KESWICK POWERPLANT VOLTAGE REGULATOR
COMMISSIONING
FEBRUARY 1992
U.S. DEPARTMENT OF THE INTERIOR Bureau of Reclamation
Denver Office Research and Laboratory Services Division
Electric Power Branch
1090 (4-81) reau of Reclarnat~on
1. REPORT NO.
,090 (4 81) reau of Reclarnat~on TECHNICE 1 REPORT NO
R-92-06 4. TITLE AND SUBTITLE
KESWICK POWERPLANT VOLTAGE REGULATOR COMMISSIONING
Dmitry Shusterman, J. C. Agee 9. PERFORMING ORGANIZATION NAME AND ADDRESS
Bureau of Reclamation Denver Ofice Denver CO 80225
12. SPONSORING AGENCY NAME AND ADDRESS
Bureau of Reclamation Electric Power Branch Research and Laboratory Services Division Denver CO 80225
15. SUPPLEMENTARY NOTES
- REPORT STANDARD TITLE PAGE 3. RECIPIENT'S CATALOG NO.
5. REPORT DATE
February 1992 6. PERFORMING ORGANIZATION CODE
8 PERFORMING ORGANIZATION REPORT NO.
R-92-06
10. WORK UNIT NO.
11. CONTRACT OR GRANT NO.
13. TYPE OF REPORT AND PERIOD COVERED
14. SPONSORING AGENCY CODE
DIBR
Microfiche and hard copy available a t the Denver Office, Denver, Colorado. Ed: TH
16. ABSTRACT
In 1991, the original voltage regulating equipment was replaced on all three units a t Keswick Powerplant. J. C. Agee and D. Shusterman participated with Shasta Office personnel in commissioning the new voltage regulator during the week of July 29, 1991. This report describes the commissioning tests.
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS-- *voltage regulators1 control equipment/ *commissioning /power system stability1 power system stabilizers
b. IDENTIFIERS- Keswick Powerplant/ Shasta OfEcel Denver Ofice Laboratories
c. COSA TI Field/Group 09C COWRR: 0905 18. DISTRIBUTION STATEMENT
SRIM:
I (THIS REPORT) 1
19. SECURITY CLASS (THIS REPORll UNCLASSIFIED
21. NO. OF PAGES 0 A A'+
20. SECURITY CLASS 1 22. PRICE
KESWICK POWERPLANT VOLTAGE REGULATOR
COMMlSSlONlNG
Dmltry Shusterman J. C. Agee
Electric Power Branch Research and Laboratory Services Division
Denver Office Denver, Colorado
February 1992
UNITED STATES DEPARTMENT OF THE INTERIOR A BUREAU OF RECLAW=
Mission: As the Nation's principal conservation agency, theDepartment of the Interior has responsibility for most of ournationally owned public lands and natural and culturalresources. This includes fostering wise use of our land andwater resources, protecting our fish and wildlife, preservingthe environmental and cultural values of our national parksand historical places, and providing for the enjoyment of lifethrough outdoor recreation. The Department assesses ourenergy and mineral resources and works to assure that theirdevelopment is in the best interests of all our people. TheDepartment also promotes the goals of the Take Pride inAmerica campaign by encouraging stewardship and citizenresponsibility for the public lands and promoting citizenparticipation in their care. The Department also has a majorresponsibility for American Indian reservation communitiesand for people who live in Island Territories under U.S.Administration.
The informationcontainedin this report regardingcommercialproducts or firms may not be used for advertising orpromotional purposes and is not to be construed as anendorsement of any product or firm by the Bureau ofReclamation.
ii
CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulator Adjustment Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratings and Calibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OfflinePerformance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OnlinePerformance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Limiters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Rejection Performance . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table
Figure
12345678910111213
14(a)14(b)
TABLES
123
VoltsJhertz limiter data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Timed field current data. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Load rejection performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURES
Main field saturation curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exciter field saturation curve . . . . . . . . . . . . . . . . . . . . . . . . . .RC circuit modification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Offline closed loop frequency response for Unit 3 (P604 =60% and 70%) . . . . . . .Offline closed loop frequency response for Units 1,2, and 3 (P604 = 70%) ... . . .Offline step response of auto regulator for unit 3 (final settings) . . . . . . . . . . .Offline step response of manual regulator for unit 3 (final settings) .........Online step response of auto regulator for unit 3 . . . . . . . . . . . . . . . . . . . .Online frequency response for unit 3 . . . . . . . . . . . . . . . . . . . . . . . . . .Generator capability curve. . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum excitation limiter coordination curves. . . . . . . . . . . . . . . . . . . .Load rejection (unit breaker trip, 36 MW, 12MVAR) .................Load rejection (lockoutrelay trip, 36 MW, 12MVAR) . . . . . . . . . . . . . . . . .Load rejection, single phasing condition,22 MW . . . . . . . . . . . . . . . . . . . .Loadrejection, normal conditions,22 MW . . . . . . . . . . . . . . . . . . . . . . .
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INTRODUCTION
Keswick Powerplant houses three medium-size hydroelectric generators. Units 1 and 2 wereuprated in 1990, and unit 3 was uprated in 1991. In addition, the original voltage regulators onall three units were replaced with new automatic voltage regulating equipment consisting ofoperational amplifier-type voltage regulating and limiting circuits, control relaying, and athyristor-type power amplifier. The original rotating main exciter was retained.
J. C. Agee and D. Shusterman (Controls and Automation Section) participated with ShastaOffice personnel in commissioning the new voltage regulator during the week of July 29, 1991.
CONCLUSIONS
The manufacturer provided the modifications necessary for satisfactory regulator performance.These modifications, identified during commissioning of units 1 and 2, included lead/lagmodification of the regulator circuit, relocation of the field over-voltage relay from the exciterfield to the main field, and installation of a contactor in the field discharge circuitry. Also, themodified add-on circuit board in unit 3 was replaced with the older version to provide betteroperation ofthe volts-per-hertz (V/Hz) limiter and to match parts in units 1 and 2.
A 49.9-ohm resistor was added to the current feedback circuit in all three units to increasedynamic range. The regulator settings on all three units were chosen to provide identicalperformance for consistent operation. Slight differences in potentiometer settings exist due tocomponent tolerance.
REGULATOR ADJUSTMENT CRITERIA
Because the Keswick generators are rated under 50 megavolt-amperes, they are not equippedwith a power system stabilizer (PSS). The absence of a PSS could allow the automatic voltageregulator to decrease the local mode stability margin if the regulator was adjusted to maximumresponse speed. Therefore, the regulators were tuned for moderate speed and a high dampinglevel. Because these units do not share a common transformer, the regulators were set at zerodroop.This setting will providevoltageregulation at the 6.9-kilovoltbus.
RATINGS AND CALIBRATIONS
Units 1, 2, and 3 at Keswick are rated 41.053 megavolt-amperes at 0.95 power factor. Ratedvoltage is 6.9 kilovolts, and rated current is 3435 amperes. Full megavolt-ampere output isobtained at a real power of 39 megawatts and a reactive power of 12.8 megavars.
The PT(potential transformer) ratio is 60:1, and the CT (current transformer) ratio is 5000:5.The voltage regulator terminal voltage transducer at regulator card test point 741 (TP741) hasa base of 10 volts per unit.
Base field current of 360 amperes is required to produce rated tenninal voltage on the air gapline of the generators (fig. 1). The field resistance at 25°C is 0.252 ohm. At an operatingtemperature of 75 °C, the resistance was calculated at 0.302 ohm, providing a base field voltageof 109 volts.
Rotating exciter base field current of 6.2 amperes is required to produce 109 volts out of theexciter on the air gap line (fig. 2). The exciter field resistance is approximately 6.5 ohms at atypical operating temperature of 40°C, resulting in a base exciter field voltage of approximately40.3 volts.
At rated load (39 megawatts, 12.8 megavars), the main field current is approximately760 amperes; therefore, the main field voltage is approximately 230 volts (at 75°C). The exciterfield current is approximately 18 amperes and the exciter field voltage is approximately117 volts.
INITIAL STARTUP
Initial voltage application was successful on the first try. The generator and exciter saturationcurves were verified to match figures 1and 2.
OFFLINE PERFORMANCE
The added time constant of the rotating exciter produces marginal stability in the originalunmodified regulator control system. This condition was corrected during previouscommissioning tests by rdding an RC (resistor- capacitor) network in the firing angle circuitryas shown in figure 3 [1] . The RC network consists of a I-microfarad capacitor in series with a49.9-kilohm resistor connected across the series combination of resistors R1141 and R1142.Report R-90-21 contains the analysis of the resulting control system. The manufacturerprovided these modifications in the unit 3 regulator circuit board.
To improve system response, the gain of the voltage regulator was increased by adjusting gainpotentiometer P604 on all three units from 60 percent to 70 pe.rcent. The frequency response ofthe closed-loop voltage regulating system for unit 3 with the unit off line at rated voltage andspeed is presented in figure 4. Two responses are presented for settings of P604 at 60 percentand 70 percent. At a 70-percent setting, the bandwidth increased from approximately 1.3 hertzto 1.7 hertz, with a marginal increase in overshoot compared to the 60-percent response.
The frequency responses of all three units with P604 at 70 percent is presented in figure 5. Theresponses are similar. The step response of unit 3 at the fmal settings is presented in figure 6.The IO-percent to 90-percent rise time is 0.2 second and overshoot is 17 percent.
1 Numbers in brackets refer to references at the end ofthe report.
2
The automatic (voltage) regulator minimum voltage reference was set by PI04 to produce60 percent of rated terminal voltage with the reference setter at minimum. The maximumvoltage reference was set by P454 to produce 105 percent of rated terminal voltage with thereference setter at maximum.
The manual (current) regulator for this unit controls main field current. The modification (RCnetwork) also acts on this controller to insert lead/lag compensation identical to that placed inthe automatic (voltage) regulator circuit. The offline step response of the manual regulatingsystem is presented in figure 7. The 10- to 90-percent rise time is approximately 1 second, andthe overshoot is 10 percent (for increasing voltage).
The manual regulator minimum current reference potentiometer (P125) was set to produce30 percent of rated terminal voltage (80 amperes of main field current). The maximum currentreference potentiometer (P334) was set to produce 100 percent of rated (main) field current atfull load and rated power factor, overexcited. This corresponds to a main field current of760 amperes.
ONLINE PERFORMANCE
The unit was synchronized and loaded on the first attempt with no problems. The small-signalstep response of the closed-loop automatic voltage regulating system with the unit online ispresented in figure 8. The 10- to 90-percent rise time is approximately 0.8 second and theovershoot is 16 percent. The control system performance is well damped, with one overshoot.
Figure 9 contains the Bode plot of the online automatic voltage regulating system. The 3-decibelbandwidth is approximately 0.52 hertz, and the resonant peak magnitude is less than 2 decibelsabove the steady-state gain. Local mode resonance, occurring at a frequency near 1.8 hertz, isdamped.
The reactive droop potentiometer (PI08) was set to zero since the unit does not share atransformer with another unit. This setting provides voltage regulation at the machineterminals (6.9-kilovolt bus).
AUTOMATIC LIMITERS
The regulator is equipped with V/Hz (volts per hertz), minimum excitation, and maximumexcitation limiters. These limiters act in the automatic voltage regulator mode only and takecontrol under certain conditions. They do not function in the manual (current) regulator mode.
The V/Hz Jimiter limits the ratio of terminal voltage to speed. A frequency transducer monitorsthe terminal voltage to determine the unit speed (frequency). The transducer converts speed tovoltage, which is then fed into the automatic regulator. The regulator then maintains the ratioof terminal voltage to speed.
3
Table 1. - Voltslhertz limiter data.
PI'1 Freq2 nI Freq2 V/Hz(volts) (hertz) (pu) (pu) (pu)
118.7 58.3 1.03 0.972 1.062115.0 56.3 1.00 0.938 1.066111.4 54.1 0.97 0.900 1.074
1PI' base 115 volts.
2 Frequency base 60 hertz.
The V/Hz limiter should be operated with a large loop gain (potentiometers P104 and P112 athigh values). At low gain settings, the V/Hz ratio drifts too far from the preset value andprevents the limiter from coordinating with the V/Hz relay.
Unit 3 was originally equipped with a modified add-on board. One of the modifications on thisboard reduced the value of capacitor C301 from 22 microfarads to 2 microfarads. Previousexperience showed that this low value of C301 forces the limiter into oscillations at the highgain settings. Therefore, the original add-on board No. Al-401-340-010 was replaced with theolder version No. Al-401-340-003.
To provide for maximum V/Hz gain, P104 was set to 100 percent, and the range was set to100 percent on P112. The V/Hz limiter was set at a ratio of 1.06 per unit via potentiometerP405. The limiter performance was tested by increasing the automatic regulator output tomaximum and then lowering speed. The limiter maintained a ratio of 1.06 per unit (:to.01) at allspeed values (see table 1).
The V/Hz loop gain on unit 1 was very low during testing. Subsequent testing ofthe unit 1 V/Hzlimiter showed that its performance was unsatisfactory. Therefore, the settings of the V/Hzlimiter on unit 1 were adjusted to equal the settings on units 2 and 3. The limiter operatedsatisfactorily during retesting.
The minimum excitation limiter prevents the generator from operating excessivelyunderexcited. The capability curve on figure 10 contains the desired minimum excitation curve.Saturation of operational amplifiers in the limiter circuits limited the maximum setting of slopepotentiometer P726 to 55 percent. This setting produces the rather steep slope seen onfigure 10. Because of operational limits, the slope was tested at the lower breakpoint, thenadjusted to the higher level.
The maximum excitation limiter has two functions. First, it provides a fixed instantaneous fieldcurrent limit, allowing high-level excitation for a short time. Second, the limiter provides aninverse time characteristic after which the excitation limit is reduced to the rated value.
4
The instantaneous overexcitation was set via potentiometer P510, limiting overcurrent to145 percent of rated field current. The timed field current limit was set to 100 percent throughpotentiometer P527. The time delay potentiometer P517 was set to produce the time delayshown in table 2.
Table 2. - Timed field current data (fig. 11).
% Ifd above setpoint
1035.250
Time delay
8 see3 see2 see
RELAY COORDINATION
The field overvoltage transfer to current regulator mode and lockout trip circuits were testedand timed. The field overvoltage transfer to current regulator mode was set at 130 percent ofrated field voltage (300 volts) and a 15-second time delay. The field overvoltage lockout tripcircuitry was set at 130 percent of rated field voltage and a 25-second time delay. The relaypick-up voltage was adjusted by setting the relay shunt resistor wiper to 83 percent (the relayoperates at 250 volts). The shunt resistors for the field overvoltage relays on units 2 and 3 wereset similarly. These coordination levels are presented in figure 11, along with the maximumexcitation limiters and the short-time field current capability curve.
LOAD REJECTION PERFORMANCE
Load rejections were executed at 5 megawatts, 15 megawatts, 22 megawatts, and 36 megawatts,12 megavars. The unit breaker trip of the 36-megawatt, 12-megavar load rejection is presentedin figure 12. The unit breaker trip verified proper operation of the regulator phase back. The36-megawatt, 12-megavar load rejection via the lockout relay (86) is presented in figure 13. Thisload rejection ensured proper operation of the thyrite discharge circuitry.
.
Load rejection testing detected a bridge single-phase condition, which was traced to a faulty41E breaker. The 22-megawatt load rejection under the single-phasing condition is presented infigure 14(a). The 22-megawatt load rejection following correction ofthe condition is presented infigure 14(b). Overvoltage was reduced from 110 percent to 104 percent.
Results of the load rejections are summarized in table 3.
5
Table 3. - Load rejection performance.
Load Overspeed (%) Overvoltage (%)
5MW 100.5 101Unit Brk Trip
15MW 114 101Unit Brk Trip
22MW 127 102Unit Brk Trip
22MW 121 10486 Trip
36 MW, 12 MVARS 152 123Unit Brk Trip pre-rejection 103
36 MW, 12MVARS 147 12486 Trip pre-rejection 103
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6
REFERENCE
[1] Agee, J. C., and G. K. Girgis, Keswick Powerplant Unit 1 Excitation SystemCommissioning, Bureau of Reclamation, Research and Laboratory Services Division,Electric Power Branch, December 1990.
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APPENDIX
POTENTIOMETERSETTINGSFOR UNITS 1,2, and 3.
Main Regulator Board
Parameter Comments U1 (%) U2 (%) U3 (%)
P1256 Gate Max Retard Lim 75 75 75Pl131 Reactive I Cal 72 70 70P956 FreqN olt Cal 70 70 70P936 Real I Cal 70 75 70P747 FreqN olt Cal 55 60 50P734 Vt. Feedback Cal 20 20 20P726 Min Exc Limit Slope 42 50 55P827 Min Exc Limit B.P. 45 55 55P709 Min Exc Limit 50 50 45P636 I Reg Limiter 55 50 55P617 Min Exc Limiter Gain 100 100 100P604 AVR Gain 70 70 70P603 AVR Load 100 100 100P527 If Timed Limit 42 42 42P517 If Timed T.D. 90 100 100P510 If Inst Limit 70 70 70P454 Max V Ref 50 55 50P337 I Reg Gain 0 0 0P334 Max I Ref 60 65 56P325 If Feedback Cal 8 10 7P125 Min I Ref 8 7 10P108 Reactive I Droop 0 0 0P104 Min V Ref 5 3 2SW 301-1 Lead Lag Adj (Res) CLOSED CLOSED CLOSED
2 Lead Lag Adj (Cap) CLOSED CLOSED CLOSED3 Lead Lag Adj (Cap) OPEN OPEN OPEN
Auxiliary Board
P132 Var Reg N/A 100 100 100P136 Var Reg N/A 100 100 100P336 Var Gain Adj N/A 0 0 0SW147-1 P/F Var Reg Switch OPEN OPEN OPENSW147-2 Auto Tracking On/Off CLOSED CLOSED CLOSEDP405 Nominal V/Hz Adj 40 40 40P104 V/Hz Gain 100 100 100P112 V/Hz Range 100 100 100P439 Reactive Line Drop 0 0 0P443 Real I Line Drop 0 0 0P446 Line Drop Range 0 0 0Cur Reg Setter (Initial) 35 28 32
(Preset) 45 45 49Volt Reg Setter (Initial) 67 67 67
(Preset) 89 89 89
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16
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BV DATE PROJECTk:5W i Co. K. ~HEET_OF-
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18
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Figure 11. - Maximum excitation limiter coordination curves.
19
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20
:: Ii =:2 . ~:; I) 1"1t'1,""::;:; 1'[:31' t'j(). =:OOI);:::~ i
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Figure 13. - Load rejection (lockout relay trip, 36 MW, 12 MVAR).
21
~ ~, TH1E=tC1: 34: 47 DATE:::;: 1-,JUL-91 CHAF.:T F.:F'EED=2. 5(j t'H'1,/::; T E :::;T t'fC1.~;
Figure14(a). - Load rejection, single-phasing condition, 22 MW.
22
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Figure 14(b). - Load rejection, normal cond~ions, 22 MW.
23
APPENDIX
POTENTIOMETERSETI'INGS FOR UNITS 1,2, and 3.
Main Regulator Board
Parameter Comments V1 (%) V2 (%) V3 (%)
P1256 Gate Max Retard Lim 75 75 75P1131 Reactive I Cal 72 70 70P956 FreqN olt Cal 70 70 70P936 Real I Cal 70 75 70P747 FreqN olt Cal 55 60 50P734 Vt. Feedback Cal 20 20 20P726 Min Exc Limit Slope 42 50 55P827 Min Exc Limit RP. 45 55 55P709 Min Exc Limit 50 50 45P636 I Reg Limiter 55 50 55P617 Min Exc Limiter Gain 100 100 100P604 AVR Gain 70 70 70P603 AVR Load 100 100 100P527 If Timed Limit 42 42 42P517 If Timed T.D. 90 100 100P510 If Inst Limit 70 70 70P454 Max V Ref 50 55 50P337 I Reg Gain 0 0 0P334 Max I Ref 60 65 56P325 If Feedback Cal 8 10 7P125 Min I Ref 8 7 10P108 Reactive I Droop 0 0 0P104 Min V Ref 5 3 2SW 301-1 Lead Lag Adj (Res) CLOSED CLOSED CLOSED
2 Lead Lag Adj (Cap) CLOSED CLOSED CLOSED3 Lead Lag Adj (Cap) OPEN OPEN OPEN
Auxiliary Board
P132 Var Reg N/A 100 100 100P136 Var Reg N/A 100 100 100P336 Var Gain Adj N/A 0 0 0SW147-1 P/F Var Reg Switch OPEN OPEN OPENSW147-2 Auto Tracking On/Off CLOSED CLOSED CLOSEDP405 Nominal V/Hz Adj 40 40 40P104 V/Hz Gain 100 100 100P112 V/Hz Range 100 100 100P439 Reactive Line Drop 0 0 0P443 Real I Line Drop 0 0 0P446 Line Drop Range 0 0 0Cur Reg Setter (Initial) 35 28 32
(Preset) 45 45 49Volt Reg Setter (Initial) 67 67 67
(Preset) 89 89 89
241:lu.s. GOVERNMENT PRINTING OFFICE: 1991-4573-185/60,003 REGION NO.8
Mission
T h e mission of the Bureau of Reclamation is to manage, develop, and protect water and related resources in a n environmentally and economically sound manner in t h e interest of t h e American public.
A free pamphlet is available from the Bureau entitled "Publications for Sale." I t describes some of the technical publications currently available, their cost, and how to order them. The pamphlet can be obtained upon request from the Bureau of Reclamation, Attn D-7923A, PO Box 25007. Denver Federal Center. Denver CO 80225-0007.
