REPORT ON

DEFECTS OBSERVED DURING

COMMISSIONING OF ELECTRICAL
SYSTEM

CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
9.

Generator Relay Panel.

Digital Automatic Voltage Regulator.
Transducer Panel.
Electrical Control Panel.
NGT Panel.
Generator Circuit Breaker Panel.
6.6 KV Switchgear.
LT Boards Incomer/Buscoupler Breakers
General Points.

1. Generator Relay Panel

1.1Low Forward Power Protection- Please refer the scheme prepared for
Generator Protection. Both Low forward Power & Reverse power Protection
have been envisaged in the scheme. With LFP, Turbine is being tripped &
then from turbine trip command from Gas Turbine, GCB & DAVR are
opened via 186D & 286D relays. With Reverse Power Protection, Only GCB
& DAVR are opened via 186D & 286D relays. Our first observation is that if
reverse power protection is already envisaged then there is no need of LFP
in Gas Turbine. Unnecessary tripping of Gas Turbine is taking place due to
this protection. Hence we request you to kindly review the requirement of
Low forward power protection trip. Currently this protection is disabled in
the unit.
1.2Supply of VTs for SPVT used in measurement- Two VTs with Two
secondary cores in each VT is envisaged in SPVT. One Core of each VT is
Star Connected & another core is DELTA connected. Delta Connected VTs
are being used in measurement circuit of energy meters mounted in GRP
& for measurement power & Voltage in Transducer Circuit. This is creating
an error in measurement of MW/MVAR/Termination Voltage. Supply Circuit
of VTs have been taken from Core 1 of VT 2 in GTG-1. However BHEL PEM
& BHOPAL are requested to take care of this point is rest of the units &
units coming in BHEL PSWR.
1.3Logic of BI4 (186A2, 286A2, 186D1, 186D2) ANDED with BI7 (GCB
Lock out) - Usability of this protection is needed to be reviewed.
Whenever above two conditioned are ANDED 186A1 & 286A1 are being
tripped.
1.4Hard Wired Interlocking of HVCB Closing-The HVCB Closing interlock
has been envisaged in Soft in DCS only. However Since it is related to 400
KV breakers & no chance is to be taken during closing. We propose to
provide the (186A1+286A1+186C+286C) NC series contact in closing
circuit of HVCB. Further it has been observed in recent projects that where
ever Hard wired interlocking is envisaged in HVCB closing Circuit, the
same has not being implemented by BHEL Bhopal during GRP panel
erection & wiring. This point must be taken up in most priority in upcoming
projects in BHEL PSWR.
1.5Feedbacks of HVCB & TIE Breakers for ECP & DCS- The NO contacts
are available for each HVCB & TIE breaker in GRP for feedback. However
only one feedback is available for NC contact of each of them in GRP
drawing which can be used either in ECP/DCS. Rewiring was done &
contacts were separated for in GRP 4, TB 2-69, 70 (52MX4, 17, 18 Number
Contact) & TB 2-71, 72 (52 TX4, 17, 18 number contact). Kindly
incorporate the same in next 3 turbines of Bawana & projects of BHEL
PSWR if applicable.
1.6Overall Differential Protection- CRITICAL MATTER - Overall
differential protection has been given. However due to LCI operation
Overall Differential Protection is always coming into picture during start up
machine. We suggest providing this protection ANDED with turbine Speed

greater than 95% in next 3 gas turbine units of Bawana & in BHEL PSWR
sites. The matter may please be discussed with BHEL Hyd & this logic may
please be implemented.

2. Digital Automatic Voltage Regulator- CRITICAL MATTER

2.1Feedback required for ECP/DCS- Only one number feedback of DAVR
channel status is available in DAVR. However minimum of two feedbacks
are required which is to be used for ECP/DCS indications & logic. Wiring of
contacts has been done at Bawana site for taking care of feedbacks
required in DCS. One complete set of TBs was added. TB 2R details are
replicated. The same point has to be implemented in rest of the units of
Bawana & units of BHEL PSWR sites if applicable. Since originally only one
feedback was available in the panel, it is observed that same terminal
details at DAVR end are provided in the interconnection details
provided by PEM (ELECTRICAL) & PEM (C & I). Hence it is requested
to have proper coordination between PEM Electrical as well as C & I while
preparing cable schedules as well as interconnection details.
2.2Tripping of Excitation Transformer- Excitation Transformer over current
tripping is envisaged for tripping of DAVR only. However excitation
transformer has been connected after GCB. Hence excitation transformer
is directly connected to 400 KV line. In case of any fault in excitation
transformer HVCB breaker must be opened. Same has been implemented
in Bawana Unit 1 & Direct tripping has been given to 186A1 relay (GRP 1,
TB 2-50 & TB 3-18). Same may please be implemented in rest of the units
of Bawana & BHEL PSWR sites.
2.3Tripping of GCB/GT in case of DAVR protection trip- In case of
tripping of DAVR on protection during machine in operation, GCB should be
opened. However the direct tripping from DAVR trip to 186A2 is not
envisaged in this project. 186A2 & 286A2 was given direct tripping at
Bawana Site. You are requested to incorporate the same & provide the
same in rest of the units of Bawana. This point is a general observation in
most of the projects of BHEL PSWR.
2.4Feedback for the availability of Aux Supply used for LCI panel:
Feedback for the availability of 415 V Aux Supply used in LCI panel of
DAVR. Due this if this aux supply has failed, we will not know about it.
When machine is started in LCI mode, LCI is tripping due to non starting of
firing in DAVR. Hence it is proposed to provide one number contractor in
LCI panel of DAVR monitoring the supply & a feedback of the same may be
wired up in the logic of DAVR ready to start which enables LCI starting
from MARK VI.
2.5Interface details between DAVR & MARK VI/LCI Panel- Interfacing
details were not available between DAVR & MARK VI/LCI Panel. Site has
prepared the details as per the requirement. You are requested to review

the details & kindly incorporate them in next three units of Bawana.
Further Details may please be sought from concerned units in advance for
BHEL PSWR projects & proper cable schedules & interconnection details
may be made.
2.6Cable Schedules for Power/Control Cables in DAVR:- A serious look is
required to be placed in making cable schedules of power as well as
control cables. A cable size of 2 run of 1Core 630 Sqmm per phase is
envisaged for auxiliary supply of LCI in DAVR panel. However the TB
available in the panel can handle a max of 185 Sqmm easily. Hence TB
was modified forther location of TB was required to be changed to
accommodate that cable. Similar is the case with most of the power
cables. Another example of this is the cable size envisaged for 3 Phase
Aux Supply in Generator Relay Panel. 3.5*25 Sqmm is envisaged. However
3C*4/10 Sqmm is sufficient for the load of the GRP. Termination details of
even CTs were not available at site which is required for operation of auto
channel operation in DAVR.
3. Transducer Panel- CFA 01, CFA02- CRITICAL MATTER
3.1MW & MVAR Transducer: There are at least two number Mega
Wattmeters & MegaVar Meter required for one Gas Turbine unit. However
only one number Wattmeters & MegaVar is provided in the panel. Another
set of MW & MVAR transducer was taken from unit 2 GTG at Bawana
project & wiring of the same is done at site. Wiring details may be taken
from bawana site & transducers may please be supplied as required in
next three units of Bawana. Further this point may please be reviewed for
BHEL PSWR site projects & if required same may please be supplied for
them before commissioning.
3.2Interconnection Details between CFA 01/02 & ECP/DCS/Mark VIInterconnection details between Transducer panel & ECP/DCS/Mark VI were
not available at site & site was forced to make the cable schedule &
interconnection details at site. The interconnection details of the same are
attached for your reference, kindly incorporate the same & provide
schedules for rest of the units of Bawana Project. Further kindly make the
details as required for units of BHEL PSWR.
4. Electrical Control Panel: CRITICAL MATTER
4.1Push Button for Speed Raise/Lower: A push button for speed
raise/Lower is not available in ECP of Bawana project. This push button is
must during synchronisation of machine with grid. BHEL PEM/EDN is
requested to incorporate the same in all units of Bawana Project. Furhter
this point must be taken care off in units supplied in BHEL PSWR.
4.2Push Button for Trip Selection Switch: Push button supplied for TRIP
Selection of I/C1,B/C, I/C-2 is spring loaded. However it should be pressed
to select type of button. BHEL PEM/EDN is requested to review the details
as provide the details as required for sync of LT breakers.

4.3Isolation of Positive of DC Supply of HT breakers (GCB & HVCB)CRITICAL MATTER - As per synchronising philosophy adopted by BHEL,
Positive of breaker Closing Coil of each & every Breakers is taken directly
at ECP TBs which are shorted together (TBP 11 to 17). Primarily the closing
supply of GCB is 125 Volts & HVCB is 220 V, Secondly the DC supply of two
HV breakers cannot be allowed to be shorted at one place. Hence all
breakers closing supply must be isolated & should to electrical control
panel only after respective breaker selection. The isolation of supply of
GCB/HVCB of unit-1 was done at Bawana project, however you are
requested to take the details & confirm the same. Further details may
please be made for rest of the units of Bawana Project. Also you are
requested to prepare the details taking into account the flow of DC in case
of sync selection from ECP/ATRS mode since proper looping is required to
be done for flow of DC in ECP/MARK VI. The details may please be
reviewed for the schemes applicable for units in BHEL PSWR & if there is
any discrepancy then same may please be corrected.
4.4Schematic of Check Sync/guard Relay Wiring -CRITICAL MATTER:
Kindly look into the check sync relay wiring for bawana project. If this
scheme is applied then machine is never going to synchronise with GRID
since the change over contact (3,4 & 11) of 25CX1 (Multipier of 25 C), TB 3
has been wrongly connected directly to Guard relay contact also. Hence as
soon as Check sync relay is operating at the same time guard relay is also
operating & sync circuit is not completing. Scheme was modified in unit-1
of Bawana Project. You are requested to modify the scheme for LT breakers
& Unit-1 & scheme may please be modified suitably for rest of the units of
Bawana project. Further same may please be checked for units supplied in
BHEL PSWR & if required scheme may please be modified as required.
4.5Cable Schedule between ECP & CTE panels: - Pair cable has been
used for PT voltage selection & movement of Voltage of selected breaker
from ECP to CTE & CTE to ECP for synchronisation. The details may please
be reviewed & if required cable schedule may please be changed for rest
of the units of Bawana Project.
4.6Large number of cable details as well as terminal details are not available
for ECP like TB details for movement of DC of sync circuit (check sync
relay & guard relay circuit) since positive in this circuit moves through a
contact which is shown as IRP however actually no details are available for
the same either in DCS/CTE panel. For example TBP 05 & 06, a DTAG was
made in DCS for creating this IPR(Check/ATRS Mode Selection) & a spare
relay was used for implementing the scheme. You are requested to provide
the details for TBP 07 & 08, 09 & 10 of auxiliary circuit of Bawana project,
further details may please be reviewed for the drawing supplied for units
in BHEL PSWR project.
5. NGT Panel: CRITICAL MATTER - One number Isolation (Neutral
Disconnect Breaker) breaker is supplied in NGT panel of which is used
during LCI operation of Generator. This Complete module is supplied by
RSI switchgear. Points to be taken into account are:

5.1The operation of this breaker was from Local in originally supplied NGT
module. This is highly dangerous since anybody can operate the
close/open switch from local during machine operation & star can come as
isolated earth system.
5.2The feedback of this isolation breaker is required in MarkVI for LCI starting
of machine. However in actually supplied panel wiring as well as limit
switch contacts are not available for wiring.
5.3These is interlock between this isolation breaker & starting switch (89 SS)The interlock is that if 89 SS is close then earth switch should not be close
& if earth switch is close then 89 SS should not close. For implementing
this logic neither TBs were available in NGT cubicle, nor were termination
details available for the same from BHEL PEM.
5.4A single phase Motor is supplied for the operation of this isolator breaker.
The supply details of the same were not available in the cable schedules
of PEM.
5.5The supply for operation of the motor was taken from 240 Volts UPS,
3C*2.5 sqmm cable was used for this purpose. Further a 240 V AC
contactor (2 NO & 2NC) was added into the NGT cubicle & TBs were added
into the cubicle for the wiring for feedback of Mark VI & interlock wiring.
The contactor was made to be in picked up condition which the isolator is
in open condition. Further local operation was disabled in GTG-1.
5.6The details of termination made at site may please be taken from Bawana
site. You are further requested to make changes in the wiring of rest of the
units of Bawana site. The matter may please be reviewed for NGTs
supplied at BHEL PSWR sites & if required proper changes may please be
made.
5.7The Quality of the breaker supplied is also needed to be addressed. The
quality is really poor. There were alignment problems in the chain
mechanism of the motor. Also if command for open/close operation is
removed in between & again command is given then the motor moves but
sufficient torque is not generated for operation of the isolator switch.
Hence NGT panel is needed to be opened & motor shaft is moved by hand
to take it to a position in which it can operate from command. However it
should not happen in such a critical device operation.
6. Generator Circuit Breaker Panel:
6.1Interconnection details of GCB with other systems like DAVR, ECP, GRP are
not proper & most of the details were not available. Further it is seen that
same TB details have been provided in the Electrical as well as C & I cable
schedules. Interconnection details GCB & DCS/Mark VI were not available.
6.2Site has prepared the details & cable laying & termination has been done
accordingly. You may kindly take the details from Bawana Site &

incorporate the same in the cable schedule & interconnection details. Also
kindly check the details prepared for the projects in BHEL PSWR.
6.3Interlocking Details with different systems like mark VI, mark Vie & NGT
panel may please be finalised in consultation with the different units &
details may please be prepared accordingly since lot of problems were
facing in hook of the different systems.
7. 6.6 KV Incomer Closing/Tripping:
7.1The cable schedule & interconnection details for interlock in closing circuit
of 6.6 KV incomer breakers were not available. Further details for sync of
incomer were not available.
7.2Site has prepared the details for closure of incomer 1. Kindly take them
from site & prepare the details for rest of the units & breakers.
8. LT Boards Incomer/Buscoupler Breakers: CRITICAL MATTER
8.1As per philosophy used by BHEL EDN/PEM 24 V closing/Tripping supply is
supplied from DCS which is used for closing/tripping of LT breakers.
However potential free contact is required in LT breaker as 48 V supply is
available from GE make relays in LT breakers.
8.2Site has done the modification for 7-8 breakers in unit 1 of Bawana. Kindly
incorporate the details into the cable schedule/interconnection. However
PEM/EDN engineering is requested to sort out the problem for rest of the
units of bawana. Same may please be checked for the projects in BHEL
PSWR.
8.3Logics of LT Breakers/ DG board- The logic required in maxDNA system is
needed to be reviewed since most of the under voltage contacts details
are not provided by PEM which is required for termination & completion of
Logic.

9. General Problems:
9.1The Cable schedules which are prepared for most of the projects is needed
to be reviewed since lot of overdesigning is seen which creates problems
at site.
9.2The interconnection details prepared are replicated in electrical as well as
C & I.
9.3In most of the interconnection details, one side details are not available
due to which cable termination cannot be preceded.

9.4Interconnection details of DAVR/GCB are not available for most of the

projects.
This report is generated to provide the feedback to units the points which are
critical for execution of the projects & are normally found missing at sites. A
lot of focus is required to be put while preparing cable Schedules &
Interconnection details.
This report is for information to all.