Factory acceptance test FAT and site acceptance test SAT work instructions for electrical and automation systems in a power plant Johan Dahl Bachelor’s thesis Electrical Engineering Vaasa 2013 BACHELOR’S THESIS Author: Johan Dahl Degree programme: Electrical Engineering Specialization: Automation Technology Supervisor: Roger Mäntylä Title: Factory acceptance test FAT and site acceptance test SAT work instructions for electrical and automation systems in a power plant. ____________________________________________________________________________ Date Number of pages Appendices 20.05.2013 39 5 ____________________________________________________________________________ Abstract This Bachelor’s thesis was commissioned by ABB Power Generation, located in Vaasa. The department designs and commissions automation and electrical systems for gas, diesel, nuclear and hydropower plants. Currently there is a great variation in FAT and SAT work instructions depending on who performs these tests. My goal with this thesis work has been to get standard FAT and SAT templates and the company’s goal is to get everyone to use the same templates. The thesis consists of an investigation of what is to be tested with FAT and SAT, and also how to do the testing. The result of this investigation is a basic template of how these documents can be designed. The template applies mainly to system testing for hydro power plants, but can easily be modified for other plant types, since the system parts and functions designed by ABB do not differ that much between the plant types. ____________________________________________________________________________ Language: English Key words: FAT, SAT, work instructions ____________________________________________________________________________ EXAMENSARBETE Författare: Johan Dahl Utbildningsprogram och ort: Elektroteknik, Vasa Fördjupning: Automationsteknik Handledare: Roger Mäntylä Titel: Utveckling av fabriks godkännandeprov FAT- och godkännandeprov efter leverans SAT- arbetsinstruktioner för el- och automationssystem i ett kraftverk. ____________________________________________________________________________ Datum Sidantal Bilagor 20.05.2013 39 5 ____________________________________________________________________________ Abstrakt Detta ingenjörsarbete beställdes av ABB Power Generation, som finns i Vasa. Avdelningen designar och tar i bruk automations- och elsystem för gas-, diesel-, kärn- och vattenkraftverk. För tillfället finns det en stor variation mellan FAT- och SAT- arbetsinstruktioner, beroende på vem som genomför dessa tester. Mitt mål med ingenjörsarbetet har varit att få standardiserade FAT- och SAT- mallar. Företagets mål är att få dessa standarddokument och att få alla att börja använda samma mallar. Avhandlingen består av en undersökning av vad som ska testas med FAT och SAT, och också hur testningen görs. Resultatet av undersökningen är en grundläggande mall av hur dessa dokument kan designas. Mallen gäller främst systemtest för vattenkraftverk, men kan lätt modifieras för andra anläggningstyper, eftersom systemens delar och funktioner som designats av ABB inte skiljer sig så mycket mellan olika anläggningstyper. ____________________________________________________________________________ Språk: engelska Nyckelord: FAT, SAT, arbetsinstruktioner ____________________________________________________________________________ TABLE OF CONTENTS ABSTRACT ABSTRAKT 1. Introduction ........................................................................................................................ 1 1.1. The commissioner ......................................................................................................... 1 1.2. Purpose .......................................................................................................................... 2 1.3. FAT (Factory Acceptance Test) ................................................................................... 3 1.4. SAT (Site Acceptance Test).......................................................................................... 3 2. Hydropower theory ............................................................................................................ 4 2.1. Hydropower introduction .............................................................................................. 4 2.2. Plant overview .............................................................................................................. 5 2.3. Main systems and components ..................................................................................... 7 2.3.1. Flow control equipment ......................................................................................... 8 2.3.2. Turbine .................................................................................................................. 8 2.3.3. Generator ............................................................................................................... 9 2.3.4. Low voltage systems ........................................................................................... 10 2.3.5. High voltage & medium voltage systems ............................................................ 10 2.3.6. Automation .......................................................................................................... 10 2.3.7. Protection relays .................................................................................................. 20 2.3.8. Excitation ............................................................................................................. 32 3. The standard templates ................................................................................................... 34 3.1. General ........................................................................................................................ 34 3.2. AC800 + S800 ............................................................................................................ 34 3.3. 800xA and panel ......................................................................................................... 35 3.4. Turbine modules ......................................................................................................... 35 3.5. Excitation .................................................................................................................... 35 3.6. Protection relays ......................................................................................................... 36 4. Discussion .......................................................................................................................... 36 5. List of references .............................................................................................................. 38 APPENDICES __________________________________________________ ABBREVIATIONS Abbreviation Description________________ ABB Asea Brown Boveri FAT Factory Acceptance Test SAT Site Acceptance Test EMC Electromagnetic Compatibility DIN Deutsches Institut für Normung AVR Automatic Voltage Regulator MTU Module Termination Unit HMI Human Machine Interface TWh Terawatt hours MVA Mega volt ampere 1 1. Introduction This Bachelor’s thesis is about FAT and SAT work instructions and commissioning documents for the automation and the electrical systems in a power plant. Standard documents are needed for the business unit. Information about the main systems and components in a power plant and the electrification around it is also partly covered. More information about the background for this thesis is found in chapter 1.2. At a meeting held on 8 Feb 2013 it was decided that the thesis work will be restricted to hydro power plants. 1.1. The commissioner ABB is a global leader in power and automation technologies with a turnover of about 40 billion USD in year 2011. ABB resulted from the merger of the Swedish corporation ASEA (Allmänna Svenska Aktiebolaget) and the Swiss company Brown Boveri & Cie (BBC) in 1988, but its history spans over 120 years. ABB’s success has been driven particularly by a strong focus on research and development. The ABB Group operates in approximately 100 countries around the world and employs about 145,000 people. ABB has offices in around 87 countries and their head office is located in Zürich, Switzerland. The firm’s shares are traded in Zürich and the Stockholm Stock Exchange in Sweden since 1999, and the New York Stock Exchange in the United States since 2001. The ABB Group consists of five main divisions: - Power Products - Power Systems - Discrete Automation and Motion - Low Voltage Products - Process Automation 2 ABB’s slogan is “Power and productivity for a better world”. /1/ This thesis has been commissioned by ABB, Power Generation. The office is located in Strömberg Park in Vaasa and is part of the Power Systems division. The Power Generation department plans automation cabins for different power plants, e.g. diesel, gas, nuclear and hydro power plants. 1.2. Purpose At the moment there are no standard FAT or SAT work instruction documents. Both testers and commissioners have variations of their testing/commissioning documents. The main goal of this thesis was to create standard testing documents, so that the business unit will get ABB standard FAT/SAT material and so that all testers/commissioners will use the same templates. Better quality can also be reached if everyone starts using identical templates. Another possible goal of this thesis work is to create an Excel macro that produces these template documents according to which project properties you choose. 3 1.3. FAT (Factory Acceptance Test) Factory Acceptance Tests are done at the factory to make sure that certain requirements are met, which results in high quality products. The tests are normally done with the customer, and also, in certain more demanding cases, with a third party inspection agency. Although all cabins should be fault-free when they arrive from the subcontractors that assemble them, faults sometimes occur. Therefore these factory acceptance tests are needed. At a FAT, installations are double checked so that they match the drawings for the specific project. Functions that should work when cabins are installed at site are also simulated to check the automation functionality. All possible faults, deviations and wishes are also noted. 1.4. SAT (Site Acceptance Test) Site Acceptance Tests are done at the specific places where commissioning is done. These tests are also done to make sure that certain requirements and a high quality are met amongst ABB’s projects and to offer customers quality testing and documents. Normally the same test procedures as at FAT are followed, plus procedures that cannot be done at FAT. E.g. breaker control is excluded from FAT but done at SAT. The results of the SAT are noted in the test protocols and then signed by both the customer and the commissioner. 4 2. Hydropower theory Hydroelectric power generation involves storing a hydraulic fluid (normally water) and converting the energy of the fluid into mechanical energy in a turbine, and converting the mechanical energy into electrical energy in an electric generator. This form of renewable energy production is the most widely used form of renewable energy, and accounts for 16% of the global electricity generation, which was 3427 TWh of the electricity production in 2010. It is expected to increase another 3,1% each year for the next 25 years. /12/ 2.1. Hydropower introduction Hydropower has been used since ancient times to operate various mechanical devices, such as watermills, sawmills, textile mills, lifts etc. The first hydroelectric power plants came into use in the late 1800s. They provide significant flexibility in base load, peak and energy storage applications. The initial capital costs of hydropower plants are high, but thanks to low operating costs, simplicity, low operating and maintenance costs, high reliability and long service life, they make a very cost-effective option of generating electricity. /12/ Some valuable operating characteristics are their fast responses for starting, loading, unloading and following system load variations. Other advantages are their ability to start up without power from the power grid (“black start capability”) and to transfer rapidly from generation mode to condenser mode, and the pumped storage application. Capacities of hydroelectric power plant units can range from a few kilowatts to nearly 1 GW. Multi-unit plants can range up to around 20 GW. /11/ 5 2.2. Plant overview There are three main types of hydroelectric plant arrangements, classified according to the method of controlling the hydraulic flow: 1. Run-of-the-river plants, which have small amounts of hydraulic fuel storage and thus little control of the flow through the plant. 2. Storage plants, which have the ability of storing large amounts of hydraulic fuel and thus the ability to control flow through the plant on a daily or seasonal basis. 3. Pumped storage plants, in which the direction of rotation of the turbines is reversed during off-peak hours, pumping water from a lower reservoir to an upper reservoir, thus storing energy for production of electricity during peak hours. /11/ The storage plant type is the most common type of large hydroelectric power plant. Figure 4 below shows a model of this type of plant.