COMMISSIONING CHECKLIST FOR

AUTOSYNCHRONISER
(ASR)

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR: TECHNICAL SERVICES NOIDA

Commissioning Checklist

DOCUMENT No. PWR/TSX/C&I/01/243/00/11

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Contents
1. Introduction
2. Brief description of different modules used in Auto synchronizer panel.
2.1

7TN-35

Power Supply Module

2.2

TM-6100

Measurement Input Module.

2.3

TW-2300

U Limit Value Detection and Voltage leveling

2.4

TW-2400

Frequency Adjuster Module

2.5

TW-2500

f Limit Value Detection Module

2.6

TW-2600

Switching Point Determination Module

2.7

TS -3000

Relay Module

2.8

TW-2000

Starting stage

2.9

TL-6100

Combining stage

2.10 TS- 2800

Command Module

2.11 TW -2700

Supervision Module

3. Requirements of drawings and documents

4. Requirements of tools/instruments
5. Pre- commissioning checks
6. Functional check list for autosynchroniser
7. Recommended Sequence of operation
Annexure I

BHEL

POWER SECTOR TECHNICAL SERVICES, NOIDA

Commissioning Checklist

DOCUMENT No. PWR/TSX/C&I/01/243/00/11

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1. INTRODUCTION:
Autosynchroniser module 7VE21 (Siemens make) is normally used for
synchronization of steam turbine generator with grid. It is supplied as a part of EAST
package and located in CJJ08 panel. Load Measuring Unit (LMU) and Load
Shedding Relay (LSR) modules are also located in same panel.
Auto synchronization is used for fast & trouble free synchronization of generators
with the grid. Generator voltage and frequency is compared with that of grid by ASR and
appropriate commands are issued for voltage and frequency correction. When voltages
and frequencies are matched and as soon as switching point is found it gives final closing
command to GCB.

2. BRIEF DESCRIPTIONS OF DIFFERENT MODULES USED IN

AUTOSYNCHRONISER (ASR) PANEL (EDN/SIEMENS)
2.1

7TN 35 Power Supply Module: It receives 24V signal after getting ON command to
make ASR operative.

2.2

TM 6100 Measurement Input Module: This module receives the two voltages grid
voltage & generator via two manual switches F09 and F10 (figure -2, Annexure-I). The
outputs deliver AC Voltages for voltage and frequency equalizing and angle-proportional
signals (triangular wave voltage) for determination of the switching-time point, the
frequency difference.

2.3 TW 2300 U Limit Value Detection and Voltage leveling Module: This Module
determines the voltage difference between the two voltages, grid and generator voltages
and generates control signals for the Raise/Lower settings of the generator voltage. When
the voltage difference is less than the set value (U), no more setting commands are
produced and a release signal is given to the combining stage.
Plug Setting for range of U (if grid voltage and generator voltage difference is less
than U it is assumed as voltages are matched)

BHEL

Plug Setting for pulse time tp is set which determines the duration of pulse given to
AVR for raise lower command of excitation voltage.

Plug Setting for pulse interval which determines the time between two consecutive
pulses.

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Commissioning Checklist
2.4

2.5

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TW 2400 Frequency adjuster Module (Speed Controller)

This module determines the difference between the frequencies of Voltages U1 & U2 and
generates control commands for adjusting frequency f2 (generator frequency). These
commands are not given between f = 0.05 and 0.08 Hz

Setting of pulse per beat 2, 4

Setting of pulse-time

TW 2500 Limit value determination Module

This module determines the frequency difference between two voltages U1 and U2 from
the two triangular wave curves and, if this is less than a set frequency difference, it gives
a release signal for the generation of a switching command.

2.6

DOCUMENT No. PWR/TSX/C&I/01/243/00/11

Plug Setting for range of f

TW 2600 Switching Point determination Module

This Module determines the switching point for the closing command of the Power Circuit
Breaker from the two Triangular wave curves obtained from the measurement of input
module.

Selection of Breaker make time tE

2.7

TS 3000 Relay Module: The module converts Electronic control signals into control
signals with galvanic separation.

2.8

TW 2000 Starting stage Module: In this module, the measurement is released after
receipt of an external starting signal.

2.9

TL 6100 Combining stage:-This module combines all signals necessary for a closing
command, determines the duration of the closing command and Resets the apparatus after
a successful closing command.

2.10 TS 2800 Command Module: This module gives closing command to the Power circuit
Breaker.
Plug setting for selection of Command time
2.11 TW 2700 Supervision Module: This module gives blocking signal when inadmissible
values or differences are detected in the signals for determination of switching point.

Note: For further detail ASR manual by BHEL EDN may be referred.

BHEL

POWER SECTOR TECHNICAL SERVICES, NOIDA

DOCUMENT No. PWR/TSX/C&I/01/243/00/11

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3. REQUIREMENTS OF DRAWINGS & DOCUMENTS:

Generator control & relay panel drawings (either in BHEL scope or customer scope). used for

extending PT supply to ASR panel and breaker closing command

Excitation system panel GA drawing and control schematic

Cable schedule and interconnection diagram for ASR.

4. REQUIREMENT OF TOOLS/INSTRUMENTS:

Multimeter for measurement of voltage, frequency and continuity testing

OMICRON Relay testing kit which has facility to supply two set of variable voltage (order
of 100-110 V) and variable frequency (order of 47.5 to 52.5 Hz).
Pliers, tester, connector etc.

LIST OF PRE COMMISSIONING CHECKS

5.

CHECK FOLLOWING FLUG SETTINGS

S.no

Description

1
Range of U
(TW2300)
2
3

Pulse time(tp)
(TW2300)
Pulse interval(tw)
(TW2300)

4
Range of f
(TW2500)

BHEL

Plug-setting
options

Recommend
ed plug
settings

2V
5V
15V
30V

2V

Less than U is considered as

matching condition

1S

width of the pulse which goes for

voltage correction

2S

Interval between two pulses

which goes for voltage correction

1S
3S
2S
5S
0.1HZ
0.25HZ
0.5HZ
0.75HZ
1.0HZ

0.1HZ

Pulse time (tP)

(TW2400)

0.1S
0.2S
0.4S

0.2S

Pulse per Beat

(IMP/BEAT)
(TW2400)

2
4

Remarks

Less than f is considered as

matching condition

width of the pulse which goes for

frequency correction

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Commissioning Checklist
7

BREAKER - MAKE
TIME ( tE )
(TW2600)

COMMAND TIME
(tK)
(TL6100)

50 mS
100mS
150mS
200mS
250mS
300mS
350mS
400mS
450mS
500mS
550mS
600mS
100MS
250MS
500MS
1000MS

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150mS

250mS

Duration of Close Command

issued to GCB for closing.

Check if all cards are as per schematic and properly inserted

Check for inter connection of all cables between external panel and auto-synchronizer
inputs/outputs
Check continuity of the inter panel cabling with a good continuity tester or multimeter.
Check IR value for PT circuit inside the panel.

6. CHECKS TO
SHUTDOWN

BE

CARRIED

OUT

WITH

MACHINE

UNDER

Arrange Relay testing kit which has facility to supply two set of variable voltage (order of
100-110 V) and variable frequency (order of 47.5 to 52.5 Hz)
Feeding of voltage to ASR should be done from generator control panel at output terminals
of PT.
Remove wires of Close Command to GCB.
Switch On Auto-synchronizer and check the voltage extended is as per scheme (simulate
the speed contact if required to satisfy the permissive of ASR).
After feeding voltages, keep grid voltage and frequency constant and vary the generator

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Commissioning Checklist

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voltage. Check that, the Voltage Raise Command (Grid Voltage > Generator voltage) or
Voltage Lower Command (Generator voltage > Grid voltage) goes to AVR in the form of
pulses. These pulses can be checked at ASR panel (Terminals 14, 15, 16 of TB X07 in figure
1, Annexure-I) as well as at AVR panel. Verify it at AVR panel.
Slowly bring generator voltage near to grid voltage.
When both Voltages becomes equal i.e Voltage difference becomes less than U Voltage
Correction Command stops and DELTA V < LED starts glowing, indicating the voltages
have matched.
Vary generator frequency to check that Raise Frequency Command (grid frequency >
generator frequency) and Lower Frequency Command (generator frequency > grid
frequency) going to speeder gear in the form of pulses to raise/lower the speed of turbine.
These frequency correction pulses can be checked at ASR Panel (Terminals 16, 17, 19 of TB
X06 in figure 1, Annexure-I)
Slowly bring generator frequency near to grid frequency.
When both frequencies become equal i.e frequency difference becomes less than f
Frequency Correction Command stops.
Now voltage and frequency has already matched phase difference is monitored and when
Switching Point is found DYN LED glows for short time and a Close Command is issued
by ASR to GCB. This Close Command Pulse can be verified by a good quality multimeter
at ASR Panel (Terminals 18-19 & 20-21 of TB X07 in figure 1, Annexure-I) as well as at
GCB end.
Once Close Command has been issued no further adjustment command will be generated
from ASR module. If further check is required first switch OFF the ASR then again switch it
ON.

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POWER SECTOR TECHNICAL SERVICES, NOIDA

DOCUMENT No. PWR/TSX/C&I/01/243/00/11

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7. RECOMMENDED SEQUENCE OF OPERATION

S.No.

3
4
5

Description

a) Auto/ manual
Command for ASR
ON initiated.
b) Grid and Generator
signals are fed
(frequencies to be
different)
ASR started

Grid & Generator

Voltages matched
Grid & Generator
Frequencies matched
Phase difference
monitored and
switching point found

After closing command

LED status

Adjustment
commands

GCB
CLOSE
Command
issued

a) All BLOCK LEDs

OFF.
b) LED Ready ON
c) LEDs A & B Blinking

No adjustment
command issues in
this stage

NO

a) LED Ready OFF

b) LED Runs ON

Both Voltage and

Frequency
Adjustment
command initiated, in
the form of Pulses.

NO

Voltage adjustment
stops

NO

Frequency
adjustment stops

NO

LED DYN ON

NO

YES

a) LED Runs OFF

b) STAT OFF
c) DYN flashes dimly
periodically
d) LEDs A& B
Flickering
e) DELTA V< ON

NO

NO

a) LED DELTA V <

ON
b) LED STAT ON
Flickering of Impulse
LED stops

Note: Scheme of Kahalgaon (3x500 MW) is attached for reference.

BHEL

POWER SECTOR TECHNICAL SERVICES, NOIDA

Annexure - I

Figure: 1

Annexure - I

Figure: 2