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Document Number : P3405_SAT_Procedure_Rev0.doc

Version : 1

Revision : 0

Date : 14 May 2008

400/220kV Ludhiana/Gwalior SubstationSubstation Automation System - SiteAcceptance Test Procedure


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400/220kV Ludhiana/Gwalior SubstationSubstation Automation System - Site Acceptance Test Procedure

GE T&D

P3405_SAT_Procedure_Rev0.doc

ii

NOTICE OF COPYRIGHT & PROPRIETARY RIGHTS

© 2008, General Electric All rights reserved.

The contents of this presentation are the property of General Electric No part of this work may

be reproduced or transmitted in any form or by any means, except as permitted in written

license agreement with General Electric

The information contained in this document is subject to change without notice.

TRADEMARK NOTICES

WESDAC is a registered trademark of General Electric Company, General Electric and/or GE

Harris Energy Control Systems Canada, Inc. All other brand and product names mentioned in

this document are trademarks or registered trademarks of their respective companies.


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Table of Contents

About This Document.............................................................................................................. vi Purpose of this Document ....................................................................................................... vi

Definition of Terms.................................................................................................................vii

Chapter 1 SAT Requirements................................................................................................. 1-1

1.1 Scope of Tests .............................................................................................................1-1

1.2 Hardware Environment ............................................................................................ 1-1

1.3 Software Environment............................................................................................... 1-1

1.4 System Availability Tests ..........................................................................................1-2

1.5 Test Equipment ..........................................................................................................1-2

1.6 Test Witness................................................................................................................ 1-2

Chapter 2 Communications Equipment and Time Synchronization Equipment Tests .... 2-3

2.1 LAN Communications Functional Check................................................................ 2-3

2.2 Network Management Software (NMS) Check ......................................................2-4

2.3 IEC 60870-5-101 Serial Communication Check .....................................................2-4

2.3.1 Gateway Communications to PLCC Modem ..........................................................2-4

2.3.2 IEC 60870-5-101 Serial Communications Verification ..........................................2-4

2.4 Time Synchronization Tests......................................................................................2-5

2.4.1 Time Synchronization Equipment Functional Check.............................................. 2-5

2.4.2 System Time Synchronization Check...................................................................... 2-6

Chapter 3 SAS Operational Tests........................................................................................... 3-1

3.1 System Data Retrieval ...............................................................................................3-1

3.1.1 Digital Inputs Retrieval............................................................................................3-1

3.1.2 Digital Outputs......................................................................................................... 3-2

3.1.3 Analog Inputs........................................................................................................... 3-2

3.2 Software Interlock Logic ........................................................................................... 3-3

3.3 Synchronizing Tests ................................................................................................... 3-3

3.3.1 Check Synchronization............................................................................................ 3-33.4 220kV Auto-Sequencing ............................................................................................ 3-4


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3.4.1 220kV Auto-Sequencing..........................................................................................3-4

Chapter 4 HMI/Server Tests ................................................................................................... 4-1

4.1 HMI Functions Test................................................................................................... 4-1

4.1.1 Shutdown and Startup of Servers.............................................................................4-1

4.1.2 HMI Security and Access Test ................................................................................4-14.1.3 HMI SLDs and Bay Details Screens........................................................................4-2

4.1.4 HMI Alarms and Events Processing........................................................................ 4-2

4.1.5 HMI Trending Display.............................................................................................4-3

4.1.6 HMI Reports Function ............................................................................................. 4-3

4.2 HMI Server Function Tests....................................................................................... 4-3

4.2.1 HMI Workstation Memory and Disk Utilization.....................................................4-3

4.2.2 HMI Server Redundancy Checks.............................................................................4-4

Chapter 5 Substation Controller/Gateway Function Tests.................................................. 5-5

5.1 Gateway IEC 60870-5-101 Data Retrieval...............................................................5-5

5.1.1 Master Station Digital data Retrieval.......................................................................5-5

5.1.2 Master Analog data Retrieval ..................................................................................5-5

Chapter 6 Engineering Workstation (EWS) Tests............................................................... 6-1

6.1 Setting and Configuration of BCUs..........................................................................6-1

6.2 Setting of Protection Relays ......................................................................................6-1

6.2.1 Setting of UR Relays ............................................................................................... 6-1

6.2.2 Setting of Siemens 7SA522 Relays ......................................................................... 6-1

Chapter 7 Remote Workstation (RWS) Tests ....................................................................... 7-1 7.1 HMI 7-1


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v

MODIFICATION RECORD

VERSION REV. DATE INITIALS COMMENT

1 0 16-May-2008 MaheshSathe

Created.


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About This Document

Purpose of this DocumentThis document defines the scope and procedure for the Site Acceptance Tests (SAT).

All the tests shall be carried out based on this document. The test results shall be recorded on

SAT Check List. (Refer P3405_SAT Checklist_Rev0)


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Definition of TermsAI Analog Input

ASE Applied Systems Engineering Test Kit Manufacturer

BCU Bay Controller Unit

BPU Bay Protection Unit

DBX Data Base Terminal

DI Digital Input

DO Digital Output

COS Change Of State

EWS Engineering Work Station

FOC Fiber Optic Cable

GDP Graphic Display PanelHMI Human-Machine Interface

IEC International Electrotechnical Commission

IED Intelligent Electronic Device

IRCON short name for IRCON International Limited, Ministry of Railways

LAN Local Area Network

NMS Network Management System

OWS Operator Work Station

Powergrid short name for Power Grid Corporation of India Limited

p.u. Power UnitsSAS Substation Automation System

SAT Site Acceptance Test

SIT Site Inspection and Test

SNMP Simple Network Management Protocol

SNTP Simple Network Time Protocol

SOE Sequence Of Events


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1-1

Chapter 1 SAT Requirements

1.1 Scope of TestsThe Site Acceptance Tests (SAT) will verify that the Substation Automation System (SAS)

functions are per the approved design.It is not the scope of this SAT document to test the Protection portion of the substation.

The SAT tests have been divided into relevant sections in order to perform the tests

systematically. Upon successful verification of the tests in each section, pertinent forms and

test results shall be completed and signed for acceptance by the customer or its

representative.

After the SAT has been successfully verified, the System Acceptance document will be

signed by representatives from Powergrid, IRCON and GE.

1.2 Hardware EnvironmentThe SAS hardware equipment consist of:

Bay Control Units in respective Bay Panels in the Kiosks.

Protection Relays in the Protection Panels.

HMI/Operator Workstation system consisting of Redundant Servers.

Engineering Workstation.

Time Synchronization Equipment consisting of a GPS Receiver Unit, Time Display

Unit and IRIG-B/PPS Distribution Unit.

Substation Controller/Gateway Subsystem.

LAN Switch Equipment distributed in the Bay Panels/Kiosk.

1.3 Software EnvironmentThe following Firmware and Software applications are used in the system:

F650 Firmware Version 3.70 with IEC 61850 (Server) capability.

F600 Substation Controller, with IEC 61850 (Client) capability.

D200 Gateway Firmware with support for IEC 60870-5-101.

UR Protection Relays Firmware Version 5.2, with IEC 61850 (Server) capability.

Siemens 7SA522 Firmware Version 4.6, with IEC 61850 (Server) capability.

Siemens DIGSI 4.7TM

shall be used in the configuration of Siemens IED.

HMI using Factory Link 7.5 Platform with IEC 61850 (Client) capability.

The Configuration files and applications are archived in the Engineering Workstation.


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1.4 System Availability TestsThe 1000 hours system availability test will be covered in another document.

1.5 Test EquipmentTo conduct the test procedures outlined in this document, the following equipments are

required to be arranged by M/S IRCON and supplied at site.

- Digital Multimeter.

- 3 Phase Current and Voltage Injection kit - if the bays are not commissioned.

- Protocol Analyzer. (Optional item)

1.6 Test WitnessIRCON/Powergrid shall provide a Representative to witness and sign-off this SAT.


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2-3

Chapter 2 Communications Equipmentand Time Synchronization Equipment

Tests

2.1 LAN Communications Functional CheckPurpose

1. To verify that LAN Switch Backbone redundancy is functional and running.

2. To verify that Ethernet LAN communications in the Substation Automation System

are functional and running.

Set up/Program

1. In the HMI, navigate to “Communication Network Architecture”.

2. Setup multiple Ping screens in the EWS to different devices in the system.

Procedure

LAN SWITCH BACKBONE - REDUNDANCY CHECK.

[ ] 1 Select LAN Switch SW-4A. On this LAN Switch, disconnect the LAN cable

connected to SW-01A. (i.e. Port 14 on SW-1A)

[ ] 2 Verify in the Ping screens and the HMI Communications Summary Screen

that there is no communication failure of the devices in the system.

[ ] 3 On LAN Switch SW-1A, disconnect the LAN cable connected to SW-02A(i.e. Port 17 on SW-1A).

[ ] 4 Repeat step 2.

[ ] 5 Restore LAN cables on SW-1A.

[ ] 6 Select other Backbone switches and the network should remain undisturbed

for any 2 failures in the communication network.

[ ] 7 These link failures should be indicated in the Alarm List. Verify the same at

every step of the test.


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2.2 Network Management Software (NMS) CheckPurpose

1. To verify that NMS software is functional and running

Set up/Program2. OWS-1, OWS-2 are running under normal conditions.

Procedure

NMS SOFTWARE.

[ ] 1 Start the NMS Viewer (iSNMP DataViewer)

[ ] 2 Verify that the LAN Port status and the Network Analyst Data is valid.

[ ] 3 This data is represented in the graphical form in the HMI.

2.3 IEC 60870-5-101 Serial Communication Check

2.3.1 Gateway Communications to PLCC Modem

Purpose

To verify Gateway communications to PLCC Modem.

Setup

1. Using the EWS, connect to D200 Gateway.

2. Ensure the communications cable to gateway to NSK5 modem is connected to

the correct ports of the NSK5 modem.

Procedure

[ ] 1 On the Gateway Wesmaint screen, go to 68k Monitor.

[ ] 2 In 68k Monitor, bring up the serial analyzer function by typing at the prompt

“sa com 1”.

[ ] 3 Observe that IEC 101 transmit packets are captured in the screen.

[ ] 4 This will test communications up to the output of the NSK5 modem.

2.3.2 IEC 60870-5-101 Serial Communications Verification

Purpose

To verify that the Gateway IEC 60870-5-101 communications to PLCC modem are

functional.

Notes:

a) PLCC communication equipment is supplied by others. IEC 60870-5-101

communications shall be tested up to modem serial port.

b) To test IEC 60870-5-101 communications to RSCC, coordination is required.


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Set up/Program

1. If the LDC communication is up and running, the data can be verified with the

LDC. In absence of this connection, use an ASE Test Set to simulate IEC 60870-

5-101 Master Station polling at the cable connection to PLCC modem.

Procedure[ ] 1 Verify that communication is established with the ASE test set.

[ ] 2 Verify that the ASE test set is sending request on the primary channel and that

the SAS Gateway is responding on both the primary and the secondary

channels.

[ ] 3 Disconnect the ASE test set from the primary channel and connect it to the

secondary channel; verify that the SAS Gateway will respond on both

channels to requests received on the Secondary channel

2.4 Time Synchronization Tests

2.4.1 Time Synchronization Equipment Functional Check

Purpose

To verify that the following components of the Time Synchronization Equipment are

functional and receiving satellite time updates:

1. GPS Receiver

2. External Time Display Unit

Procedure[ ] 1 Disconnect the GPS Receiver Antenna. Set the GPS Receiver to send LocalTime. Change the value of this local time to 00:00:00.

[ ] 2 Verify that the External Time Display Unit displays this local time. This

confirms that the IRIG-B signal from the GPS unit to the Time Display Unit is

functional.

[ ] 3 Verify that the IEDs, Operator Workstations and Substation Gateway times

match this local time. This confirms that the SNTP packets are broadcasted by

the GPS receiver and received by the end devices.

[ ] 4 Verify that GPS Receiver Out-of-Lock Alarm is received in the OWS.

[ ] 5 Restore the GPS Receiver Antenna connection. Verify that the GPS Receiveris locked up to at least 3 satellites. Verify that the GPS is updated to satellite

time.

[ ] 6 Verify that the IEDs, Operator Workstations and Substation Gateway times

match this satellite time update. This confirms that the time updates are

broadcasted by the GPS receiver and received by the end devices.

[ ] 7 Confirm that the External Time Display Unit is also updated to the new time.


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2.4.2 System Time Synchronization Check

Purpose

To verify that the GPS System time is received by all SAS devices and working

according to the time synchronization requirements of IEC 61850.

Procedure

SAS IED TIME SYNCHRONIZATION

[ ] 1 Change the time on one Bay control unit (BCU) by a few minutes.

[ ] 2 The device will get synchronized over SNTP and the time will automatically

adjust to the correct time

[ ] 3 Repeat Step 3 for a few sample BCU’s.

HMI EQUIPMENT

[ ] 4 Set the Primary or the secondary server to an incorrect time.

[ ] 5 The machine will automatically synchronize over SNTP with the GPS clock.

[ ] 6 Repeat the procedure on the Engineering workstation.


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3-1

Chapter 3 SAS Operational Tests

3.1 System Data Retrieval

3.1.1 Digital Inputs Retrieval

Purpose

To verify that:

1. The change of state and SOEs of Digital Input points are updated in the BCU GDP

and the Substation HMI Operator Workstations.

2. That selected SOEs according to the IEC 60870-5-101 mapping table are updated in

the Master Station.

Setup

1. On the GDP of the BCU under test, go to the ‘Digital Inputs’ display screen.

2. On the Operator Workstation 1 (OWS-1), go to the Point Detail Screen

3. On the Operator Workstation 2 (OWS-2), go to the Alarm Screen.

Procedure

[ ] 1 Select a BCU to test.

[ ] 2 From the field, simulate the Digital Input points on the BCU under test by

changing their states from ‘OFF” to “ON” (single points) or from “OPEN” to

“CLOSED” (double points).[ ] 3 Verify that the change of state in the BCU GDP.

[ ] 4 Verify the same in both the servers.

[ ] 5 For points configured with alarm, verify that alarms are displayed in the

Alarm Screen with correct time stamps.

[ ] 6 Repeat steps 1 to 5 for sample Digital Input points on the BCU.


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3.1.2 Digital Outputs

Purpose

To verify that digital output operations are successfully executed.

Setup1. On the GDP of the BCU under test, go to the single line display.

2. On the Operator Workstation 1 (OWS-1), go to the bay detail under test.

3. On the Operator Workstation 2 (OWS-2), go to the Alarm/Event Screen.

Procedure

[ ] 1 From the Operator Work Station, initiate digital output requests to the BCU

under test.

[ ] 2 Verify that the corresponding outputs are activated.

3.1.3 Analog Inputs

Purpose

To verify that the Analog Input points are updated in the BCU GDP, the Operator

Workstations.

Setup

1. Select Bay under normal operations

2. Go to the BCU GDP Display screen.

3. Go to the bay detail screen on the Operator Workstations.

Procedure

AC ANALOG INPUTS

[ ] 1 Verify that the correct readings are presented in the BCU GDP display screens

and the HMI Point Detail Screens for the injected voltage and current values.

[ ] 2 Confirm that the corresponding readings are updated.

3.DC ANALOG INPUTS

Note that only the Transformer and Reactor Bays have BCUs to monitor DC

Analogs.

[ ] 1 Verify that the correct readings and accuracy are presented in the BCU GDPs

and the HMI Point Detail Screens for the s4-20mA transducer outputs.


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3-3

3.2 Software Interlock LogicPurpose

To verify that software interlock logic for CBs and Isolators are operational based on

actual field conditions.

If all interlock conditions cannot be set during SAT, the interlock inputs (auxiliary

contacts) shall be simulated in the field.

Procedure

[ ] 1 Select a bay to test.

[ ] 2 Refer to protection schematic drawings. For each interlock condition, attempt

to operate controls related to the interlock logic being tested. Verify that the

interlock is successful.

3.3 Synchronizing Tests

3.3.1 Check Synchronization

Purpose

1. To verify that Incoming and Running (Reference) voltages are within the

synchronizing range before the circuit breaker can close. The circuit breaker will not

close if any of the limiting parameters is not within the check synchronizing range.

2. To verify that the running voltage reference is properly selected (voltage selection)

depending on isolator switch conditions.

Procedure

[ ] 1 Select a BCU and corresponding Circuit Breaker to test.

[ ] 2 Verify the voltage selection based on the isolator status.

[ ] 3 Verify the voltage reading in the Enervista F650 setup software for the

synchrocheck function.

[ ] 4 Initiate a Close request on this Circuit Breaker.

[ ] 5 Verify that the Circuit Breaker closes only when configured settings are met.


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3.4 220kV Auto-Sequencing

3.4.1 220kV Auto-Sequencing

Purpose

To verify that the 220kV Auto-Sequencing logic functions correctly.

Setup

Ensure that the HMI Servers are running.

Procedure

[ ] 1 Select a Feeder to test.

[ ] 2 Turn ON the Auto-sequencing controls.

[ ] 3 Click “Transfer to TBC” or the “Transfer Bus” sequence.

[ ] 4 Verify the “Transfer Logic Status” as well as the actual isolators beingcontrolled.

[ ] 5 The sequence can be aborted at any given time by using the abort – “Set”

button.

[ ] 6 Repeat above tests with negative conditions – e.g. another Feeder is already on

Transfer Bus. Verify that the appropriate alarms are indicated and operation is

not permitted.


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Chapter 4 HMI/Server Tests

4.1 HMI Functions Test

4.1.1 Shutdown and Startup of Servers

Purpose

To verify that the HMI Redundancy is operational during shutdown of the active server.

Setup

1. Ensure that the HMI Servers are running.

Procedure

[ ] 1 With both Servers running, and the HMI client is running under normal mode.

[ ] 2 Shutdown the Active Server. (say OWS-1)

[ ] 3 Observe that the Standby server takes over and becomes the “Stand-alone”

HMI server.

[ ] 4 Restore the machines (Startup OWS-1). Observe that there is no interruption

to the Bay level devices.

[ ] 5 Observe that Viewer clients attach to OWS-1 and remote devices are still

normal and communicating with OWS-2.

Observe that the system is back to normal.

4.1.2 HMI Security and Access Test

Purpose

To verify that the OWS/HMI system has Security Classes; that these are enabled and

configured properly.

Setup


Procedure

[ ] 1 At Primary Server, Login as the “observer” user.[ ] 2 Verify that this user class has proper access level as per HMI Security


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Classification.

[ ] 3 Go to any bay detail screen. Verify if access to tool bar and object controls are

according to the allowed in the access level logged in.

[ ] 4 Repeat steps 1 to 4 for the other HMI Usernames (Operator and

Administrator).

[ ] 5 Repeat steps 1 to 4 on Secondary Server.

4.1.3 HMI SLDs and Bay Details Screens

Purpose

To verify that the Single Line Diagram and Bay Detail Screens in the OWS/HMI system

are configured properly and are in correct operating condition.

Setup


2. Log in as an “Operator”.

Procedure

[ ] 1 Verify the layout of each One-Line screen.

[ ] 2 Verify the device number and device description for each device.

[ ] 3 Verify all displayed analog and digital values in One-Line screens.

[ ] 4 Click on each device object and confirm that the correct pop up screen or

bay/device detail screen is displayed.

[ ] 5 Repeat steps 1 to 4 for each One-Line screen’s.[ ] 6 Repeat steps 1 to 5 for each Workstation.

4.1.4 HMI Alarms and Events Processing

Purpose

To verify that the Alarm and Event Points are configured properly and are in correct

operating condition.

Setup


2. Display the Alarm Logger Screen.

Procedure

[ ] 1 Select a Digital Input point from one of the BCU’s configured as an Alarm.

[ ] 2 Change the state of the selected point.

[ ] 3 Confirm that an Alarm is displayed in the Active Alarm Logger screen with

proper description and Time Stamp.

[ ] 4 Acknowledge this alarm.

[ ] 5 Locate the Event History screen and verify that this alarm is displayed and thatit is acknowledged.


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[ ] 6 Repeat steps 1 to 5 for several Digital Input points that are configured as

Alarms (Events).

4.1.5 HMI Trending Display

Purpose

To verify that the trending in the OWS/HMI system are configured properly and are in

correct operating condition.

Setup


2. Go to the trending screen.

Procedure

[ ] 1 Select Pen Editor Form.

[ ] 2 Verify that a Pen Select screen pops up.[ ] 3 Assign a point to the selected pen.

[ ] 4 Repeat step 3 for other pens.

4.1.6 HMI Reports Function

Purpose

To verify that the Reports Function in the OWS/HMI system are configured properly and

are in correct operating condition.

Setup

Ensure that the HMI Servers are running.

Procedure

HISTORICAL REPORTS

[ ] 5 Go to the Statistical Report Screen.

[ ] 6 Select an analog value to print. Select the range of date by selecting the start

and stop dates.

[ ] 7 Save the report as a CSV file.

[ ] 8 Print CSV file. Confirm that the file is printed.

DAILYREPORTS

[ ] 9 Verify that the daily reports are prepared in the “Reports” folder.

[ ] 10 Verify the validity of the data in the report.

4.2 HMI Server Function Tests

4.2.1 HMI Workstation Memory and Disk Utilization

Purpose


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To verify that the Operator Workstation/HMI Computers have Memory and Disk usage and

allocation that are within specification requirements.

Setup


Procedure

[ ] 1 On the Primary HMI (OWS-1), open the WindowsTM

Operating System Task

Manager. Note that the OWS Computers have server grade operating system.

[ ] 2 Select the ‘Performance’ tab, take note of the ‘Total” and ‘Available’

“Physical Memory information.

[ ] 3 Calculate the percentage of available memory. Close the Task Manager.

[ ] 4 Open Windows Explorer. Check the properties of the Hard Drive volume.

[ ] 5 Calculate the current usage.

[ ] 6 Record the information.

[ ] 7 Repeat for the rest of the workstations.

4.2.2 HMI Server Redundancy Checks

Purpose

To verify that the HMI Redundancy is operational during simulated loss of Level 2

communications.

To verify that the HMI Workstations support redundant LAN communications.

Setup1. Ensure that the HMI Servers are running.

2. The OWS-1 (Primary Server) is the active server.

3. The OWS-2 (Secondary Server) is in Standby Mode.

Procedure

[ ] 1 Verify that the devices are online with the HMI.

[ ] 2 On OWS-1 (Primary Server), disconnect LAN-A cable. Observe that Viewer

clients and remote devices are still normal and communicating with OWS-1.

[ ] 3 On OWS-1, now disconnect LAN-B cable. Observe that all the devices go

Offline.

[ ] 4 Initiate a switchover to make OWS-2 (Secondary Server) the active HMI

Server.

[ ] 5 Restore the LAN connections and system is back to normal operation.

[ ] 6


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5-5

Chapter 5 Substation

Controller/Gateway Function Tests

5.1 Gateway IEC 60870-5-101 Data Retrieval Note: This section of tests will need coordination with the Master Station

5.1.1 Master Station Digital data Retrieval

Purpose

To verify that the Substation Gateway correctly responds to polls for Digital Input andSOE data by the Master Station.

Procedure

[ ] 1 Select a Bay to test.

[ ] 2 Verify the Switchgear Status with the Master Station.

[ ] 3 Verify that SOE and COS data are received and updated in the Master Station.

5.1.2 Master Analog data Retrieval

PurposeTo verify that the Substation Gateway correctly responds to polls for Analog data

from the Master Station.

Procedure

[ ] 1 Select a Bay to test.

[ ] 2 Verify the analog values with the Master Station.


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6-1

Chapter 6 Engineering Workstation(EWS) Tests

6.1 Setting and Configuration of BCUsPurpose

To verify that the BCUs can be configured online or offline using Enervista Software.

Setup

Ensure that the EWS is running.

Procedure

[ ] 3 Run the Enervista F650 Setup application in the EWS.

[ ] 4 Change some parameters on this BCU. Store the configuration. Observe that

the parameter changed is now active.

[ ] 5 Download the original configuration file for this BCU. Observe that the

parameters changed in the previous step are now changed to the original

values.

6.2 Setting of Protection Relays

6.2.1 Setting of UR Relays

Verify the software functionality in the EWS

6.2.2 Setting of Siemens 7SA522 Relays

Verify the software functionality in the EWS.


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Chapter 7 Remote Workstation (RWS)Tests

7.1 HMIPurpose

To verify that the Remote HMI function.

Setup

The Remote HMI computer is on the Local Area Network in the control Room.

Procedure

[ ] 1 Run the HMI Client.

[ ] 2 Log-in the HMI using different user name like “Operator”, “Admin” to verify

the access rights

[ ] 3 Navigate through the various screens in the HMI along with the

Alarms/Events screen.

[ ] 4 Initiate control commands to verify the functionality.

sat procedure rev0

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