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Maintenance Jobs in DAVR Panel (A to D) Prior to Functional Testing:

A. Cleaning & checking of Electronic Circuits:

• Rack out one by one all cards from swing frame. While racking out
the cards ensure card location identification is marked (AB13, AB25
etc) on the card front plate or on the connector side of the card.
This will ensure that the same card is inserted at the exact slot in
the rack from where it is removed.
• Remove dust deposits of complete DAVR panel by blowing with the
help of clean & dry air.
• Clean each card using restricted compressed dry air. Clean the
connectors with proper electronic cleaner.
• Look for dry solder on all cards.
• Switch/jumper settings of every modules to be checked which
should be as per latest commissioning report of that particular
machine.
• Power, CT/PT Sensing, field current sensing and pulse connection
tightness to be checked.
• Look for pitting of breaker pole contacts by removing the arc
chutes.
• Field breaker contact adjustment to be done if required.
• Manual operation (Close/Trip) of the Field breaker to be done and
jamming of tripping circuit if any to be checked.
• Check the values of Discharge resistor R2 (5.5ohm, 30A, 10kW) &
Bleeder resistance R13 (150ohm, 500W).
• Resistance between Gate – Cathode of each thyristor is to be
checked, which should be in the range of 17ohms to 30ohms.
• Restore the Cards back to their respective locations.

B. Checking of LPTs:
• Check the contacts of draw out type PTs.
• Proper earthing of PT neutral is to be ensured.
• Tightness of HT fuse Clips to be checked.
• PT secondary should not have limit switches in its circuit. Discard
such limit switches if present.
• PT secondary circuit should have Fuses not MCBs in its circuit for
protection. Replace MCBs by Proper size fuses 2A/4A in case MCB
is present, since MCBs have higher contact drop.
• Tightness of all terminal links is to be checked at TB’s in PT
junction box.

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C. Checking of Power Supply MCBs:

• Switch ON Station 110V DC supply (F56).
• Switch ON MCB F51 – power supply for Channel-1. Check the
various levels of voltages (i.e. +24Vdc, +/-15Vdc, +5Vdc) with
respect to 0V on the power supply module at AA37 rack.
• Switch ON MCB F52 – power supply for Channel-2. Check the
various levels of voltages (i.e. +24Vdc, +/-15Vdc, +5Vdc) with
respect to 0V on the power supply module at AA01 rack.
• Switch ON MCB F53 – power supply for Control & Signal. Check
the various levels of voltages (i.e. +24Vdc, +/-15Vdc, +5Vdc) with
respect to 0V on the power supply module at AB01 rack.
• Switch ON MCB F79 – power supply of DC-DC converter. Keep the
MCB F80 in OFF condition. Check the availability of 48Vdc with
respect to 0V on the power supply module at AG06 rack.
• Switch ON MCB F80 – power supply of DC-DC converter. Keep the
MCB F79 in OFF condition. Check the availability of 48Vdc with
respect to 0V on the power supply module at AG16. Also
availability of 48V power supply to TB’s of Digital I/O modules A01,
A02, A03, A51, A52, A53 etc.

D. Checking of parameter Settings:

• Auto channel CPU parameters / K-Flags are to be re-checked. The
settings should be as per latest commissioning report.
• PLC parameters are to be re-checked. The settings should be as
per latest commissioning report.
• Monitoring parameters / K-Flags are to be re-checked. The settings
should be as per latest commissioning report.

E. Functional Testing of DAVR at generator standstill (E to I):

Before proceeding with any functional testing of DAVR during Standstill
condition of the Generator.
a) Isolate cable connection from AVR output TBR1&2 to Exciter field.
b) Isolate AVR P.T Sensing connection (TBR 17,18&19) by opening
links/external P.T.connections to prevent back charging of P.T.
c) Remove pulse cable connectors X3 & X4 from Auto/Manual
thyristor pulse boards.
d) Logic Forcing:
• Force the logic “Turbine speed >90%” by shorting terminals
TBA01/25 & 26, required for excitation control. This is required only
if turbine is not running at its rated speed.
• Force the logic “Generator Breaker Open” by shorting terminals
TBA01/23 & 24, required for excitation control. This is required only
if Generator breaker is completely racked out and plug kept
removed.

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• If Unit Lockout Relay is not Reset or taken out for maintenance

during DAVR test, force the logic “ULR Reset” by shorting terminals
TBA02/1 & 2, required for Field breaker control.

F. Checking the Logic Sequence of Operation:

• DAVR Logic as priority are: 1st priority – Trip, Automatic channel
changeover; 2nd Priority – Commands (Raise / Lower etc. in
multiples of 20mSec); 3rd Priority – Indications (position of channel
– Auto / Manual limiters in operations etc.)
• Keep the DAVR control in LOCAL.
• Perform all types of operation like Field breaker ON/OFF, Excitation
ON/OFF, Ch1-Ch2 changeover, Reference Raise/Lower etc as per
relevant scheme logic from the Operating & Signaling board (UNS
2661).
• Change the DAVR control to REMOTE.
• Perform all types of operation like Field breaker ON/OFF, Excitation
ON/OFF, Ch1-Ch2 changeover, Reference Raise/Lower etc as per
relevant scheme logic from the Control Desk as well as GRP panel
relay actuation.(P.T. fuse failure etc.)

G. Functional Testing of PID by Injection of Signals:

• PMG supply signal (open Link L-1, L-2 & L-3), CT signal ((open
Link 21-R, 23-R, 25-R) etc prior to injection of signals. Also open
the link S452 on UNC4660 cards (for both U01 & U02) prior to
connecting variable 3Vdc with the use of battery or DC source
having variable potentiometer.
• Inject 3phase 110Vac signal (Ug) with the help of external injection
kit at Terminals 17-R, 18-R, 19-R & 20-R (This signal should not go
towards LPTs).
• Put the links L-4, L-5 & L-6 in place and switch on Test supply MCB
F74.
• Inject 3phase Secondary Current signal (Ign) corresponding to
rated generator CT secondary current with the help of external
injection kit at Terminals 21-R, 23-R, 25-R & 22-R (This signal
should not go towards CTs).
• Connect 3Vdc variable source between terminals X-261 (+ve) and
X-265 (-ve) of U01 & U02 in each unit. Don’t inject more than 10V
DC as it may result in failure of A/D converter modules UN0610,
UN0611.
• Measure the signals developed by various points as per the signal
flow diagram Fig.-C on following modules:
1. On UNC4660 modules (U1):- Measure AC voltage
between sockets X-250 & X251, X-250 & X252, X-251
& X252. The value should be 22Vac (Ug).(with 110V
AC signal between U01 TB1,2,3)

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2. On UNC4660 modules (both U1 & U2): - Measure AC

voltage between terminals X-253 & X254, X-253 &
X255, X-254 & X255. The value should be 22Vac
(Usync).
3. On UNC4660 modules (U1):- Measure AC voltage
between terminals X-257 & X258, X-257 & X259, X-
258 & X259. The value should be 3Vac (Ig).
4. On UNC4660 modules (both U1 & U2):- Measure DC
voltage between terminals X-261 & X265. The value
should be set to less than 3Vdc as per injected
voltage (If).
5. On UN0663 modules: - Measure AC voltage between
terminals R & S, R & T, S & T. The value should be
22Vac (Usync).(AA29 & AA65)
6. On UN0663 modules: - Measure DC voltage between
terminals If & 0V. The value should be as per injected
If signal (less than 3VDC).
7. On UN0661 module: - Measure AC voltage between
terminals UR, US, UT w.r.t. 0V. The value should be
4.37Vac (Ug). Also measure Ug w.r.t 0V which should
read 7Vdc. The DAVR KV meter should also read
11KV. If not then adjust UR, US & UT pots to keep Ug
at 7Vdc.Micro Terminal reads UG = 100%.
8. On UN0661 module: - Measure AC voltage between
terminals IR & IS, IR & IT, IS & IT. The value should be
5Vac (Ig). Also measure Ig w.r.t 0V, which should
read 7Vdc. Micro Terminal reads IG = 100%.
9. On UN0661 module: - Measure If w.r.t 0V, which
should read 3Vdc.(as per injected DC signal) Micro
Terminal reads 100%.
10. On Micro Terminal: - For measured values of
Ug=7Vdc, Ig=7Vdc & If=3Vdc on UN0661 module, the
UG act, Ig, If1& If2 should read 100%. If not then the
UN0610 (A/D conversion module) if faulty.
11. On Micro Terminal: - By varying phase angle between
Ug & Ig injected with the help of injection kit,
corresponding Cos(phi), MVAR (Q), MW (P),
Icos(phi), Isin(phi), load angle (delta) etc are to be
read. These values should be as per calculated
values corresponding injected signals.
12. Check for variation of UC for both channels by
increase/decrease of Ch1/Ch2 reference value. Also
for fixed reference value alter Ug/If signal for Ch1/Ch2
respectively and ensure variation in UC of Ch1/Ch2 is
happening.

Prepared by: A K MALIK, IOCL HALDIA REFINERY; Checked by: P K DAS, BHEL-EDN, BANGALORE
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13. Check for proper functioning of Automatic follow up

circuit.
14. Check one by one all limiters by reducing the set limit
values & observe variation of control voltage UC in
Auto channel before & after the limiter comes into
operation.

• Remove the external signals injected (Ug, Ign & If). Put back the
link S-452 in place.

H. Checking of Firing Pulses:

• Switch on the Field Breaker & Excitation ON with AVR in
Channel-1 (AUTO).
• With the help of CRO, view the waveform of input/output pulses
for every phase of thyristor by connecting the probe one by one
or two at a time to its corresponding signal available on UN0809
module of Channel-AG01. The waveforms should be as shown
in Fig. –C. Also check the non availability of output pulses in
UN0809 module AG03 of Channel-II, which is not in operation,
and availability of input pulses for channel in AG03.(input pulses
at r+,t-,s+ r-,t+,s- outpulses R+,T-,S+,R- T+,S-)
• Repeat the above procedure after switching over the operation
to Channel-II.(Manual input/output pulses will be available but
input pulses will be available for Auto channel but Auto channel
output pulses will be blocked).

I. Light load Test of DAVR:

a) Set switch S865 to Pos1 in UN0663 modules (AA29 & AA65)
(Raise/Lower of Excitation is possible from modules front plate
only)
b) Set Switch S850 to Pos’0’ (10degrees Rectifier Limit)& Switch
S851 to Pos.F (170 degrees, Inverter limit) in UN0663 modules
(AA29 & AA65).
c) Connect back pulse cable connectors X3 & X4 at Auto/Manual
pulse boards.
• Connect the External variable resistance (RFLD) of rating 100-
ohms, 10Amps across the DAVR output at the terminal 1-R &
2R along with a DC ammeter after disconnecting the outgoing
cable to main exciter field.
• Prepare the test setup as per fig.-A.
• Set RFLD at its maximum value(100 ohms).
• Switch ON exciter Fld Breaker & Excitation ON.
• Use RAISE Push button on front plate of module (AA29/AA65)
to increase the excitation till MAX.LED lights up in module front

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plate. Measure control voltage Uc at module from plate. It will be

around +9.8 to +10VDC
• Gradually decrease the RFLD so that there is flow of around say
4.18Amps (value of no load field current at GTG-1 of Haldia
Refinery). In CRO observe all six pairs of devices are
conducting equally. Refer Fig.E
• Note down the values of Vdc, Uc (control voltage on UN0663
card) .The max output DC voltage VDC will be around 1.35 x VAC
when Uc is at max.positive DC voltage (ie +9.8 to +10VDC)
• Then reduce the reference using LOWER push button on
modules front plate to say 95%.
• Again adjust the RFLD so that the same current 4.18Amps flows
through it.
• Note down the values of Vdc, Uc (control voltage on UN0663
card).
• Repeat the above procedure of lowering Uc. Uc reaches nearly
–10VDC.Each time adjust RFLD to maintain 4.18ADC before
noting the readings.
• Set RFLD to Max.(ie 100ohms)before repeating the procedure
for 2nd channel, OR else thyristors will be damaged.
• Switch off the exciter and normalize the DAVR.
• Plot the graph using the values as measured above – a plot for
Vdc vs Uc.The curve obtained should be linear one similar to as
shown in Fig. – B.

J. Simmulated Loop testing using 50Hz supply instead of PMG

• Switch off MCB F74,& remove the links L4,L5,L6
• Connect back the Links to L1,L2&L3.
• Remove the cables for PMG supply (TBR4,5,6) Inject through a
3 phase variac AC supply equal to PMG voltage but of 50Hz at
TB 4,5,6.(Ensure proper phase sequence as per Scheme)
• Normalise switch settings of S865, S850&S851 as per
commissioning report for UN0663 module (Pos.AA29 & AA65)
• Remove the If signal injecting setup (between X261 & X265) of
U01 & U02.
• Connect back switch S452 in U01 & U02
• Replace RFLD with a resistor equivalent to exciter field winding
resistance, of high current capacity (equivalent to say 20ADC,
ceiling current)
• Decrease PT/Ct injected voltage/current to Zero
• Select AVR channel-2 Manual.
• Close Exct.Fld breaker & make Excitation ON.
• Gradually increase PT voltage to its rated value (110VAC)
• Raise Channel-2 reference so that no load current or nearly
40% of rated field current is flowing through RFLD.

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• Ensure Automatic follow up of Auto-Channel.

• Use Raise/Lower command in UNS2661 (Command input
module) of Channel-1 to delibrately create a difference (+ve)
And then (–ve) DC value in AUTO-Manual balance indicating
meter.
• Ensure automatic follow up of Auto channel for both + & -
deviation of balance indication.

Step test of DAVR at generator FSNL condition (J):

K. Step Test of DAVR:

• Ensure normalization of DAVR for its readiness of operation
with the Generator.
• Switch on the excitation in Ch-1, with a present level of say
100% of Uref.
• Through the micro terminal enter the value of Uref as 95% and
press Enter.
• Note the variation in the generator terminal voltage. Adjust PID
if necessary to obtain one over shoot, one undershoot and then
Gen. Voltages stabilizes to the voltage corresponding to
Uref=95%.
• Repeat the above procedure from UG=100% for sudden change
to Uref=105% (+5% step).
• Similarly from UG =100%, decrease the Uref with a step of 90%
(-10% step).
• Now perform the above procedure with UG from 100% to 110%
(+10% step) by suddenly increasing the reference & note the
oscillation in generator terminal voltage. In all the above cases
one overshoot followed by one under shoot and then
stabilzation in Gen. Terminal voltage to be obtained, without
actuation of over voltage stage 1 relay.
• If the DAVR stabilization takes place with over damped or under
damped behavior, then the PID filer parameter optimization is
required for which BHEL expert is to be consulted.

Dynamic test of DAVR at generator (K):

L. Dynamic Test of DAVR:

• Note: For performing this test, proper permission from
concerned management is to be obtained. If permitted, the test
may be carried out in the following procedure.
• Synchronize the generator with other running generators &
gradually load it up to 50% of its rated capacity.

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• Ensure there is enough spinning reserve in generation system

so that if the machine under test trips, further load shedding
shall not be required on account of this.
• Suddenly in one step decrease load on the generator by 25%.
Repeat this procedure of sudden de-loading at 50%, up to 100%
load. Observe the response of DAVR & system parameters
Turbine frequency etc) during this condition.
• Now increase the loads in steps permitted by Turbine control
system within max quantium and observe the DAVR response.
• Repeat the above procedure load step size of (permitted from
Turbine system) & each step change in load. Observe the
response of DAVR and system parameters.

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ATTENUATOR + CRO
PROBE -
3ph PT i/p 110Vac (Ug)

10:1
DC output
3ph CT i/p 1Aac (Ig)
D

Stn Suply 3ph 415Vac

A RFLD, 100ohm, 10A
Vdc
V

Stn DC supply 110Vdc R

A

Fig. A : Setup for carrying out Light Load Test on each channel thyristor
at generator standstill

Vdc

-10Vdc

Uc +10Vdc

Fig. – B: Vdc Vs Uc plot as results of light load test

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UNC4660 UN0663
110Vac (Ug) X250,251,252 = 22Vac (Ug)
R
110Vac (Usync) X253,254,255 = 22Vac (Usync) S = 22Vac
T
Ign (rated sec.) X257,258,259 = 3Vac (Ig)

3Vdc (If) X261-U265 = 3Vdc (If) If = 3Vdc

S452

UN0661

UR
4.37Vac = US
MICRO TERMINAL (UNS 2660) UT
UN0610 IR
5.0Vac = IS
Ugact=100% IT
Igact =100% D
If =100% 7Vdc = Ug
--- 7Vdc = Ig
3Vdc = If
A
0V

Fig.C: PID Signal Flow diagram

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Full Firing
Uc=+10VDC
VDC

600 1200 1800 2400 3000 3600

3600

Fig-E

In case if there is any missing waveform in the entire zone of +uc control voltage
then
Either- pulse is missing
Or- faulty UN0663
Or faulty Pulse final stage UN0809
Or- Thyristor device failure
Or- Pulse transformer in Pulse Transformer board faulty
Or- Thyristor Arm fuse failure
Or- Loose contact in pulse cables
Or-AC Supply not reaching at input to Thyristor bridge
Or-Improper Synchronization of Thy. Bridge AC input voltage with Usyn at
UN0663

Prepared by: A K MALIK, IOCL HALDIA REFINERY; Checked by: P K DAS, BHEL-EDN, BANGALORE