTOM Hydro (Switzerland) Ltd
Dept. HGEEM
Zentralstrasse 40
CH-5242 Birr - Switzerland

ALSTOM © 2007. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Numéro général du Document: Numéro interne du Document: REV P/P. fin Tot. P

A H S - K R S - 3 0 - B T M- P E - 0 0 - 0 0 1 A
 TABLE OF CONTENTS
1 PURPOSE OF TESTS ...........................................................................................................................................................4

2 REFERENCE DOCUMENT ................................................................................................................................................4

3 SCOPE ....................................................................................................................................................................................4

4 TERMINOLOGY ..................................................................................................................................................................4

5 EQUIPMENT UNDER TEST...............................................................................................................................................4

6 EQUIPMENT REQUIRED ..................................................................................................................................................4

7 PRELIMINARY CHECKS...................................................................................................................................................4

8 ELECTRICAL CHECKS .....................................................................................................................................................5

8.1 CHECK ELECTRICALLY THE GROUND CONTINUITY OF ALL METALLIC PARTS WITHIN THE CHARGER
CUBICLE.....................................................................................................................................................................................5
8.2 INSULATION RESISTANCE TEST .............................................................................................................................5
8.3 RECTIFIER ENERGIZING............................................................................................................................................5
8.4 AUTOMATIC SYSTEM TEST ......................................................................................................................................6
8.5 CURRENT LIMITING ...................................................................................................................................................6
8.6 RECTIFIER OUTPUT UNDER/OVERVOLTAGE PROTECTION .............................................................................7
8.7 CHECK OF ALARMS, INDICATIONS AND MEASUREMENTS ..............................................................................7
9 PUTTING IN OPERATION.................................................................................................................................................7

10 RECORDING OF INSPECTION AND TEST DATA ...................................................................................................7

Essayé par: Approuvé par : Date :

Tested by : Witnessed by : Date :
AHSMRW00LAA-PE002 Ver A - DC SYSTEM BATTERY CHARGER.doc 3/15
1 PURPOSE OF TESTS

The rectifier provides from a three-phase AC source power to charge the battery with which
it is associated and supply the load.

The tests are intended to check that the rectifier has the characteristics required for correct
operation of the system in which it is implemented.

2 REFERENCE DOCUMENT

AHSMRW00LAA-SU100 220VDC SINGLE LINE DIAGRAM

……………Equipment drawing

1060325/1050328 GUTOR OPERATING INSTRUCTIONS

3 SCOPE

All working sites.

4 TERMINOLOGY

Not applicable.

5 EQUIPMENT UNDER TEST

Chargers located in 20LAA00xRD, 70LAA00xRD.

6 EQUIPMENT REQUIRED

- Multimeter

- Megohmmeter

- Milliohmmeter for continuity check

- Stop watch

7 PRELIMINARY CHECKS

- Check the rectifier cabinet grounding

- Check :

Essayé par: Approuvé par : Date :

Tested by : Witnessed by : Date :
AHSMRW00LAA-PE002 Ver A - DC SYSTEM BATTERY CHARGER.doc 4/15
 . for loose connections

. that all printed circuit boards are correctly plugged-in

. connection conformity with the reference drawings

. that the fuses are fitted, that their ratings and types conform to the manufacturer’s
manual, and that their microswitches are set

. that the mains voltage conforms to the power supply specifications given on the name
plate

. that the ventilation grills are not obstructed

8 ELECTRICAL CHECKS

8.1 CHECK ELECTRICALLY THE GROUND CONTINUITY OF ALL METALLIC

PARTS WITHIN THE CHARGER CUBICLE

- Test to be performed with milliohmmeter type MEGGER BT 51 or a similar one capable to

generate a current of 2 amps with a voltage ≤ 6 V

- The metallic parts to be checked are; all accessible parts which does not require shut down
during normal operation or maintenance of the equipment such :

- the doors
- the handles
- key locks
- chassis
- The checks are satisfactory if the resistance value measured is < 0,4 ohm.

8.2 INSULATION RESISTANCE TEST

Check:

- insulation resistance to ground at 500 V DC of

. AC input terminals

. DC output terminals

The insulation resistance shall be higher than 10Mohms.

8.3 RECTIFIER ENERGIZING

This initial energizing shall be performed only if the checks described in paragraphs 8.1 and
8.2 have been successfully completed:

- disconnect the battery and load if the charger is set with a stand-by load resistance

- set the rectifier switch to (OFF)

Essayé par: Approuvé par : Date :
Tested by : Witnessed by : Date :
AHSMRW00LAA-PE002 Ver A - DC SYSTEM BATTERY CHARGER.doc 5/15
 - supply the rectifier and check that the voltage value and phase sequence of the AC source
in conformity with the manufacturer’s instructions

- set the rectifier on/off switch to (ON)

- check DC+/- output terminals, filtering capacitors being precharged

- check the fan (s) for correct operation

- stop the rectifier

- interconnect battery and rectifier

Depending on the rectifier technology and type, check and if necessary adjust the following
voltages as instructed in the manufacturer’s manual :

- floating mode
- equalizing mode

8.4 AUTOMATIC SYSTEM TEST

If a battery has to supply the load for a time longer than the specified (programmable) time
(e.g. during a main power failure across the rectifier), it has to be recharged.

The rectifier charges the battery at equalizing charge for a selectable time period before
return to floating charge when the main power voltage is restored.

Check the automatic system operation and adjust as instructed in the manufacturer’s
manual and technical specifications :

- the AC supply failure time period at the end of which the cycle is to be started

- the equalization time before return to floating charging mode

8.5 CURRENT LIMITING

During normal operation, the charger supplies only the average current necessary to the
load while the battery caters for peak demands.

Therefore, this equipment is protected against overloads.

Current limiting is generally factory-set. Check the set limits by applying the charger output
to a resistor.

Some systems, especially rectifiers connected to lead-acid batteries include battery current
limiting.

If the rectifier includes battery current limiting, check the current limit as above.

Essayé par: Approuvé par : Date :

Tested by : Witnessed by : Date :
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8.6 RECTIFIER OUTPUT UNDER/OVERVOLTAGE PROTECTION

Check the settings of the under/overvoltage protections as instructed in the manufacturer’s

manual.

8.7 CHECK OF ALARMS, INDICATIONS AND MEASUREMENTS

Check the rectifier indication circuits for proper operation.

As a rule, at least the following indications are provided on the rectifier front display:

. rectifier on/off
. operating modes
. rectifier current limiting
. rectifier faults
. over/under voltages
. AC voltmeter
. DC voltmeter
. DC ammeter
- Check on the rectifier output terminals that alarm, indication and measurement returns are
correct

9 PUTTING IN OPERATION

- Connect the rectifier to the battery and load and check the polarities

10 RECORDING OF INSPECTION AND TEST DATA

- The results of the checks and measurements made during the field tests shall be recorded
on the following test forms

Essayé par: Approuvé par : Date :

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 REVISION
SUMMARY
F° A B C F

1 LIST OF REQUIRED TEST EQUIPMENT 2 X

2 RECTIFIER SPECIFICATIONS 3 X

3 PRELIMINARY CHECKS 4 X

4 ELECTRICAL TESTS 4 X

4.1 - Metal part electrical continuity 4 X

4.2 - Insulation resistance 5 X

4.3 - Checks before energising 6 X

4.4 - Energising checks 6 X

4.5 - Protection devices & alarm checks 7 X

4.6 - Alarm indications 7 X

4.7 - Automatic control test 8 X

4.8 - Final settings 8 X

4.9 - Comments 8 X

Essayé par: Approuvé par : Date :

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1 - LIST OF REQUIRED TEST EQUIPMENT Tests corresponding to paragraph

Designation Reference Ind.

Essayé par: Approuvé par : Date :

Tested by : Witnessed by : Date :
AHSMRW00LAA-PE002 Ver A - DC SYSTEM BATTERY CHARGER.doc 9/15
2 RECTIFIER SPECIFICATIONS (CHARACTERISTICS)

1. BOARD NAME :………………………………………………………..

2. MANUFACTURER :………………………………………………………..

3. TYPE :………………………………………………………..

4. SERIAL N° :………………………………………………………..

5. REF. DWG :………………………………………………………..

6. RATED POWER :……………………………………………………KVA

7. AC SUPPLY :………V :……………H2 :………………………….

8. RATED OUTPUT VOLTAGE :………U :……………...…..………..……..………V

9. AC RATED CURRENT :………I :……………...…..……………...…………A

10. DC RATED CURRENT :………I :……………...…..……………...…………A

11. HIGH VOLTAGE DETECTION :………U :……………...…..…….…….…...………V

RE-STARTING :………U :……………...…..……………....….……V

12. LOW VOLTAGE DETECTION :………U :……………...…..…….…….…...………V

RE-STARTING :………U :……………...…..…….…….…...………V

Essayé par: Approuvé par : Date :

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 DESCRIPTION
TEST
3 PRELIMINARY CHECKS RESULTS

. Cabinet grounding

. Connections tight

. Printed circuit boards

. Plugged-in, connection

. Fuses

. Rating

. Type

. Microswitch set

. AC voltage

. Ventilation grills

4 ELECTRICAL TESTS

4.1 METAL PART ELECTRICAL CONTINUITY

. Number of points tested

. Maximum resistance reading

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4.2 INSULATION RESISTANCE

- ph1/Gnd

- ph2/Gnd

- ph3/Gnd

- +/Gnd

- -/Gnd

- ph1/+

- ph2/+

- ph3/+

- ph1/-

- ph/2-

- ph3/-

Transformer : Pri/Gnd

Pri/Sec

Sec/Gnd

Essayé par: Approuvé par : Date :

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4.3 CHECKS BEFORE ENERGISING

- Battery charger off position

- Check battery polarities removed

. check connection +/-

. check P.C. boards are plugged in

4.4 ENERGISING CHECKS

- A/C voltage supply :

. phase sequence checks

. put charger "ON" to allow

precharging of the filtring
capacitors

. check DC +/- at output

terminals and voltmeter
indicator

. put charger "OFF"

. close battery protection

fuses the check battery
voltage in the charger board
indicator

. put charger "ON" in manual

mode then

. increase the voltage to

required charging mode

. check floating mode

. equalizing mode

Essayé par: Approuvé par : Date :

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4.5 PROTECTION DEVICES & ALARMS CHECKS

- Thermaloverload trippings

- DC fuse rating & types

- Battery fuses

- Charger lowlimit disconnecting/reconnecting

- Charger high limit disconnecting/reconnecting

4.6 ALARM INDICATIONS

- Charger switch ON/OFF

- Charger floating mode

- Charger boost charge mode

- Charging equalizing mode

- Charger test mode

- Charger faults

Essayé par: Approuvé par : Date :

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4.7 AUTOMATIC CONTROL TEST

- Timer checking

- Equalizing/floating charge over clock adjustment

- Current limiting :

- Load sharing (total loads = …A)

during parallel with

- Load regulation

- Output voltage ripple

4.8 FINAL SETTINGS

- Floating mode voltage

- Boost charge mode

voltage

- Equalizing mode

- Current limiting

- Clock adjustment

4.9 COMMENTS

Essayé par: Approuvé par : Date :

Tested by : Witnessed by : Date :
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