NEELUM JHELUM CONSULTANTS

[JV between MWH-Int, NORPLAN, NESPAK, ACE & NDC]

Tel: (+92) 58224 33653

Fax: (+92) 58224 32978
e-mail: njc@njproject.com

Malik House, Lower Chatter,

Muzaffarabad.

Date:

05 April 2016

Our ref:
Your ref:

PO-20765
GZBZJ-NJC-10385 dated 02 March 2016 (R-18341)

Authorized Project Manager

CGGC-CMEC Consortium
(Office at Site C3), Chatter Kalas,
Muzaffarabad

DELIVERY: BY HAND

ATTENTION: MR HU QUANGUANG
NEELUM JHELUM HYDROELECTRIC PROJECT
C3/E1: METHOD STATEMENT ON STATOR CORE MAGNETIZATION

Dear Sir:
This is with reference to your letter mentioned above under Your Ref.
We have reviewed your submittal and we have given our comments on the various pages of the
submittal.
The status of the submittal is AEN.
Please revise your submittal and incorporate our comments and resubmit at the earliest for our further
review as well as record.

Yours faithfully
for NEELUM JHELUM CONSULTANTS

(for) WILLIAM B. DOBBS, P.E.

Project Manager
Encl:

As stated

Filing
Owner:
Printed:
Author:

130, 560
Neelum Jhelum Consultants
5 April 2016
PE Electrical

Status:

Final

Distribution:

Addressee
CEO(NJHPC); CE&PD
PM/DTL
CMEC Group
CRE-E&M / CRE-C3
Electrical
File
Doc ref: PO 20765 C3-E1 Method Statement on Stator Core Magnetization

 1- 
M&E Erection, Testing and Commissioning of Pakistan
Neelum-Jhelum Hydropower Project


1-  
Method Statement on Stator Core Magnetization for
Pakistan NJ Hydropower Station (Rev.0)








APPROVED EXCEPT
AS NOTED
Reviewed

___________

Checked

___________

Date

05.04.16
___________
Clause SP 6.2.4 refers

Refer. PO # 20765
DISCLAIMER

CHECKING IS ONLY TO CONFORMANCE WITH THE ELECTRICAL DESIGN CONCEPT OF THE

PROJECT AND COMPLIANCE WITH THE INFORMATION GIVEN IN THE CONTRACT DOCUMENTS
AND SUBSEQUENT AMENDMENTS. THE CONTRACTOR IS SOLELY RESPONSIBLE FOR
EQUIPMENT SIZING AND SELECTION IN ACCORDANCE WITH TECHNICAL GUARANTEES,
APPLICABLE IEC STANDARDS, AND ITS OWN CALCULATIONS; FOR LOGIC AND ACCURACY OF
SCHEMATIC AND WIRING DIAGRAMS; FOR PHYSICAL DIMENSIONS TO BE CONFIRMED AND
CORRELATED AT THE JOB SITE; FOR INFORMATION THAT PERTAINS SOLELY TO THE
FABRICATION PROCESS AND TO TECHNIQUES OF CONSTRUCTION; AND FOR COORDINATION
OF ELECTRICAL DESIGN WITH OTHER DISCIPLINES.

February 2016

Contents

1. Overview......................................................................................................... 1
2. Test Objectives and Standards .................................................... 1
2.1 Test objectives ................................................................................... 1
2.2 Standards ........................................................................................... 1
3. References ............................................................................................... 2
4. Technical Data ................................................................................ 2
4.1 Fundamental parameters of stator core ............................. 2
4.2 Parameters of test .............................................................. 2
5. Calculation of Test Parameters ....................................................... 2
5.1 Calculation ........................................................................................ 2
5.2 Choice of test devices .......................................................... 3
6. Work Preparations........................................................................... 4
6.1 Test devices and materials..................................................... 4
6.2 Prerequisites of test ................................................................... 5
6.3 Layout of excitation coil ....................................................... 5
6.4 Layout of temperature-measuring elements.......................... 5
6.5 Wiring for test ................................................................................... 5
7. Arrangement of Human Resources ............................................... 6
8. Main Safety Measures ...................................................................... 7
8.1 Equipment safety management ................................................. 7
8.2 ........................................................................ 8
Safety management for test procedures and measuring workers ....................... 8
8.3 Safety precautions during the test ......................... 9
8.4 Civilized construction measurements ..................................... 10
9. Quality Measures .......................................................................... 10
10. / Hazard Identification and Pre-control ........................... 11
11. Test Operation and Procedures ................................................... 11
12. Analyses of Testing Results ........................................................ 12
12.1 ( 1T)........................................................ 12
Calculation of testing parameters (convert the magnetic flux density into 1T) ..... 12
12.2 analyses ................................................................................. 13

Comment-1:
- Please refer to WAPDA's letter No GM/NJHEP/03/822 dared July 07,2007 titled "Letter of Acceptance". In Clause 2(xxv), under
"Chinese Standards" the following is stated: "you confirm that for the Main Equipment under Lots E1 and M1, the requirements of
the specified standards' shall be met whereas for auxiliary system acceptable Chinese standards can also be used". Since
Generator is main Equipment, you must give reference of only IEC standards (we may also accept B.S.S and ANSI). So re-write
this submittal accordingly.

1. Overview

4 243MW 972MW

Neelum Jhelum Hydroelectric Project will have 4 turbine units with a total capacity of 972MW. The
magnetization test will be carried out on stator which should first be assembled by welding and piled
with core sheets, in order to examine the quality of manufacture and installation for the core and
make good preparations for following works.
2. Test Objectives and Standards
2.1 Test objectives

The stator core is stacked by silicon steel sheets. We should conduct magnetization test after the core
stacking to prevent the core during the operation from overheating due to a short circuit which may
threaten to ruin the safe operation of units. The objectives of magnetization test were to examine if
the insulation of core has a short circuit and if compressing bolts are tightened.

During the test, we will measure the total power loss of stator core and also the temperatures at every
position of stator frame in order to find out the overheating spots. Accordingly were able to verify
the unit loss and temperature rise, and then discover the possible defects. Finally were able to judge
whether the the quality of manufacture and installation for the core is acceptable or not.
See Note below
2.2 Standards (GB-501502006)

S/N
Item

1
Maximum temperature rise of stator core

2
Maximum temperature difference of stator core

3
Maximum temperature difference between stator core
and press fingers and stator frame

4
Unit core loss

5
Test duration
Note:

Criterion

Remarks

d25

See Note

d15

See Note

d15

See Note

d 1.43w/kg

See Note

90 min

See Note

- Indicate here clause number of the above mentioned Chinese standard i.e GB 50150-2006. Further, attach a photocopy of
the Clause No in Chinese languge as well as its English translation
should be provided.
1
- Please indicate IEC standard which is corresponding to Chinese standard # GB-50150-2006. In case there is one such IEC
standard (or more then one standard) then provide a copy of the said IEC standard. Further you should highlight those
clauses of IEC standard which are related to your S/N 1 to 5 indicated above in clauese 2.2.

Provide English Translation of

these Chinese standards.

3. References
1)
Relevant drawings and technical documents.
2 GBT85642003

GBT8561-2003: Specification for Installation of Hydraulic Turbine Generator Units.

3GB501502006
GB50150-2006: Standard for Hand-over Test of Electric Equipment and Electric Equipment
Installation Engineering.
4GB/T20835-2007
GB/T20835-2007: Guide for Magnetization Test of Generator Stator Core
4. Technical Data
4.1 Fundamental parameters of stator core:
length of stator

L1=2750 mm

height of stator core slot depth

hc=178.9mm

inner diameter of stator core

D2=6310 mm

outer diameter of stator core

D1=7350 mm

number of ventilating slot

N=59

width of ventilating slot

b=6 mm

4.2 Parameters of test:

exciting voltage

E1 =11kV

magnetic flux density

B = 1.00T

rolled steel density

7.6t/m3

stacking coefficient of stator core

K=0.95

5. Calculation of Test Parameters

5.1 Calculation
Sectional area of rear of stator core: S = Lh= K(L1nb)h
of which:
K(stacking coefficient of stator core)=0.95
L(length of stator core)=K(L1-nb)
h(height of rear of stator core)=(D1-D2)/2-hc
S =2276.2341.1/100=7764.12 (cm2)
Induced voltage of measuring coil: E2 = 4.44fBS10-4=172.36 (V)
Turns of excitation coil: W1 = E1/ E2 =63.81 ( turns); so W1=60 ( turns)
Turns of measuring coil: W2 1 W2 (measuring coil)=1 ( turn)
Weight of iron yoke: G=7.6SDav/1000=129862.97kg
Test capacity:
2

Give some supporting for document for example some Chinese standard or
some other official document (e.g code of standard practice).

excitation coil current: I =DavH0/ W1= 4181.51/60=69.69(A)

average diameter of stator iron yoke: Dav=D1-h =700.89 cm
1.9
H0 ampere-turns per unit length/ ampere-turn/cm
(based on experience)
test capacity P=1.73269.6911=1327.73(kVA)
5.2 Choice of test devices
Turns of excitation coil and sectional area
60 5 3.5A/mm2
69.69A/3.5A/ mm2=19.91mm2 35mm2 10KV
500
The turns of excitation coil is 60 according to calculations, and excitation coil should be wound
around stator core in 5 parts equally. Therefore, the sectional area should be equal to 19.91mm2
(69.69A/3.5A/mm2). For the convenience of winding, we propose to choose the 10kV single-wire
cable with 35mm2 and 500m per length.
Choice of high voltage switchgear
69.69A 130%
69.691.3=90.59 150A
The test current should be 69.69A after calculation. A high voltage switchgear should be chosen on a
principle that the breaking capacity should be more than 130% of test current, i.e. 90.59 (69.691.3).
Accordingly a 150A vacuum circuit breaker is appropriate.
Choice of construction power

P=1.73269.6911=1327.73(KVA) 325 mm2 11kV

The test power is obtained from the HV terminal of a construction transformer set in erection bay-1.
The test power should be 1327.73kVA (P=1.73269.6911) through calculation. In order to reduce
the voltage drop we will choose 2 lengths of 11kV high-voltage copper wire cables (325 mm2)
which serve as incoming line power.
Setting of protection customization
0.3 1.2 69.691.2=83.63A 0
6 69.696=418.14A
The time of over-current protection is 0.3 seconds and the multiple of over-current is 1.2,
i.e.69.691.2=83.63A. Time of quick-break protection is 0 second and the multiple of quick-break is
set to be 6, i.e.69.696=418.14A. The protection for outgoing line should be set.
Measuring coil
10M 4mm2
3

We propose to choose a single-wire cable as the measuring coil. Its insulation should be more than
10M and sectional area be 4mm2. Adopting the same method, we will wind measuring coil around
the area of excitation winding group. The coil should be put in the slot and be wound around stator
active core but not the whole frame.
6. Work Preparations
6.1 Test devices and materials

S/N
Description
Model
10kV
1
200A
10kV switchgear
10kV
2
35mm2
10kV power cable
3

4
5
6
7
8
9

10
11
12
13
14

10kV
10kV power cable

325mm2

Low power-factor
300V5A/0.5
wattmeter

T24-AV 0.5
Voltammeter

0.5
Frequency meter

10000/100 V0.2
Potential transformer

300/5 A0.2
Current transformer

0100
Infrared temperature
measuring gun

Single-wire soft
500V4mm2
copper cable

Noise meter

10mm
Insulation rubber

5004
Tape

5m
Wooden ladder
4

Unit

Panel

Qty.

500

320

set

set

set

set

set

3
1
1
1

piece

50

Piece

m2

20

Piece

Set

Remarks

1000
4

Soft-core cable for excitation

Used to connect the HV terminal

of construction transformer


S/N
15
16
17
18
19
20

Description

Earplug

Megohmmeter

Copper colloid wire

HV insulation tape

Insulation tape

Alcohol thermometer

Model

2500V500V
2.5mm2
10kV
500V
0-75

Unit

Pair

Set

Roll

Roll

Set

Qty.

Remarks

100
2
100
2
3
80

6.2 Prerequisites of test

The work of stator stacking has been completed according to the Method Statement on the Stator
Assembly. Besides, all of relevant inspections have been acceptable.

The environment around stator core should be very clean, especially the ventilating trench in which
there definitely are free of any wastes such as metals.
120mm2
The stator frame should be connected with earthing network by the copper wire cable with 120mm2
or more.

The insulation of clamping bolts should be qualified.

10kV
90.12A 0.3 6
We should examine the operating circuit of 10kV switchgear circuit breaker and check if the
operation of switchgears protection device is correct or not. The setting value of protection device
for over-current should be 90.12A with 0.3 seconds of delay and 6 multiples of quick break.
6.3 Layout of excitation coil
10 kV35 mm2
5 72 12 60

20
5

A length of 10kV single-phase copper soft-wire cable (35 mm2) will be wound around excitation coil
at same direction. It will be divided into 5 equal parts (72), and 12 turns for each part so 60 turns in
total. We should avoid overlap in winding. Cable should be close to stator as much as possible. For
the consideration of variation on winding during the test, excitation cable should be reserved with
about 20m for winding stator core in 2 circles. After that we will make high-voltage cable heads.
4 mm
Between excitation cable and core edges should be put the rubber pad whose thickness should not be
less than 4mm.
4mm2 5mm

Once the measuring coil is turned we should wind it at the proper position of core by the copper wire
(4mm2), closed to slot. Put a 5mm thick rubber on the edged part of stator core.
2500V 1000M
500V 10M
We should examine the insulation of excitation coil cable with a 2500V megger. The insulation
should not be less than 1000M. Besides, we should examine the insulation of winding cable by a
500V megger. The insulation should not be less than 10M.
6.4 Layout of temperature-measuring elements
+X.-X.+Y.-Y
Lay out an alcohol thermometer for each upper press fingers and lower press fingers along the
direction of +X and -X, +Y and -Y.
+X.-X.+Y.-Y
Lay out an alcohol thermometer for stator frame along the direction of +X and -X, +Y and -Y.
12
Divide stator core into 12 equal parts. Lay out an alcohol thermometer in the top, middle and bottom
to measure temperature and make records.
6.5 Wiring for test

Note:
One person out of these 4 persons shall be declared
as "leader of the Testing Team" and every person of
the testing team should be aware of this fact.

Indicate Rating of the wattmeter as

well as its Accuracy class.

Note:
K10kV HV switchgear

U1 U2 voltage meter

W low power-factor wattmeter

F frequency meter

A current meter

CT current transformer

PT potential transformer
7. Arrangement of Human Resources
Human resources for testing

S/N
Type of Work
Amount
1
Managers
4
2
Technician
1
3
Testers
4
4
Crane operator
1
5
Crane rigger
1
6
Safety officers
4
7
Electricians
2

Helpers

10

Total

Remarks

8
2
8 to read and record temperature inside
stator and 2 to read and record outside
stator

27

8. Main Safety Measures

8.1 Equipment Safety Measurements
1

Well insulate the field coils and measuring coils and well dress the damaged locations to avoid
burning the stator core when the lead short circuit happens to the ground because of the bad
insulation of leads.
2
Prepare a special safety measurement to avoid dropping metal tools and any other materials inside
the generator.
3

Metal objects, such as steel ruler, uninsulated cable and mercurial thermometer, are prohibited to
close to the stator core.
4
The test equipment shall be reliably grounding.
5
7

(indicate here type of Fire Extinguisher

for example FM-200 Gas Filled type etc).
Arrange power fire extinguishers around the generator and arrange special man there to take in
charge of the safety situations.

(Indicate the size of the grounding Cable as well as its

Rated Voltage).

6
The stator frame shall be reliably grounding.

7
Check the insulation resistance of tightening bolts for stator core and make sure that it meets the
requirement. Change this to "warning tape".
810kV 10kV
Safety belts and warning boards must be set around the 10kV high voltage switchgear and 10kV
system. Special duty man shall be arranged to safe guard this equipment.
8.2 Safe Measurements for Test Personnel and Measuring Workers
1

which can withstand 2kV r.m.s for 1 Minute.

All the participants must be in insulated shoes.

2

During the test, test personnel shall keep close watch over and carefully observe the data and stator
core. The test must be immediately terminated once some abnormalities, such as abnormal data,
loosen stator core or local heat and smoking happening, being found.
3
During the test, all parties shall be well coordinate to make sure that the construction power will be
reliable.
4
During the test, communication shall be smooth and unobstructed to make sure a unified command.
5

During the test, it is not allowed to touch the stator core by both hands simultaneously to avoid
electric shock. Pay attention to the safety situation when read the thermometer at a high place.
Reliable anti-sliding measures must be set at the bottom of the wood ladder to avoid any fallings
For this reason all persons who participate
because of sliding. of the ladder.
in this test must wear uniform so that an
6
irrelevant person is instantly found out.
Inflammables and explosives are prohibited to put in the test zone.
7
Irrelevant personnel are prohibited to enter the test zone.
8
It is prohibited to touch the core bolts by hands and touch the core by both hands simultaneously.
9
8

All the test participants must hold fast to his position and not allowed to be absent without leave.
10
The staff entering into the generator are not allowed to take any metal objects, such as keys and cell
phones, except the test instruments.
8.3 Safety Precautions during the Test
1
Any other work which may cause loud noise are not allowed surrounding the test zone.
2

"Testing Team Leader".

Once the following abnormalities take place, immediately report to the senior commander and ask if
it is necessary to terminate the test.
1) 1T 25
a)

"1T" stands for what?

Please explain it.

The peak temperature of the core rises over 25 when converting to 1T.
2) 1T 15
b)
The maximum temperature difference of the core becomes over 15 when converting to 1T.
3) 1T 15
c)
The maximum temperature difference between the core and the stator frame becomes over 15
when converting to 1T.
d)
4)
When some phenomena, such as local sparks, reddening , smokes or big vibration, happening during
the test.
3

After terminating the test because of abnormalities, check and dispose the abnormalities. The test can
be re-start after being inspected and approved by the Engineer and Manufacturer
4 5m

Without the permission of the person in charge of the test, non-staffs are not allowed to enter the test
and switchgears layout zone and their surrounding zone within 5m. special man shall be arranged to
guard it.
5
During the test, construction items requiring high-power are prohibited to use. Only some lightings
can be remained.
6
During the test, the powerhouse bridge cranes are strictly prohibited to across overhead the test zone.
7 "Testing Team Leader"
The whole test shall be unified commanded by the general leader of this test.
9

8.4 Civilized Construction Measurements

1

Make the site normalized and ordered, reasonably arrange the work procedure to avoid any mutual
interferences, and strictly conduct the test as per the operation specifications and the method
statement approved by the Engineer.
2

Keep the erection site orderly and clean; orderly put all types of materials and equipment in arranged
position without holding the walkway or any other access; and timely shift the surplus materials,
wastes and rubbishes to keep a clean environment after the construction.
9. Quality Measures
1

During the test, strictly perform the Three-Inspection-System of quality, which means the
self-inspection, re-inspection by the quality control group and the final inspection by the project
department. Once these inspections being qualified, report it to the Engineer for inspection and
acceptance. Regarding the any quality problems, one-vote veto system is necessary to perform and to
eliminate the quality hidden troubles.
2

During the test, each procedure shall be performed as per the requirement of iron loss test and self
inspected to avoid the unqualified process entering the following procedure. Records of inspection
must be done during the test.
3

Carry out a technical disclosure to all the test participants and staff members to let them know what
to do and how to do. Also, it is necessary to carry out some more relevant trainings, such as the
relevant standards, operation key points, safety and civilized precautions.
4
The applied measuring instruments and tools must be qualified to ensure the accuracy of erection.
Further all the meters (e.g. voltmeter, ammeter etc). must have been duly
calibrated from some recognized authority.

10

10. / Hazard Identification and Pre-control

hazard

accidents may happen

control measures

remark

fire

Wholly check the insulation of all the test cable and

Sparks caused by the

aging test cable or loosen
wiring terminals.

strictly conduct the wiring work as per the relevant

(e.g. C.T.S. Fire Extinguisher)
requirement.

2
Fire extinguishers must be equipped with in the test
area. It must be ensured that these are recently manufactured.

Prepare a regulation of temporary electricity supply

and a regulation of safety operation.

Electric
shock

that they have received.

All kinds of electrified

equipment, power line
and power distribution
box.

All the electricians must be on duty with certificates

and receive the safety training.

Arrange and layout the electrified equipment, power

line and power distribution boxes according to the
specifications.

Accident
downfall

1
Prepare the management system and operation
regulations of high altitude work.

During the test cable 2

enwinding work, PPE
being not properly used,
and scaffolds being not
correctly set as per the
regulations, will cause
accident downfalls and
even casualties.

Carry out the safety training for those working at

height.

3
Strictly and properly wear the safety belts and other
PPE.

11. Test Operation Procedure

1
Check all the wiring to be correct and invite the Engineer and representative of Manufacturer to
confirm it.
2
Make sure the vacuum circuit breaker to be normal and reliable.
11

3
During the test, all the lightings which may shine directly to the stator core shall be turned off.
4
During the test, a special man shall be arranged to take in charge of the operation of test switch and
guard this work.
5 10kV 10kV

Switch the 10kV isolation switch on and observe the switchgear by hands. Switch the 10kV vacuum
circuit breaker on by remote control and observe the current, voltage and power. The indications of
each instrument should be less different with estimations. Listen and observe the sounds and
vibration situation of each part of stator core. if any situation of smoking, overheating and strange
sounds is observed we should switch the vacuum circuit breaker off immediately.
6 0.95T

(Tesla)

According to the values of current and voltage verify the situation of test. The magnetic flux density
should be more than 0.95T, otherwise we should change the winding turns of excitation.
7 90 15

Magnetization test lasts for 90 minutes and record the readings of each meter at every 15 minutes.
Measured points should be located at the forehead and teeth of stator core. Measure the surface
temperature of stator core by a far infrared temperature instrument to find out over-heating spots for
which we should pay more attention to check and make records.
8
When the test duration is reached cut off power and stop testing. Analyze the tested results.
9
After iron loss test is finished, the stator core cools down to ambient temperature, then press the core
again.
12. Analyses of Testing Results
12.1 Calculation of testing parameters ( convert the magnetic flux
density into 1T)
2
PFe=PFe /G
10000/B
kg/W
1 unit loss of the back of stator corePFe

of which
PFe tested total loss reading of power meterW
G total weight of yoke
B tested magnetic flux density
12

 W/kg W/kg
The unit loss cannot be more than W/kg or the permissible unit loss W/kg according to the adopted
sheets.

shall not

10000/B2
2 maximum temperature difference t1(K) t1(K) = t1 t2
of which
t1 maximum temperature in press fingers
t2 minimum temperature in press fingers
15Kshall not
Maximum difference cannot be more than 15K according to standards.
3 maximum temperature rise t2(K) t2(K) = t3 t010000/B2
of which
t3 maximum temperature in stator core or in press fingers

t0 initial temperature in stator core

t2 25Kshall not
Maximum temperature rise t2 cannot be more than 25K according to standards.
12.2 analyses

Stator core can be deemed to be unqualified in the following cases. Finding reasons and eliminating
defects are needed.
a)
1
t1 15K

In the case that temperature difference between the press fingers t1 is more than 15K;
b)
2
t2 25K

In the case that maximum temperature rise is more than t2 25K;

c)
3
t3 15K

In the case that maximum temperature difference between stator core and frame t3 is more than
15K.

13

 Annex Table 1:

Records of Magnetization Test on Stator

Unit#
Test date
B
G (kg)
Tested magnetic flux B
Total weight of yoke G
PFe
P10
Tested total loss PFe
Gaussian unit loss P10

Maximum temperature rise

Maximum temperature difference
Notes:
U1 excitation voltage
I1

system frequency

excitation current

n transformation ratio of excitation current transformer

U2 measuring winding voltage

P measuring power

B real magnetic flux

P0

unit loss under the real magnetic flux

W1 winding turns of excitation coil33 turns

P10 104 Gaussian unit loss converting to 104
W2 winding turns of measuring coil 1 turn
Time (min)

U1 (V) F (HZ)

I1 (A)

U2 (V)

initial
10
20
30
40
50
60
70
80
90
14

P (W)

B (GS)

P0 (W/kg)

P10 (W/kg)

 Annex Table 2

Records on Temperature ()
Time (min)
Slot#

10

20

up
18

middle
down
up

36

middle
down
up

54

middle
down
up

72

middle
down
up

90

middle
down
up

108

middle
down
up

126

middle
down
up

144

middle
down
up

162

middle
down
up

180

middle
down
15

30

40

50

60

70

80

90

 up
198

middle
down
up

216

middle
down

Upper press
fingers

Lower press
fingers

+X
+Y
-X
-Y
+X
+Y
-X
-Y
+X

+Y

Frame

-X
-Y

+X

Back

+Y

+X

Frame shell

+Y

Note: if the slot of temperature measuring is covered by excitation cable we can move the
temperature measuring spots properly.

16