START UP & COMMISSIONING OF HP

1.1 Planning
For small hydro plants, the specifications should stipulate that the lead equipment supplier (usually
turbine supplier) is responsible for startup & commissioning activities and as such should furnish a
comprehensive and coordinated schedule of start up and commissioning which chronologically
details field activities. Time duration after completion of field tests of various electrical and
mechanical systems should not exceed 10 to 15 days for small hydro installation. A well planned
schedule will make it possible to carry out certain tests in parallel to minimize the time duration for
start up and commissioning.
1.2 Start Up & Commissioning Activities
The process of start-up and commissioning of hydro electric plant has following stages:
Field Tests
Start up Tests
- Dry condition tests (Prestart up, pre-commissioning tests)
- Watered up condition tests
Commissioning Tests
Testing of Control System
Commercial Operation
Technical Review of Commissioning of a Small Hydropower Station
1.2.1 Field Tests
At this stage all systems and subsystems are individually tested
Test at this stage include following:
- All critical unit clearances and dimensions are checked
- Alignment of unit shaft system
- Calibration and adjustment of all temperature sensing devices, pressure switches, flow switches,
transducers is done
- Continuity of all cabling and their connection as per cable schedules are checked
- Operation of all control system in both energized and de-energized state is checked
- Hydrostatic tests of all pressurized fluid system
- AC/DC high potential tests
- Bench test of protective relaying
- Check out also include all field testing that can be performed before the turbine begins to operate
All tests carried out must be properly documented for each system and subsystem and signed by tests
engineers of manufactures and plant owner. This documentation helps the owner to identify potential
problem in specific equipment before start-up and take remedial measure in advance.
1.2.2 Start-up Tests
Before starting of machine, start up tests of generating units, all other systems and subsystems should
have been done during field tests. These tests are divided in two categories.
Pre-commissioning tests (Dry Condition)
Commissioning tests (Watered up condition)
(a) No load tests
(b) Load tests or performance tests
1.2.3 Pre-commissioning Tests
These tests are conducted before charging the water conductor system of the unit. These checks can
be carried out in parallel with field testing. Some typical tests are as follows:
Hydrostatic tests of generator coolers, bearing coolers and piping.
Insulation resistance & dielectric test of generator
Functional checks and adjustment of generator speed switches and pressure switches
Functional checks of brakes, wicket gates, and excitation system
The entire unit must be thoroughly inspected before charging with water for tools, other objects
which might have been inadvertently left in the unit.
Check penstock man hole draft tube manholes are properly closed and tightened
Check working of all hydro-mechanical gates & valves etc
Check main & auxiliary transformers and their cooling arrangement
Check switchyard & switchyard equipment
Check all unit auxiliaries & station auxiliaries for their proper functioning
Arrange all clearances from in charges of different systems & subsystems

1.2.4 Watered up Tests
- Unit is charged with water, leakages from penstock and DT main holes, coolers, shaft seals are
checked, remedial action, if found necessary, are to be taken.
- Check penstock pressure, DT pressure, cooling water pressure and availability of water at proper
pressure in each cooler
- Ensure working of flow meters
- Then machine is rotated for the first time at slow-speed, ensure for any abnormal sounds or
interference in machines, take immediate remedial action, if necessary.
- This is a critical stage as for the first time all equipment components are operating as an integral
system at rated head and flow condition
- The first unit rotation is done at slow speed then machine is run at 25, 50, 75 and final 100% speed
- Following test at this stage are done
On line field test of generators such as telephone interference factor, wave form deviation etc.
Shaft run out
Bearing temperatures stabilization (this is called bearing run also)
Reliability of start, stop, synchronizing unit is also to be confirmed
All protective devices, lock out relays and emergency stop system are checked at low load to ensure
that they are functional
All these tests are divided in two categories:
(i) No load tests: These test conform the operation of the generator and powerhouse auxiliaries
equipment under no load conditions. These are follows:
- Phase rotation check
- No load saturation test
- Short circuit saturation test
- Operational tests, check thermal relays, speed switches, RTDs, flow switches
- Excitation system checks
- Point to point continuity test to verify the components are connected properly
- Insulation resistance tests to check the condition of cable insulation
- Functional test of each component and the interconnected system of components in both auto and
manual mode
- Test of the software and hardware associated with the computer control system
Besides above following checks are also essential:
(ii) Load Test: These test conform the operation of generator under load condition. These are
follows:
- Heat run test to determine maximum temperature rise
- Load rejection tests
- Brake operational time to safely stop the machine
- Measurement of excitation field current at generator rated output
- Measurement of cooling water flow rates for the bearings
- Unit capacity test
The load rejection test is performed at 25, 50, 75 and 100% rated load which confirm the unit can be
safely stopped under any operating condition. During these tests pressure rise in penstocks and speed
rise of the machine are measured to confirm that both of these parameters are within design limit.
Any abnormal noise, alarm, high temperature and any unusual or unexpected condition must be
thoroughly investigated.
1.2.4 Commissioning Tests
The unit is operated at rated output for a specified number of days. If no major problems occur
during contractually required period of operation at rated out-put, the unit is taken over by owner for
commercial operation. The unit index test and efficiency tests are also performed during commission
phase.
The performance testing is mandatory as per MNES for every SHP.
Commercial Operation:
The unit is called on commercial operation, from the date it is available to sell power to public. This
date immediately follows completion of commissioning tests.
1.3 Technical Review of Commissioning Activities
Small hydropower plants are found to be having more technical shortcomings than usually
considered. This is because of misconception that the small power output of the plant would require
small amount of required engineering input. As a result general lack of engineering details in the
project design, planning, as also in the specifications of major plant equipment is evident. These
conditions lead to technical flaws that may not be discovered until start up and commissioning of
unit. By this time, the flaws usually are not correctable without large, unexpected expenditure and
also time over run. Each hydroelectric plant is unique in certain aspects. If proper engineering
diligence is not used during initial design stages, the owner will receive a poorly designed plant
that cannot produce expected energy due to lack of water, improper turbine setting or net head rating
or improper sized generator. If proper engineering diligence is not applied during installation of
equipment, startup and commissioning will become a difficult exercise of turbine generator
equipment problems, connected plant wiring, control system failures and protective relay trips.
To avoid such an eventuality the owner must employ knowledgeable engineers or engineering firm to
carry out technical review at every stage of design & engineering manufacturing, shop assembly,
shop tests, installation, field testing as also start up and commissioning of the plant.
Some items require technical review before the start up process begins while for other items review
take place during start up and commissioning activities.
1.3.1 Items to Review Before Unit Start up & Commissioning
(i) Combined electrical / mechanical review task:
Review factory & field test certificates for all major pieces of equipment.
- Turbine
- Governor
- Speed increaser
- Intake gates, draft tube gates, spillway gates, inlet valves
- Generators
- Main power transformers
- Generator switch gears (medium voltage)
- Low voltage switch gears
- Unit or plant control switch boards
Confirm that manufactures have provided detailed written installation instructions for all major
pieces of equipment, including detailed dimensional record sheets
Review all detailed dimensional record sheets in conjunction with a visual inspection of all major
pieces of equipment.
(ii) Mechanical review task
Verify that hydrostatic tests have been performed on all pressurized fluids systems.
Review operational check out sheets for each mechanical system, including calibration sheets for
all level switches, flow switches, pressure switches etc.
Review unit alignment check out sheets
Review bearing setting, centering, gaps check out sheets
Review generator air gap check out sheets
Review functionality check out sheets for brakes, cooling system, oil pressure unit system, gland
seals repair seals, top cover drainage system, greasing system etc.
(iii) Electrical review tasks
Review system ground resistance test certificate and ensure adequate ground connection as per
relevant ISS.
Review surge protection of powerhouse/ switchyard
Confirm that phasing check has been performed across generator circuit breaker
Review the station battery/ battery charger arrangement and operational check out sheet
Verify that all relays are bench tested and that the settings are as per design and that CT shorting
screws have been
1.3.2 Items to Review or Inspected during Unit Start up and Commissioning
(i) Mechanical review
Observe first mechanical rotation of unit
Observe and review results of bearing temperature run
Observe and review results of unit load rejection tests
Observe turbine index test, verify that results are consistent with manufacturers promised
performance
Verify unit alignment and balance
Monitor for excessive vibration and GB run out;
(ii) Electrical Review
Observe unit manual starts, stops and synchronizations
Observe unit automatic starts, stops and synchronization
Observe one manually initiated emergency stop sequence
Observe unit stops by activation of each lock out relay
(iii) Review of PLC used for unit control
Identify manufacturers recommended chassis and logic ground points and see whether they are to
be connected collectively or grounded separately. If connected collectively confirm how common
mode noise is prevented from entering the PLC
Verify the grounded resistance value for chassis and logic grounds are consistent with the
manufacturers recommendation
Ensure that surge protection are provided on all inputs to the I/O racks that will be susceptible to
voltage transients including all cables routed to devices located outside the powerhouse.
Ensure that the 120 V AC power for PLC is reliable and free of voltage transients usually an
inverter fed by 125 V DC station batteries.
Confirm that the final PLC software coding has been well documented and that the document is
available for future plant maintenance and trouble shooting.
Finally it should be ensured that written installation instructions which include detailed dimension
records sheets have been provided by manufacturer. These sheets are used to record important
installation information e.g. the installed generator air gap, installed turbine clearances, installed
turbine, generator speed increaser shaft alignment. The completed dimensional record sheets should
be compared with manufactures tolerance requirement to confirm proper installation of the
equipment. They will also be used during future unit maintenance outages.