vol 10 commissioning final-01-12-13 10 commissioning...renewable energy guidelines nov. 2013 iii...

Renewable Energy Guidelines

Volume 10

Pakistan Poverty Alleviation Fund, Islamabad

Commissioning Guidelines PV ‐ MHP

Copyright © Pakistan Poverty Alleviation Fund – 2013

Reproduction is authorized provided the source is acknowledged and provided a reference copy is being sent to

PPAF and the reproduction is not sold.

For further information: Pakistan Poverty Alleviation Fund, www.ppaf.org.pk

Note: The information contained within this document has been developed within a specific scope and might be

up‐dated in the future.

The Renewable Energy Guideline Series has been developed by the German‐Pakistan project “Development of

Hydropower and Renewable Energy (HRE) in Khyber‐Pakhtunkhwa”, funded by German Development Bank

(KfW) on behalf of “Ministry for Economic Cooperation and Development” (BMZ).

Pakistan Poverty Alleviation Fund (PPAF)

Project team:

Mr. Zaffar Pervez Sabri

Senior Group Head, Public Goods and Services

Mr. Kamal Afridi

General Manager, Water, Energy & Climate Change

Mr. Shaukat Ali

Renewable Energy Specialist

Contact address:

1‐Hill View Road, Banigalla, Islamabad

PAKISTAN

E‐mail: [email protected]

Phone: (+92‐51) 261 3935‐50

Name of Consultants:

INTEGRATION

Team:

Dr. Ulrich Frings ‐ Team Leader

Mr. Sher Khan – Deputy Team Leader

www.integration.org

Author:

Ulrich Frings Mohammed Sadeq

Date: June, 2013

Renewable Energy Guidelines Nov. 2013 i

Volume 10 Commissioning Guidelines

Guidelines & Manuals

Volume 1: Life Cycle Cost Analysis in MHP Planning

Volume 2: Community Contribution Aspects in Rural Power Supply Systems

Volume 3: General Design Criteria on MHPs

Volume 4: Design Aspects of Community PV Systems

Volume 5: Operation & Maintenance Aspects of MHPs

Volume 6: Quality Assurance & Control of Civil Works

Volume 7: Health, Safety & Environmental Aspects in Civil Works

Volume 8: Transmission & Distribution in Rural Power Supply Systems Design ‐ Specification ‐ Installation

Volume 9: Electro‐Mechanical Equipment for MHPs Design ‐ Specification ‐ Installation

Volume 10: Commissioning Guidelines PV ‐ MHP

Volume 11: Micro/Mini Hydropower Design Aspects

Volume 12: Civil Works in Rural Power Supply Systems

ii Renewable Energy Guidelines Nov. 2013


Table of Contents 1 Commissioning of MHP Systems ................................................................................................ 1

Salient features ................................................................................................................... 1 1.1 Technical status................................................................................................................... 1 1.2 Performance check of installation .................................................................................... 11 1.3 Performance test .............................................................................................................. 15 1.4 Installation completion certification and remarks ............................................................ 15 1.5

2 Commissioning of PV plants ..................................................................................................... 19 Mechanical and visual inspection for PV‐ array area ........................................................ 20 2.1 Measurement of PV array ................................................................................................. 22 2.2 Mechanical and visual inspection for dc/ac Inverters ...................................................... 23 2.3 Measurement of dc/ac inverters ...................................................................................... 24 2.4 Mechanical and visual inspection for ac/dc ‐ dc/ac island inverter.................................. 25 2.5 Measurement of ac/dc/ac island inverter ........................................................................ 26 2.6 Mechanical and Visual inspection for distribution board ................................................. 27 2.7 Mechanical and visual inspection for battery/string/inverter fuse .................................. 28 2.8 Mechanical and visual inspection for battery/string/inverter fuse: ................................. 28 2.9 Mechanical and visual inspection for battery/string/inverter fuse .................................. 28 2.10 Mechanical and visual inspection for battery/string/inverter fuse: ................................. 28 2.11 Mechanical and visual inspection for battery/string/inverter fuse .................................. 29 2.12 Measurement of battery bank .......................................................................................... 29 2.13 Testing internal installation (Powerhouse) ....................................................................... 30 2.14 Training, awareness protocol ............................................................................................ 31 2.15 General installation testing & results ............................................................................... 32 2.16

Acronyms and abbreviations

A Ampere AC Alternating Current AKRSP Aga Khan Rural Support program ACSR Aluminium Conductor Steel reinforced CDM Clean Development Mechanism CO Community Organizations DC Direct Current EC European Commission ELC Electronic Load Controller E&M Electro‐mechanic FDC Flow Duration Curve GI Galvanized Iron

GIS Geographic Information System GIZ German Technical Cooperation GOs Government Organization GPS Global Positioning System HDPE High Density Polyethylene H&S Health & Safety hrs hours HV High Voltage Hz Hertz (frequency unit) INGOs International Non Governmental Organization KfW German Development Bank kW Kilo Watt

Renewable Energy Guidelines Nov. 2013 iii


kWh Kilo Watt Hour kV Kilo Volt LED Light‐Emitting Diode Lit Liter LSOs Local Support Organizations LT Low Tension LV Low Voltage MCB Moulded Circuit Breaker MCCB Moulded Case Circuit Breaker MDPE Medium Density Polyethylene MHP Mini/micro Hydropower Plant MSDS Material Safety Data Sheets NGOs Non‐Governmental Organizations O&M Operation and Maintenance PF Power Factor PCD Pitch Circle Diameter PPAF Pakistan Poverty Alleviation Fund POs Partner Organizations (COs) PPIB Private Power Infrastructure Board PURE Productive Use of Renewable Energy PPE Personal Protective Equipment PV Photovoltaics PVC Polyvenylchloride SM Social Mobilizer SRSP Sarhad Rural Support Program RCBO Residual Current Breaker with Overload Protection SSLS Solar Street/home Lighting System Rs. Pakistani Rupees T&D Transmission and Distribution TOP Terms of Partnership V Volt WOs Women Organizations

XLPE Cross‐linked polyethylene

Renewable Energy Guidelines Nov. 2013 1


1 Commissioning of MHP Systems

Salient features 1.1

Name of plant: Name of Owner:

Location:

Manufacturer: Supplier/Installer:

Ownership: Private/community No of households:

Gross head ___m; Design flow m³/sRated output _______kW

System: Single‐phase/Three‐phaseVoltage

_____V; Maximum current

_______A

Start of construction of project: day/month/year

Commissioning date: day/month/year

Technical status 1.2

1.2.1 Intake

Type of intake: Permanent/Temporary

If permanent, any cracks observed: Yes/No

Any leakage observed: Yes/No

Trash rack at intake: Installed/Not installed If installed, Clearance: mm,

Any structured cracks observed: Yes/No

Type of Trash rack: metal/local (special)

Flow controlling mechanism: Sluice gate/wooden stop logs/bush‐boulder/Others (specify)

Remarks on Intake ‐ Briefly discuss any major defects observed.

1.2.2 Headrace

Length of headrace (section 1): m Type of headrace (section 1): open earth/open

Rectangular/Trapezoidal/Triangular Cemented, DPE conduit/others (specify)

Length of head race (section 2): m Type of head race (section 2): open earth/open

Rectangular/Trapezoidal/Triangular cemented/HDPE conduit/others (specify)

Length of headrace (section 3): m Type of head race (section 2): open earth/open

Rectangular/Trapezoidal/Triangular cemented/HDPE conduit/others (specify)

2 Renewable Energy Guidelines Nov. 2013


Any leakage observed: Yes/No

Any cracks observed: Yes/No

Remarks on Headrace – Briefly discuss any major defects observed

1.2.3 Forebay

Type of Forebay: Stone masonry in c/RCC/Others (specify)

Trash rack: Installed/Not installed

If installed, Clearance: mm

Any structured cracks observed: Yes/No

Type of Trash rack: metal/local (specify)

Spillover: incorporated/not incorporated

Flushing arrangement: Works weIl/defects observed

Air vent pipe: installed/not installed

Remarks on Forebay ‐ Briefly discuss any minor/major defects observed:

1.2.4 Gravel trap/settling basin

Type: Stone masonry in c/RCC/Others (specify)

Flushing arrangement: Works weIl/defects observed

Remarks on Gravel Trap ‐ Briefly discuss any minor/major defects observed

1.2.5 Penstock pipes

Penstock Length (section 1/top): m Section 1: HDPE /GI/MS; Thickness ______mm;OD

Penstock Length (section 2/mid): m Section 2: HDPE /GI/MS; Thickness ______mm;OD

Penstock Length (section 3/bot): m Section 3: HDPE /GI/MS; Thickness ______mm;OD

Any leakage observed in Penstock: Yes/No

Ground clearance maintained:

Yes/No (minimum 300 mm)

Expansion Joint: Flange connected/Welded

Any leakages in expansion joint: Yes/No



No. of joints: ____ Nos

Maximum expansion measured: J1=______ J2=_____ J3=____ J4=______

HDPE conduit buried: Yes/No

No. of Penstock Sections: ___________

Remarks on Penstock pipes ‐ Briefly discuss any major defects observed

1.2.6 Anchor blocks/support pier

Any cracks observed in Anchor blocks: Yes/No

Any cracks observed in support piers: Yes/No

Remarks on Anchor blocks/support piers ‐ Briefly discuss any minor/major defects observed

1.2.7 Powerhouse

Powerhouse size (internal): L______m B____ m H _______m

Construction: Stone masonry in c/Dry stone/Others (specify)

Powerhouse roof: Corrugated GI/Plain GI/Others (specify)

Powerhouse floor: Compacted earth/Dry stone slabs/Cemented

Adequate working space for O/M: Yes/No

Cleanliness: Yes/No

Adequate lighting in PH: Yes/No

Free of undue leakages: Yes/No

Tailrace safely disposed off: Yes/No

Earthing done properly: Yes/No (Earth resistance < 10 ohm:)

Remarks on Powerhouse ‐ Briefly discuss any major defects observed



1.2.8 Tailrace

Construction: Stone masonry in c/Earth/Others (specify)

Section: Rectangular/Trapezoidal/Triangular Condition of tailrace: good/bad

Any cracks observed in structure: Yes/No

Remarks on Tailrace ‐ Briefly discuss any major defects observed

1.2.9 Turbine and driving system

Type of Turbine: Pelton/Cross flow / Francis / others (Specify)

Pressure gauge installed: Yes /No If yes, Size of gauge: ______ kg/cm² Pressure head during plant operation: ______ kg/cm² Pressure head during plant closure: ______ kg/cm² Type of valves installed: Spear valve/Gate valve:

Runner mounting: Vertical/Horizontal

Driving System:

Type of Belt: V ‐Belt/Flat Belt OR Direct coupling/others (Specify)

Size /No: __________ Size _________No

Alignment: Well aligned/deviation observed

Remarks on Turbine and driving system ‐ Briefly discuss any m句or defects observed

1.2.10 Generator

Specification:

Type: Synchronous/Induction Phase: 3 ‐phase/ 1‐phase Voltage: ______V Capacity: _______kW PF _______ RPM _______min‐1 Full load current: _______A Frequency: _______Hz Insulation class: Protection class: _______IP

Manufacturer:

Earthing done properly: Yes/No (Earth resistance < 10 ohm)

Remarks on Generator: ‐ Briefly discuss any major defects observed



1.2.11 Load controller and ballast

Load controller type: ELC/ELC‐Extension/IGC/Others (Specify)

Capacity: _______kW Rating voltage: _______Volt Current: ________A Condition of load controller: operates well/deviation observed . Ballast:

Ballast heater type: Immersed in tail race /Immersed in separate water tank

/Wall mounted space heaters/Others (specify)

Ballast heater specifications: __________V; _______W; Quantity ______nos.

Remarks on Load Controller: ‐ Briefly discuss any defects observed.

1.2.12 Control panel and switchgear

Protection provided: Yes No

Over voltage/under voltage: _____ ______

Over frequency/under Frequency: _____ ______ Overload/Short circuited: _____ ______

Are the installed fuses/breakers of adequate size: Yes/No

Size of MCCB/MCB: __________A Rated breaking capacity of the breaker: ______KA

Type of Fuse installed: Rating: ______ A

Emergency switch and feeder switch working properly: Yes/No.

Lightning arrestors installed at the power house: Yes/No.

Earthing of lightning arrestors properly done (R<10 Ohm)

Yes/No _____Ohm

all metal parts in power house well connected to earth Yes/No ____ Ohm

central neutral connector installed where all metal parts are directly connected to (with screws)

Yes/No

Measuring instruments incorporated in the Control panel to measure the following:

Main voltage and Ballast voltage Yes ( ) No ( ) 2. Load currents Yes ( ) No ( ) 3. Frequency Yes ( ) No ( ) 4. Power (kW) Yes ( ) No ( ) 5. Energy (KWh) Yes ( ) No ( ) 6. Reactive Energy (kVAr) Yes ( ) No ( ) 6. Indicator lamps Yes ( ) No ( )

7. Time totalizer (turbine operating hours) Yes ( ) No ( )



Remarks on Control Panel and switchgears ‐ Briefly discuss any defects observed

1.2.13 Cable, connections and supply

Type of power cable used in the power house:

Size of Cable

Cable jointing and connections properly?

Type of Service cable used for hooking up:

Size of Cable:

Tapping connection done properly?

Consumer end voltage within limit?

Receiving end voltage at peak load:

At start of village: _____Volt

At mid of village:______ Volt

At end of village:______ Volt

Copper/Aluminium

________mm²

Yes/No

Concentric/Twin /flat/Others

_________mm²

Yes/No

Yes/No (total V drop < 8%)

voltage trop in %: ________

voltage drop in %_________

voltage drop in %:_________

1.2.14 Transmission/distribution lines

Type of transmission/distribution

Length of the system:

Voltage transmission line:

Voltage distribution line:

Type of cable:

Type of Pole:

Overhead/underground

_________m;

________kV

________kV

ACSR/ABC/PVC Mild

Steel/Wood/Concrete/Other



Lightning arrestor installed at each end of line and at every lightning prone areas of the system.

∙ If neutral on top, is it grounded directly?

∙ Are earthings provided to each lightning arrestor?

∙ Are all joints along the earth path being brazed/soldered?

∙ Should line patrolling be carried out before commissioning?

∙ Is measured ground resistance < 10 ohm?

∙ Are Fuses/switches (DB) provided at branch points of the distribution lines for load more than 10 kW. Are DB boxes weatherproof and rain protected?

∙ Shall pole stays be used at all poles at angle and at line

ends?

∙ Preservative or anti corrosion paint (Black Japan paint) applied on pole foundation?

∙ Safety clearances adequate?

General clearances: Ground to Wire: Off road:

Across road:

Along sides of motor road:

Insulator type acceptable?

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

________m

________m

_________m

Yes/No

Remarks on electrical lines: Briefly discuss any defects observed in construction, finishing, cable jointing and terminations, service cable tapping, bedding, clearance and safety of transmission and distribution system.



Transformers: Type:_________ No:__________ Capacity: _________ kVA _________ kVA _______ kVA Nominal losses: no load________ ________ load no load________ _________load no load_________ _________load installed at: masonry/concrete stands/between poles/inhouse/other installation height above ground:_______ m transformers well protected against any form of unauthorized access: Yes/No Cable with connected: Yes/No lightning arrestors installed Yes/No Resistivity:_______ Ohm feeder switches and fuses installed and well working: Yes/No earthing installed and workable: Yes/No __________Ohm

Remarks on Transformers:

1.2.15 Subscriber connection

Power Limiters installed:

Yes/No

Power limit

Number

Limit switch type

Remarks

House Connections:

connection: wires/single/cables/PV cables/other diameter:_____mm²

Meter: No/Mechanic/Electronic _____nominal current A

safety devices installed

Yes/No Type: Ordinary fuses/breaker/earth fault current switch

Nominal A:_________ fault current:__________ mA



1.2.16 Manuals and other related documents

All the specified manuals are supplied (Acceptable) 口

Few of the specified manuals are supplied

(Not acceptable ‐ Non Critical) 口

Non of the specified manuals are supplied (Not acceptable‐ Critical) 口

Confirm supply of following manuals:

(a) Operation, Maintenance and trouble shooting manual. Yes/No

(b) Check list for fault detection and communication with manufacturer, checklist for normal operation (bearings, instruments, belts, coupling rubbers, noise vibrations). Yes/No

(c) Technical manual of as ‐ built plant.

Yes/No

(d) Sample (master copy) of operation sheet for the operator (e.g. data, instrument readings, observations, reading interval, signature etc). Yes/No

(e) Sample (master copy) of maintenance sheet for the operator (lubrication intervals, check intervals, signature etc). Wiring diagram of power station with description of all

fuses (type and size). Yes/No

(f) Address, phone number of suppliers and sub‐suppliers for spare parts, ordering and guarantee claims. Yes/No

(g) Wiring diagram of power station with description of all fuses and switches (type and size) (h) operation diary Yes/No

Yes/No

Remarks:

1.2.17 Spares parts and tools

List the spare parts and tools supplied to the plant:

Spare parts Tools

Description Remarks/Condition Description Remarks/Condition

Comment on supplied v/s quoted list of spare parts and tools:

Recommend any additional spare or tool that is required for the site and equipment condition:



1.2.18 Other remarks and observations

a. All power and control cable within the powerhouse are armored cable (or PVC cables in HDPE conduit) and are either buried or in trench: Yes ( ) No ( ) b. Power and control cable terminations without control boxes are

marked/numbered and connected through terminal connectors. Yes ( ) No ( )

c. Equipment outer surface is painted with matching color where needed. Yes ( ) No ( )

d. Equipment metal parts are earthed with all different parts connected

in parallel to one star‐point (central neutral point). Yes ( ) No ( ) e. Connecting underground cables along straight‐through sections are

done using jointing kits. Yes ( ) No ( )

Remarks:



Performance check of installation 1.3

1.3.1 Situation 1 ‐ Static condition

(Nozzles, valves all closed; fore bay drain closed; Approximately required amount of water diverted toward headrace and penstock pipe slowly filled and water expelled via spillover channel.)

Static head indicated by pressure gauge in powerhouse, Hg = ______m (1 bar = 1 kg/cm² = 10m)

1. Flow‐controlling mechanism at intake

a. Flow c an completely be blocked if desired, and amount of water flowing toward

headrace can be controlled (acceptable) 口

b. Flow cannot be stopped and controlled (not acceptable ‐ non critical) 口

2. Free board in Headrace Canal

a. Free board of at least 30 cm or half the height of water at design flow is maintained

throughout (Well and Acceptable) 口

b. Free board of at least 10 cm is maintained throughout (acceptable) 口

c. Free board less than 10 cm (not acceptable non critical) 口

3. Headrace performance:

a. Minor leakage or no leakage through headrace (Acceptable)

口

b. Minor leakages but in many parts of the headrace (Not acceptable‐ non critical)

口

c. Major leakages and cracks in the structure (Not acceptable‐critical)

口

4. HDPE pipe Burial

a. All HDPE sections along headrace are buried or covered (acceptable) 口

b. Any portion not buried or not covered (not acceptable ‐ critical) 口

5. Spillway

a. All of design flow can safely be expelled from the spillover channel (acceptable) 口

b. All design flow can not be expelled safely from spillway channel

(not acceptable ‐ critical) 口

6. Penstock

a. No water leakage from penstock joints/welded section (Acceptable) 口

b. Water leakage from penstock joints/welded section (not acceptable ‐ critical) 口

7. Support piers and Anchor blocks

a. Metal penstocks are adequately supported to form straight lengths (acceptable)

口

b. Penstock line sagging (not acceptable ‐ critical) 口

c. Cracks in the structure (not acceptable ‐ critical) 口



8. Earth resistance Test

a. Neutral earthing at powerhouse < 10 ohm (acceptable) 口

b. > 10 ohm (not acceptable ‐ non critical) 口

c. > 50 ohm (not acceptable ‐ critical) 口

Value: ______Ohm

d. Any other remarks for performance check during static condition

1.3.2 Situation 2 ‐ Dynamic condition

(All valves are slowly opened to maximum open condition so as to operate the set at full flow condition. Forebay should still be filled with water up to the spillover channel crest level. Bring more water if required)

Note dynamic head indicated by the pressure gauge in powerhouse, Hn =___________m

Water discharge at tailrace, Q =_______m³/s

(approximate measure by means of weir at tailrace)

Gen.

volt

Gen. Freq. _____Hz

Feeder line current __________A

Ballast volt/current _____(full ballast; (no village load)

____V

2 Gen.

volt

_____ V Gen. Freq. ___

HzFeeder line

Ballast volt/current______(village load = 50% of rated plant capacity)

Volt. Change_____ V

Freq.change__ Hz ______current A

2a Switch OFF village load

Time to return to steady state condition:

sec

2b Switch ON village load

Time to return to steady state condition:

sec

3 Gen. voltage: ________________V

Gen. Freq. ____Hz Feeder line Ballast volt/current_______(set ‐ zero)

Volt. change ______V

Freq. Change__Hz current _____A Pf of village load ____________

3a Switch OFF village load

Time to return to steady state condition: _______ sec

3b Switch ON village load

Time to return to steady state condition: _______ sec

3c For Micro Hydros: Power factor of village load should be maintained at no worse than 0.8. For this, if some tube lamps are used, total wattage due to tube lamps should not be more than about one ‐ third of total wattage due to incandescent lamps (or resistive loads).

4 Calculate approx. total power produced, P = Generated voltage x Feeder line current x Power factor

Give the Value power produced, kW



P:______

Guaranteed power produced (acceptable) 口

Guaranteed power not produced (not acceptable ‐ critical) 口

5 For Micro Hydros: Calculate approximate power factor = Cos [tan‐1 {P2 x 1.73} / {P 1 + P2}), Where, P1 = total resistive wattage; P2 = total tube lamp wattage; power factor of tube lamp 0.5

6 Calculate water to wire efficiency = P x 102/(Hg x Q) =

7 Calculate MHP efficiency = P x 102/(Hn x Q)=

8 The following tests are mandatory during commissioning:

Checking operation of mechanical and electrical protection systems; Compared to

nominal values trip setting of the protection devices should be as follows (both

synchronous and induction generator where applicable)

1. Over voltage at 10% 2. Under Voltage at 20%

3. Over frequency at 15% 4. Under frequency at 10%

Insulation test of cables, generator, transformer and braking system

No‐load test with AVR Excitation test

Loading test (Load acceptance, load rejection, output test, stability of

controller/governor)

Efficiency test water to wire using calibrated test ballast and instruments

1.3.3 Other tests and observations on dynamic situation:

1. Check for unusual noises and vibrations, bearing temperature and other anomalies: (with total ballast

and without excitation):

A=Acceptable: NA=Not acceptable

Rated Vibration Noise Bearing Temp Body Temp

Speed

20%

Un‐noticeable (A) Uniform high pitch sound Cool to touch (A) Warm to touch (A)

Minimum (A) (A) Hot to touch (A) Hot to touch (A)

Noticeable (NA) Non uniform high or low Too hotωtouch (NA) Too hot to touch

pitch sound (NA) (NA)

50%



Noticeable (NA) Non uniform high or low Too hot to touch (NA) Too hot to touch


100%



Noticeable (NA) Non uniform high or low Too hot to touch (NA) Too hot to touch


2. Power cables temperature (near termination/contact point)

a. Cool Acceptable 口

b. Warm Not Acceptable – Critical 口

3. Meter readings as compared to readings of a hand held test meter readings



a.Within 5% ( acceptable) 口

b. More than 5% (not acceptable ‐ non critical) 口

4. Earth fault test trip and simulation test (in case of under ground lines)

a. Successful (acceptable) 口

b. Unsuccessful (not acceptable ‐ non critical) 口

5. 110% sustained over current simulation test result

a. De excites (acceptable) 口

b. Under‐voltage operation below 20% (not acceptable ‐ critical) 口

c. Feeder breaker trips (acceptable) 口

d. Generator over heats (not acceptable ‐ critical) 口

e. Nothing happens (acceptable provided feeder load switching off does not cause more than 10%

over voltage or excitation breakers trip)

6. 120% sustained over current simulation test result

a. De excites ( acceptable) 口

b. Under‐voltage operation below 20% (not acceptable 一 critical) 口

c. Breaker trips (acceptable) 口

d. Generator over heats (not acceptable ‐ critical) 口

e. Nothing happens (not acceptable – critical) this may cause over voltage even for ballast heaters

when feeder load gets switched off)

T. Sustained over 10 % voltage simulation test

a. Excitation breakers trip (acceptable) 口

b. Nothing happens (not acceptable – critical) 口

8. For both synchronous and induction generator,

a. Steady state voltage deviation: within ‐ 5% to +5% (acceptable) 口

b. Beyond ‐ 5% to + 5% (not acceptable ‐ critical) 口.

9. For synchronous generator (ELC),

a. Steady state frequency deviation: within ‐5% to +5% (acceptable) 口

b. Beyond ‐5% to +5% (not acceptable ‐ critical) 口

10. In case of induction generator (IGC),

a. Steady state frequency deviation: within ‐5% to + 10% (acceptable) 口

b. Beyond ‐5% to + 10% (not acceptable ‐ critical) 口

11. Transient voltage and frequency deviations due to sudden load changes

a. Within 15% and 20% respectively (acceptable) 口

b. Beyond that (not acceptable) 口

12. Any other remaining remarks or observation on dynamic test performed 一

(Requirements as per the prevailing standards for MHP installation should be met)



Performance test 1.4

The performance test includes a 36 hour continuous operation for Micro hydropower and 72 hours continuous operation for Mini hydropower plants.

Operation recorded (hourly basis) in operation diary: Yes/No

Plant operation was well without any defect/interruption in operation Yes/No

if No please specify:

Check for unusual noises

A=Acceptable: NA=Not acceptable

Vibration Noise Bearing Temp Body Temp



Noticeable (NA) Non uniform high or low Too hot touch (NA) Too hot to touch


2. Power cables temperature (near termination/contact point)

a. Cool Acceptable 口

b. Warm Not Acceptable – Critical 口

3. Meter readings as compared to readings of a hand held test meter readings

a. Within 5% ( acceptable) 口

b. More than 5% (not acceptable ‐ non critical) 口

Installation completion certification and remarks 1.5

1. Installation fully accepted with 1 year warranty

Signature of Inspector Signature of Owner Signature of Installer/Supplier

Name: Name: Name:

Date: Date: Date:

2. Installation conditionally accepted provided all defects are of non‐critical type and that they

would be corrected within defects correction period of 1 year. ("Non critical")

Signature of Inspector Signature of Owner Signature of Installer/Supplier

Name: Name: Name:



Date: Date: Date:

3. Installation not accepted as one or more of the defects are of critical type_

("NOT accepted ‐ critical")

Signature of Inspector Signature of Owner Signature of Installer

Name: Name: Name:

Date: Date: Date:

Witness 1: Witness 2: Witness 3:

Note: Please also attach the photographs of various civil and electromechanical components along with the testing commissioning format

Flow Measurement Methods:

1 ‐ Salt Dilution Method

Water flow measurement by salt dilution method of _____________________ River

Date/Time:

Weather:

Salt used: _______ gram Water temp:____ °C

Baseline Conductivity:___________________ mS (i.e. conductivity in the river before pouring salt

solution)

Salt constant k = _______

Time (sec)

05 10 15 20 25 30 35 40 45 50 55 60 Sum

Water conductivity in µS

Minutes

1

2

3

4

5

6

7

8

9



10

TOTAL:

Area (A) under the curve =

Note that the "Area" here is the area under the graph of conductivity in μS in the vertical axis and time

in second in the horizontal axis excluding the baseline conductivity (i.e., conductivity measure before

pouring the salt solution upstream). Hence, the units of "Area" under the graph are μS*Sec.

Q=Mk/A

Note:

Use separate sheet if other method has been used for flow

measurement.

Give minimum estimated flow using MIP method.

18 Renewable Energy Guidelinesl Nov. 2013


Power Output Test Form

Name of MHP: Owner: Date

Location District:

No Village Load Power Ballast Load Power

UAN IA pf PA UBN IB pf PB UCN IC pf PC Total Power

Freq. UAb UBb UCb PA PB PC Total Ballast Power

weir height

Discharge

Pressure gauge

Valve position

Remarks

(V) (A) (kW) (V) (A) (kW) (V) (A) (kW) (kW) (Hz) (V) (V) (V) (kW) (kW) (kW) (kW) (m) (m³/s) (kg/cm²) (%)

1

2

3

4

5

6

Design Head (m): Design Flow (m³/s): Design Power (kW): Minimum Power requirement (kW):

Actual Head (m): Actuval Flow (m³/s): Actual Power (kW): Stream Flow at Intake (m³/s):

I/We hereby certify that I/we have measured and ferified power outpur from the MHP.

I/we hereby certify that the measured power output for the design flow of this installation is _______ kW

Data Recorded by Name Signature and Date

Owners's Representative:

Installer's Representative as witness

Inspector:



2 Commissioning of PV plants

Date: Region:

Village / Area:

Installation Company:

Technician name: , Tel: (From Installation Company: ___________________________________)

PPAF responsible: , Tel: (Name/ Function: __________________________ / ________________)

PO responsible: , Tel: (Name/ Function: __________________________ / ________________)

Community responsible: , Tel: (Name/ Function: __________________________ / ________________)



Mechanical and visual inspection for PV‐ array area 2.1

PV String array Loose Tight

Fence Loose Tight

Cable connections Loose Tight Rust

Shading on the PV array Yes No

Vegetation under PV array Yes No

PV Module Serial No.



dc/ac inverters: Type /Serial Nos.

ac/dc/ac island inverters: Type / Serial Nos.

___________________________________ ___________________________________

___________________________________ ___________________________________

___________________________________ ___________________________________

___________________________________ ___________________________________

___________________________________ ___________________________________

___________________________________ ___________________________________

___________________________________ ___________________________________



Measurement of PV array 2.2

(please take the measure at sunshine)

No

Electrical Equipment

To be Measured

Voltage (V) Current (A) Connected to

Remark Ref

(STC)

Measured Var

Ref

(STC)

Measured Var dc/ac inverter no. MPP‐Tracker no. // to string no.

1 PV String 1 / DC ___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

Remark:

Recommendation:



Mechanical and visual inspection for dc/ac Inverters 2.3

Type or No.

Functional Yes No

Mounting Loose Tight

Cable connection Loose Tight

Noise Normal High



Measurement of dc/ac inverters 2.4

Type or No.

No

Electrical Equipment

To be Measured


Remark

Ref

(STC)

Measured Var Ref

(STC)

Measured Var Distribution box no. Fuse no.

_______________/ AC 220‐240 ……. (Max)

_______________/ AC 220‐240 ……. (Max)

_______________/ AC 220‐240 ……. (Max)

_______________/ AC 220‐240 ……. (Max)

_______________/ AC 220‐240 ……. (Max)

_______________/ AC 220‐240 ……. (Max)

_______________/ AC 220‐240 ……. (Max)

Remark:

Recommendation:



Mechanical and visual inspection for ac/dc ‐ dc/ac island inverter 2.5

Type or No.

Functional Yes No



Noise Normal High



Measurement of ac/dc/ac island inverter 2.6

Type or No.

No Electrical Equipment

To be Measured


Remark

Ref

(STC)

Measured Var Ref

(STC)

Measured Var Distribution box no. Fuse no.

_______________/ AC

202‐253

……. (Max)

_______________/ AC

202‐253

……. (Max)

_______________/ AC

202‐253

……. (Max)

_______________/ AC

202‐253

……. (Max)

_______________/ AC

202‐253

……. (Max)

_______________/ AC

202‐253

……. (Max)

_______________/ AC

202‐253

……. (Max)

_______________/ AC

202‐253

……. (Max)

Remark:

______________________________________________________________________________

Recommendation:



Mechanical and Visual inspection for distribution board 2.7

Type No.

Functional Yes No



Connected to:

Inverters Nos. Strings Nos. Battery Banks Nos. Other ‐ describe

Remark:

Recommendation:



Mechanical and visual inspection for battery/string/inverter fuse 2.8

Type Battery bank/String/Inverter No.

Functional Yes No



Mechanical and visual inspection for battery/string/inverter fuse: 2.9


Functional Yes No





Functional Yes No



Mechanical and visual inspection for battery/string/inverter fuse: 2.11


Functional Yes No







Functional Yes No



Mechanical and visual inspection for battery bank

Type or No.


Battery Commissioning Report missing OK

Measurement of battery bank 2.13

Type or No.

No Electrical Equipment

To be Measured

Voltage (V) Current (A) Connected to Remark Ref

(STC)

Measured Var Ref

(STC)

Measured Var Fuse no: ac/dc/ac inverter no:

Battery bank 48

Battery bank 48

Battery bank 48

Battery bank 48

Battery bank 48

Remark:

Recommendation:



Testing internal installation (Powerhouse) 2.14

Are all Socket outlets functional? Yes No If No, How many socket outlets are not functional? Are all Switches functional? Yes No If No, How many switches are not functional? Are all Bulbs functional? Yes No If No, How many Bulbs are not functional? Air Conditining Installed? functional? Yes No Heating Installed? functional? Yes No Doors & Windows sufficiently tight and closing? Yes No Other openings ( please describe )?

Remark:

Recommendation:



Training, awareness protocol 2.15

Participants list

Name Position

1

2

3

4

5

6

No Title of lecture Time Delay

1 Source of PV‐Solar system 180 min

2 Conversion of solar energy

3 DC to AC conversion

4 Battery protection 60 min

Remark:



General installation testing & results 2.16

Remark:

Recommendation:

vol 10 commissioning final-01-12-13 10 commissioning...renewable energy guidelines nov. 2013 iii...

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