Bharat Heavy Electricals Limited (A Govt. of India Undertaking) Tarapur Atomic Power Project - 3&4

BHARAT HEAVY ELECTRICALS LIMITED
PS: WR NAGPUR
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM
PROCEDURE NO: TAPP3&4-41300-CP-1

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DATE OF ISSUE: NOV. 2003

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(A Govt. of India Undertaking)
TARAPUR ATOMIC POWER PROJECT 3&4

TG OIL SYSTEM
TAPP3&4- 41300-CP-1
PREPARED BY
CHECKED BY
REVIEWED BY
APPROVED BY
ISSUED BY

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TG OIL SYSTEM

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REVISION LOG
Revision Details
Issue
No.
Rev.
No.
01
NA
Preparation Details
Date
Page
No.
NOV. 03
NA
Details
First Issue
Prepared by
Checked by
Reviewed by
Concurred by
Approved by
V.K.Kuhikar, Dy.Mgr
R.M, Bagul. Engr., QA
J. Mathew, Incharge-TG
PREPARED BY
CHECKED BY
REVIEWED BY
APPROVED BY
V.K. Kuhikar
R.M Bagul
J. Mathew
S.K Jain
Dy.Manager
Engineer, QA
Incharge-TG
Construction Manager
ISSUED BY

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TG OIL SYSTEM

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CONTENTS
SLNO.
TITLE CLAUSE
PAGE NO.
COVER SHEET
REVISION LOG
CONTENTS
1.
PURPOSE
2.
PRE-REQUISITES
2.1
STATUS OF OTHER SYSTEMS

SYSTEM REQUIREMENTS
MANPOWER REQUIREMENTS
2.4
REQUIREMENT OF SPECIAL EQUIPMENTS

REQUIREMENT OF OUTSIDE AGENCIES
2.6
HAZARDS & PRECAUTIONS
8.
GENERAL METHOD
10
9.
DESIGN INTENTS
31
10.
EXPECTED PROCESS PARAMETERS
31
11.
WORK PLAN
32
12.
TEST REPORT FORMAT
33
13.
REFERENCE
49
14.
VERIFICATION PROCESS
49
15.
FLOW CHARACTERISTICS OF OIL THROTTLE

Nb25, Nb50, Nb65, Nb80 & Nb100 (5 PAGES)

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Purpose:
To flush the complete lube oil and control oil system to remove mechanical
impurities, dirt, welding slag etc. by simulating conditions similar to operating
conditions of plant by adopting thermal shock process, for effective oil flushing oil
system is flushed in loops as:
a. Lube oil system flushing
b. Jacking oil system flushing
c. Control oil system flushing and purification system
d. Seal oil system
To circulate the Lube oil and Jack Oil in the systems after the completion of oil
system flushing and adjusting the pressure and flow in the Circuits.
To carry out the logic checks and operational performance of various active
components in the system i.e. various pumps.
2.0
Pre-requisites:
2.1
Status of other systems:

a. All erection activities in lube oil, control oil, jacking oil, oil purification circuit
should be completed.
b. Temporary supports should be removed.
c. AOPs (Auxiliary Oil Pump) and control fluid pumps are available for running.
d. Oil Purification (BHEL Temporary Centrifuge) System should be available for
operation.
e. Service air should be available near filters for cleaning of filters.
f.
Cooling water at oil cooler should be available.
g. Seal oil system: Ensure following:

1. Erection of seal oil pump unit, seal oil unit, seal oil valve rack, measuring
instrument rack, and seal oil storage tank and interconnected piping.
2. Physical cleaning of seal oil storage tank.

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3. Acid cleaning of seal oil pipelines.

4. Availability of control and power supply for motors and starting panels.
5. Trial run of the following motors and coupled with respective pumps as
per Commissioning Procedure No. TAPP3&4-41000-CP-1M:
a)
Airside seals oil pump motor (AC)
3 nos.
b)
H2 (Hydrogen) side seals oil pump motor (AC)
1 nos.
6. Disconnect airside seal oil inlet pipes at the seal body on both sides of
generator and connect it to H2 side drain by a temporary piping.
7. Disconnect H2 side seal oil inlet and out let pipes at seal body on both
sides of generator and interconnect it by a temporary piping.
8. Disconnect ring relief oil inlet pipe at seal body on both sides of generator
and interconnect by a temporary piping in to air side seal oil drain pipes.
9. Take out float valves MKW03AA001 and AA002 from seal oil tank.
MKW03BB001.
10. Keep the springs of regulating valves A1, A2, and C at completely
released condition.
11.Make necessary arrangement for heating seal oil up to 60-70 0C during oil
flushing process. This can be achieved by wrapping wire heaters over the
seal oil inlet pipes.
h. All temporary loops are made as per approved schemes (1-131480-99001 &
0-13149-99001 & 2.1-7111-7404/3) given as enclosure of this procedure.
i.
Waste oil system piping should be completed.
j.
A telephone should be available near by and the telephone numbers of

hospital, ambulance and fire brigade is displayed.
k. Fire fighting equipments shall be made available.

l.
The operating personnel shall be aware of the procedure.
m. Provision for emergency stopping of oil pumps from Local / Main Control
Room has to be made.
n. Sufficient quantity of safety appliances such as helmets, face mark, hand
gloves, Crum boots, Apron, nose breather are made available for use at site.

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o. The team for this operation shall be aware of this procedure for oil flushing
and shall act at the time of any emergency.
p. The team should be aware of first aid to be followed in case of accident
involving injury to personnel.
q. The team should be aware of operating procedures of fire extinguisher to be
used for quenching minor oil fires.
r. The team should be aware of restarting the operation in case of system
stoppage due to failure of power supply.
2.2
System Requirements
a. Flushing oil quantity (estimated) = 36 Cu.M. Properties of oil should be
compatible with regular operation oil.
b. Manpower with required tools for attending to any leak, cleaning the oil filter
and to adjust throttles.
c. Operating personnel to co-ordinate the activities.
d. Power supply for the pumps is available.
e. Lighting arrangement for oil tank and other operating floors is available.
f. Portable fire fighting equipments in all the floors and at oil flushing area is
available.
g. Temporary Oil purifier for purifying the oil is available.
h. Availability of laboratory facilities for analysis of mechanical impurities and
moisture content of Oil samples.
i. Availability of service Air for filters cleaning.
j. Availability of Communication facility at flushing area.
k. The temporary pipes, which are included in the process, are of same size as
main pipes and are separately cleaned mechanically (using wire brush and
compressed air) before their installations.
l. Fabrication and erection of the system is completed as per drawing.
m. Cooling water to Oil cooler after flushing of the ACW lines upto cooler
inlet/outlet valves available for thermal shock operation during Oil flushing.

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n. Oil coolers inspected through oil line connection and, if required, the same
shall be cleaned before starting of flushing.
o. Temperature indicators before and after oil cooler are made available for Oil
as well as cooling water.
p. Before filling the oil in Main oil tank (MOT)/SOST (seal oil storage tank), both
tanks are cleaned carefully.
q. All C&I installation and calibration of Oil tank level indicators, level switches
etc. completed before Oil filling.
r. Vapour extraction system with vapour extraction fan is available for operation.
s. All the filter elements in the system, other than the tank filters are removed
before initial flushing.
t. The necessary by pass work as per scheme (1-131480-99001 & 0-1314999001& 2.1-7111-7404/3)) enclosed is carried out and the correctness of
looping checked.
u. Insulation of Turbine & piping shall be completed (or otherwise no insulation
work shall be permitted during oil flushing) and TG floor, Oil Tank & flushing
area completely cleaned.
v. Availability of Hydraulic pumps 5 to 300 bars as backup for hydraulic test.
2.3
Manpower requirements:
Commissioning team of mechanical, electrical & C&I engineers & supporting
manpower and BHEL as executing agency.
2.4
Requirement of special Equipments:

Nil
2.5
Requirement of outside agencies:

a. NPCIL-TG Commissioning group for co-ordination.

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Hazards & precautions

a. The hydraulic systems of governing system are equipped with oil storing
accumulators. Loosening or tightening of any mechanical item should be done
after depressurization & draining of the system.
b. While testing and adjusting the LP Bypass & governing systems no insulation
work shall be allowed.
c. Debris in and around oil systems and MOT (Main Oil Tank) floor to be
removed.
d. Approach / Stair Case / Platform wherever required are made available.
e. Sign boards to be displayed at strategic location to indicate that Oil System is
charged and oil pumps are ON.
f. Welding / cutting shall not be carried out in flushing area.
g. Load on pumps shall not exceed full load current of the motor.
h. An operator to be posted near the pump area and instructed that he should
trip the pumps in the event of emergency being notified to him by the team /
observers.
3.0
General method
a. Oil throttle internals in oil supply line to bearings are to be removed and are
provided dummy plates on top of the throttle body. These dummy plates are
provided with oil flushing material.
b. Duplex filter elements provided in the supply line to thrust bearing are to be
removed. These elements are to be put back in position during the final stage
of flushing.
c. The regular adaptors in the bearing pedestals for supply are replaced with
flushing device so that oil is deflected to bearing-to-bearing pedestal instead
of going to the bearings.
d. MOP (Main Oil Pump) is to be completely removed and a flushing device is to
be placed in position.

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e. Blind flange dummy is to be provided at flange as indicated in the scheme (1131480-99001 & 0-13149-99001) .
f. The jacking oil pumps are disconnected at the discharge flanges of the pumps
and rotates as required and oil supply pipe to be connected through a
temporary valve (of high pressure duty) to the dummy flange in the AOP
discharge header.
g. The header of the jacking oil supply line has a dummy flange at the exciter
side. From this a temporary connection is run to the oil return pipe blank
flanges of flushing, with an isolating valve.
h. Pressure regulating valve of JOP (Jacking Oil Pump) discharge line to be
removed and spool piece to be erected for connecting JOP discharge header
and relief drains is to be blanked.
i. The hose connections of JOP lines inside the bearing pedestals are removed
at the bearing end and left in the pedestals it.
j. The internals of non-return valves provided in individuals jacking oil line of the
bearings may be removed. Internals of combined discharge and non-return
valve in the JOP discharge line is to be removed.
k. Remove the turning gear nozzle box and provide a flushing device in its place
before boxing up the pedestal.
l. Suitable heating arrangements (by BHEL) for oil as per temperature
requirements must be made at site. Process of thermal shocks will be used,
as oil flushing is very effective at changing oil temperatures (Refer 3.3.e.1).
m. Adequate quantity of cooling water must be available for oil coolers to reduce
oil temperature during the process of thermal shocks.
n. The necessary permanent clean oil drain tank must be made available for
accepting the full charge of oil.
o. Arrangement for analysis of oil sample (mechanical impurities & moisture
content) after the flushing must be made. The sample may be taken for
checking mechanical impulses.

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p. The Governing Rack & LP (Low Pressure) bypass racks are to be excluded
from flushing. The stop valves servomotors of ESV (Emergency Stop Valve) &
LPBP (Low Pressure Bypass) and water injection valve to be bypassed.
q. Suitable piping connections to be provided as per drawing for bearing
pedestal, over speed trip device, thrust bearing trip device etc. as per flushing
loops.
r. By pass connections as per drawing (flushing loops given in this write-up) for
all extraction NRVs (Non Return Valve). The solenoid valves must be
replaced with suitable adopters.
s. Ensure the temporary pipe work is completed in seal oil system as per the
enclosed sketch.
Seal oil system:
a. Connect point A with A1 and point B with B1 with temporary pipe.
b. Connect point C with C1 and point D with D1 with temporary pipe and
c. Keep close the following valves
MKW71AA531,MKW76AA512&522,MKW71AA512
&522,MKW73AA512 & 522
d. Keep open the following vales
Temporary
valve
in
the
lub
oil
circuit,
MKW71AA511
&
521,MKW76AAA511 & 521, MKW73AA511 & 521

e. The flow restrictor bypass in the air side seal oil (MKW71BP501)will be
replaced with spool .
3.1
Precautions:
a. Leak points must be attended immediately.
b. Provision has to be made for emergency stopping of the pumps from local as
well as Main Control Room.

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c. Fire fighting equipment must be available.

d. Means to remove spilled oil must be available.
e. AOP current should not exceed the rated valve.
3.2
Oil Flushing:
Before starting oil filling, ensure the followings:
a. Adequate numbers of oil drums are available (approx. 200 drums).
b. Completion of erection of oil system.
c. Quality oil as recommended (Turbine Oil 46)
d. Install all dummy flanges and close drains and vents in the main drain
header, which are given in permanent system
Oil filling is to be done using temporary centrifuge (as shown in the attached
sketch).
During filling MOT filters are to be cleaned as and when required.
About 80% of normal service oil (normal oil requirement is 36 m 3) is filled in
for flushing.
Keep a constant watch on MOT level.
Check List For Oil Flushing:

1. Check erection of piping is complete as per the following PIDs
Pressure oil /return oil
7474-93051
Shaft lifting oil
7474-93052
Oil vapour
7474-93053
Oil drain
7474-93054
Oil purifier
7474-93055
HP control oil
7474-93071
LP control oil
7474-93072

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Signal oil
7474-93073
Test oil
7474-93074
Return oil
7474-93075
Waste oil
7474-93077
Turbine oil storage &purification system-TAPP-4-41320-1001/FS
2. Bypasses, looping dummies etc. are as per the oil-flushing scheme in Section
(1-131480-99001 & 0-13149-99001).
3. NRV flaps of JOP line to be removed.
4. Main oil tank & SOST has been cleaned and inspected.
5. Tank filter and cover is fitted with profile gasket.
6. Power supply to oil pumps is available.
7. Sufficient lights / illumination in the area is available.
8. Arrangements for giving thermal shock have been made.
9. Flushing devices to bypass oil to prevent oil entry to bearings have been fixed
at all bearings.
10. Ensure all fittings and fixture are installed for Turbovisory calibration has been
completed.
11. The bearing pedestals are cleaned and then boxed up.
12. Check tightness of flanges, sockets and nipples job.
13. Check all drains / vents in atmosphere are closed.
14. Check pressure gauges for pumps and temperature gauges for oil water
before and after cooler are installed.
15. Check sufficient manpower is available for tapping the lines thermal shock
and other operations for conducting oil flushing.
16. Check / Ensure that all the keys of pedestal and casing have been finalized
and fixed properly in their respective locations.
3.3
Flushing Lube Oil Lines

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a. Trial run of Vapour extraction fans should be completed as per STGLO-06

given in test report format.
b. First charging of oil system is to be done by running the AC EOP in order to
avoid any excessive oil spillage during first charging as discharge pressure of
AC EOP is lower than that of AOP. Ensure proper venting from all available
vents in the system.
c. For initial oil flushing the Lub oil cooler should be bypassed with the
connection provided for this purpose. This will prevent the dirt of lines from
entering in the cooler. The duration of oil flushing can be decided observing,
the main oil tank filter. Normally 2-3 days flushing should be sufficient, after
these connections to be normalized (take oil cooler in service) and oil flushing
with thermal shock method is to be carried out. Thermal shocks are continued
until desired results mentioned in 3.5 are achieved
d. Once oil system in completely filled up and all leakages are attended, AOP is
to be run for further flushing operations.
e. During flushing activity both the AOPs will be run parallely for achieving high
flow through the pipes for effective cleaning taking care of pump loading.
f. During flushing operations ensure the followings:
Thermal shock system
For thermal shock during oil flushing the two oil coolers will be used. One will be
used as hot water cooler and other as cold water cooler. Before starting thermal
shock activity ensure the following inputs.
1. Ensure that both the coolers are charged in oil and watersides and venting is
done properly.
2. The hot water cooler inlet and out let ACW (Auxiliary Cooling Water) valves are to
be kept closed once it is filled up with water.
3. Ensure that the oil and water temperature gauges are provided in the cooler inlet
and outlet line for both oil and water sides.
4. Ensure that flushing of all the loops is completed bypassing the cooler and MOT
filters are sufficiently clean.

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5. Ensure oil is getting heated as per requirement using centrifuge & churning effect
6. The oil temperature will increase. Allow increase in temperature > 60 deg. C but
keep < 80 Deg. C by adjusting the water in the cooler.
7. Ensure the cold water cooler is charged form ACW side and ACW system is in
operation
8. Change over the oil flow to the cold water cooler with the change over valve.
9. The oil temperature will start reducing. Continue cooling process till the inlet oil
(to cooler) temperature reduced to 45 deg .C.
10. While cooling process is on slowly tap the oil lines (with wooden hammer)
through which oil is flowing for descaling the dirt.
11. After completion of heating process repeat cooling process as above.
In above process of heating and cooling it must be remembered that process of
heating the oil should be more (around 1 to 1 and hrs) than cooling. Cooling
process has to be as fast as possible. For that sufficient cooling water flow has to be
ensured. This activity ensures effective cleaning of pipelines.
1. Filters in MOT are to be cleaned regularly, during the oil flushing.
2. Oil purification Unit (Bouser) / temporary centrifuge is to be run
continuously.(Drawings awaited)
g. After initial cleaning of oil lines, throttles in the oil supply line to bearings are
to be put in position. Oil flushing should then be continued for some bearing
at a time (keeping the throttles full open condition and closing the throttles of
the remaining bearings), therefore, ensuring flushing with maximum possible
flow in the oil return lines.
h. The flushing operation is to be continued by undertaking the above exercise
in rotation so that bearing oil supply lines are thoroughly flushed.
i. Turning gear line is to be flushed by opening the gate-gearing valve in such a
way that AOP motor does not get overloaded. This should be done daily once
for hour with thermal shock.

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Jacking Oil Lines:

a. The jacking oil system flushing can be started after initial dirt / muck of Lub oil
system is cleared.
b. Oil flushing is done by using the temporary connection from AOP discharge
header.
c. Initially the jacking oil header is to be flushed by using the connection from
JOP header dead end to drain header with temporary pipe.
d. After using above circuit for about 1-2 day the above connection is to be
closed and then the lines to the individual bearing are to be flushed, say 2 or
3 lines at a time for effective flushing.
e. Final flushing of the jacking oil lines will be done at high pressure (>30 kg/cm 2 )
by running the jacking oil pump.
3.5
Flushing Of Control Oil Lines:

a. After ensuring flushing circuit as per scheme in section 3.11. Keep all the
valves of control oil circuit close, and open only such small lines, which are at
end of system and will act as vent lines.
b. Open the interconnecting valves from AOP and fill up the 8-bar and 32 bar
system. Ensure that there is no leakage (if any attend to it).
c. Start one COP and pressurized the system with minimum flow. Ensure that
there is no leakages at high pressure ( 8-bar and 32-bar).
d. To achieve maximum velocity through pipeline the circuit of control oil lines
should be divided into 4 to 5 groups and circulation of oil should be rotated in
these groups.
e. For details of loop please refer scheme of loops given in this procedure.
f. Both COP will be run during oil flushing of the control oil flushing. The loading
of the pumps will be kept within the rated load

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Flushing of Seal oil system:

Flushing of the seal oil system will be carried out bypassing the seal oil pump rack
and valve rack.
A temporary connection will be drawn from the lub oil header end to the air / H2
side seal oil and ring relief oil lines (as shown in the attached sketch of the seal oil
flushing scheme). At 112 m elevation the H2 side seal oil equalizing valves
(MKW73AA011&021) will be replaced with temporary spools .The flow regulators (
of the air /H2 side seal oil and ring relief oil lines will be bypassed through bypass
valves during flushing operation.
The entire small bore piping in the seal oil racks and seal oil tank will be cleaned
mechanically / with compressed air before taking into normal operation after
flushing activities.
3.6
Criteria For Completion Of Flushing:

a. The oil analysis of sample drawn from oil purifier inlet should not have any
mechanical impurities and moisture.
b. Main oil tank filter (provided inside MOT) should be in clean condition over a
period of 24 hours.
c. Duplex filter element should be free from impurities such that no chocking of
filter should be experienced in duration of 24 hours.
d. Bearing Line filters are to be installed and flushing carried out for 24 hours
and no accumulation of dirt should be observed.
e. All criteria to be met for declaring the oil flushing completion.
3.7
Restoration Of The System:

a. On completion of flushing, hydraulic test of the system is to be done as per
the Hydraulic Test scheme No. (being submitted). Then the system is
normalized.

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b. When the oil is drained into the drain tanks provided, the drain tank, which
accepts oil, must be clean. The oil contained in the system, main oil tank and
oil coolers are to be completely drained using purifier & MOT drain lines.
c. The MOT (Main Oil Tank) / SOST are carefully cleaned and inspected as
done earlier before flushing. Jacking oil lines are to be normalized.
d. The cooler tube nest should be withdrawn for inspection and cleaning of the
coolers should be done with compressed air. Taking care so that O-rings are
protected. It is done to remove entrapped dirt particles in tube nest during
flushing operation.
e. All bearing pedestals are to be cleaned thoroughly before boxing up the
pedestals.
f. All temporary arrangements must be removed / normalized.
g. All bearing pedestal connections should be normalized. Turbine bearings
should be normalized.
3.8
Normalization of Jacking Oil Lines

a. Check NRV flaps are back in position.
b. Normalize the pipelines with the jacking oil pump discharge
c. Check pressure-regulating valves has been serviced and it is in low-pressure
position (released condition).
3.9
Hydraulic test of Lube oil & Control oil system

a. Put plugs in the relief holes of oil throttles and put the throttles in full close
position.
b. Provide dummies ( as per enclosed list ) at the last flange joint available in
the permanent piping, before it is connected to the drain in the oil canal.
c. Make a connection from jacking oil header supply line to the Lube oil circuit
as marked in the drawing given in this procedure.
d. Close the valves wherever the valves are located at the end of pipeline.

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Hydraulic tests:
a. Jacking oil lines
Test Pressure
Duration
225 Kg/Sq.cm.
10 Minutes
b. Lube oil lines

Test Pressure
Duration
12 Kg/Sq.cm.
10 Minutes
c. Control oil lines (8 Bar)

Test Pressure
Duration
20 Kg/Sq.cm.
10 Minutes
d. Control oil lines (32 Bar)

Test Pressure
Duration
96 Kg/Sq.cm.
10 Minutes
** The hydraulic test pressure & duration will be verified with the latest
recommendations of the designers before conducting the same.
After hydraulic test drain the system & normalize system. On filling the Fresh oil start
system commissioning.
3.11
Commissioning:
Lub oil and jacking oil system
1. Start main oil tank vapor fans from control system and record observations as per
STG LO-06.
2. Commission Oil purifier and record observations as per STG LO-07.
3. Before starting the Auxiliary Oil Pump, place persons in strategic locations for
observing leaks.
4. Start Auxiliary Oil Pump from control room and establish header pressure.

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5. Adjust lube oil throttles in the oil inlet lines as per design flow requirements of
individual bearing as per O&M instructions supplied by designer.
6. Check for oil flow through the sight glass at all consumption points
7. Stop AOP
8. Start AC EOP from control system and establish header pressure Record
observations.
9. Check status of pressure switches.
10. Stop EOP and start AOP
11. Check Auto Start of EOP with interlock of pressure switches
12. Check feedback of thermocouples
13. Lube oil system ready and functional with AOP available for operation.
14. Control & signal cable loop checks completion done
15. Release JOP discharge header pressure relief valve completely
16. Run AC Jacking Oil Pump from control room
17. Adjust relief valve to establish Jacking Oil Pressure at 150 kg/cm2
18. Check status of pressure switches
19. Stop AC Jacking oil pump
20. Start second Jacking Oil Pump from control room.
21. Run the pump for 10 Minutes and record observations
22. During the first charging of oil system oil spill may happen due to improperly
tightened pipe joints, uncovered openings or flooding of pedestal.
23. Before starting the oil pump, the system shall be checked for flange tightness and
correct valves line up.
24. Place persons in strategic locations for observing oil leakage before starting the
pump.
25. Funnels connected with hosepipes, empty buckets and empty drums shall be
used for collecting any drip.
26. Spraying fine sand over the spill and removing the sand after oil absorption will
clean oil drip on the floor.

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Dotted lines show temporary lines.

Flushing of JOP lines by JOP (Jacking Oil Pump)
Scheme No. 1
BRG 1
BRG 2
BRG 3
BRG 4
BRG 5
BRG 6
BRG 7
TO DRAIN
HEADER
To Lub oil
syst.
PRSS.REG.VALVE
TOMOT
JOP
1
JOP
2
MOT
JACKING OIL FLUSHING

SCHEME

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Scheme No. 2
Flushing scheme for control oil system

SIGNAL
OIL
32BAR
UNFILTERED
SIGNAL
OIL
CSDV
STOP
VALVE
1/2
32 BAR UNFILTERED
S.M.DRAIN
32 BAR
FILTERED
CSDV
CONTROL
VALVE
1/2
S.M.DRAIN
OIL FROM
PUMP DISCH
C.F.PUMP DISCIT
TEMP. HEADER Nb 80, MAN 10/20AZ001

SOL
VALVE
W.I
VAL
VE
RACK
DRAIN
VAC
BREAKER
SIGNAL OIL TO CSDV

TO DRAIN
DRAIN

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Scheme No. 3
32BAR
SU
OIL
TRIPOIL
SEC.OIL
ESV
1/2
TRIPOIL
ABOVE
HP
CONTR
OL
VALVE
1/2
PISTON
32 BAR
UNFILTERED
SUPPLY UNIT
32 BAR
FILTERED
TRIPOIL
BELOW
PISTON
HPCV1/2
S.M.DRAIN
S.M.
DRAIN
DRAIN
TO
ESV1/2

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Scheme No. 4
Nb 100 TEMPORARY HEADERS IN PLACE OF HYD. CONTROL RACK
PRI.OIL
SEC.OIL TO
HPCV 1/2
FROM C.F. PUMP

DISCHARGE
AUX.
TRIP
OIL TO
SOL.
VALVE
S.U.OIL TO
SUPPLY UNIT
TEST OIL TO O/S

GOVERNOR
AUX. TRIP OIL TO O/S

GOVERNOR
TRIP OIL TO
SUPPLY UNIT
AUX. S.U.OIL TO OVERSPEED

GOVERNOR
RACK
DRAIN

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Scheme No. 5
C.F.PUMP
DISCH.
SOL
VALVE
DRAIN
LPBP
VALVE
TO ACCUMULATOR
DRAIN
Scheme for hydraulic test
FROM AOP
TO SYST.
TO 32-BAR
JO
P
I
JO
P
II
TO 8-BAR

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Scheme No. 6
Flushing scheme for Lube oil system
BRG 1
BRG 2
BRG 3
BRG 4
BRG 5
BRG 6
BRG 7
MOP
BYPASS
THROTTLE
FROM JOP
TEMP. CONTROL
VALVE
TO JOP
TO DRAIN HEADER
DUPLEX FILTER
TO SEAL SOIL
AOP1
AOP
2
COOLER BYPASS
MOT
DIRTY
SIDE
EOP
MOT CLEAN SIDE

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Dirty oil and clean oil flushing scheme

TO MOT
NRV FLAP REMOVED
BOUSER BYPASS
TO MOT
CLEAN OIL
COMP.
DIRTY OIL
COMP.
C.O. PUMP
DIRTY OIL
TANK
D.O. PUMP
EMPTYING CONNECTION
Oil filling arrangement
TEMPORARY
TANK
CAP 2.5 M3
WIRE MESH
AND CLOTH
Nb 80MM
TO MOT
TEMPORARY
CENTRIFUGE
4.0
Design intents:

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Oil of viscosity class ISOVG 46 shall be used. For the topping of the oil system it
is preferable if the oil used is of the same brand & quality as that already in
system. The oil should comply with the requirements given in the table on sheet
no. 5.1-0130-02 of O & M manual.
Following intents will be matched:
1. Fresh oil fill initial = 60 Cu.M
2. Cooling capacity = with one cooler-inlet temp of 38 deg & 45 deg as outlet
temp when full capacity of design flow takes place through system.
3. Flow through bearing 1= 8.0 cu. Dm/sec
7. Gen front bearing=6.35 cu. Dm/sec
8. Gen rear bearing=6.35 cu. Dm/sec
9. Exciter bearing=1.37 cu. Dm/sec
10. Duplex oil filter=37 microns
11. MOT filter = 250 micron
12. JOP filter= 37 micron
13. Safety valve setting JOP =200 kg/cm2
14. Limiter setting of JOP = 150 kg/cm2
Note: Flow to individual bearings can be checked using enclosed Flow
Characteristics of Oil Throttle for Nb25, Nb50, Nb65, Nb80 & Nb100.
5.0
Expected process parameters

a. The oil analysis of sample drawn from oil purifier inlet should not have any
mechanical impurities and moisture.
b. Main oil tank filter should be in clean condition over a period of 24 hours.
c. Duplex filter element should be free from impurities such that no chocking of
filter should be experienced in duration of 24 hours.

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d. Line filters are to be installed and flushing carried out for 24 hours and no
accumulation of dirt should be observed.
e. All criteria to be met for declaring the oil flushing completion.
6.0
Work plan:
a. Commissioning of oil Vapour extraction fans
b. Commissioning of purifier
c. Commissioning of AC EOP
d. Commissioning of AOP 1&2.
e. Commissioning of JOP 1 & 2
f. Commissioning of COPs
g. Flushing through all loops as follows
Group-A Ckt. 1-MOP bypass-suct.-drain

Ckt.-2- AOP disc.-L.O. header drain header
Ckt.-3-AOP dish.-JOP header drain header
Group-B Ckt.-1-L.O. header brg. Pedestal-drain

Ckt.-2-L.O. header-seal oil drain
Group-C Ckt.1-Gov rack bypass-drain

Ckt.-2-32-bar to HPCV 1 & 2 drain
Ckt.-3 32-bar to CSDV 1 & 2 drain
Group D Ckt.-1-CSDV rack 1 & 2 bypass drain

Ckt.-2-32-bar to CSDV 3 & 4 drain
Ckt.-3-vack brk & LPBP 1 & 2 -drain
h. Commissioning of the Lube oil system

i. Commissioning of the JOP system
j. Commissioning of the control system
INPUTS SUMMARY TO START CYCLE

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1. Completion of oil pipe lines maintaining cleanliness as per directivesGov/control oil, LPBP, seal oil, jacking oil system.
2. Completion of temporary pipe loops as per flushing scheme in section 3.11.
3. Preparedness of brg. Pedestals for oil flushing
4. Completion of filling as per scheme in section 3.11.
5. Completion of thermal shocks arrangements as per Scheme No. 7.
6. Completion of C & I tapping points (TWs, ROOT VALVES ETC.)
7. Availability of 415 V AC, for AOP1, AOP2, COP 1 , COP2 JOP1, JOP2, EOP,
Oil Vapour fan 1& 2, purifier.
8. Availability of aux. Stem
9. Availability of cooling water to cold water cooler with design flow /temp
10. Availability of pressure & temp. Gauges as per scheme in section 3.11.
Sufficient manpower during flushing with shocks.
Other plans:
1.
Oil draining arrangement as per schedule.
2.
Proper team distribution & availability

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(MOT, Piping, Pedestal work C&I WORK).

3.
7.0
Sequential erection of activities as per agreed schedule for

a.
Bearing Bottom halves work completion
b.
Rotor zero position
c.
MOP work
d.
Bearing Top halves work & pedestals box-up
e.
SOP system readiness.
f.
End shield mounting
g.
LPBP / Gov. lines normalizations.
h.
MOT work
Test report format

Schedule of Check Lists for Lube Oil System and jacking oil system
Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Check list
Description
STG-LO-01
STG-LO-02
STG-LO-03
STG-LO-04
STG-LO-05
STG-LO-06
STG-LO-07
STG-LO-08
STG-LO-09
STG-LO-10
STG-LO-11
STG-LO-12
STG-LO-13
STG-JO-01
STG-JO-02
STG-JO-03
STG-JO-04
STG-CO-01
Installation of orifices
Installation of devices
Calibration of devices
Main Oil Tank Readiness
Turbine Oil Sample Results
Oil vapor fan commissioning
Oil Purifier Commissioning
Auxiliary Oil Pumps commissioning
Oil flow through sight glasses
Oil System Alarm Schedule
EOP (Emergency Oil Pump)
Feed back of thermocouples
Temperature control valve
Installation of devices
Calibration of devices
AC JOP Motor commissioning
AC JOP commissioning
COP commissioning
Checklist STG-LO-01
INSTALLATION OF ORIFICES

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Date:
SL
No
1
2
3
4
Orifice Identification
Orifice
Diameter.
Orifice Installed
(Yes/No)
(Pl refer PIDs oil system supplied by HWR)

Checklist STG-LO-02
INSTALLATION OF DEVICES
Date:
SL.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Tag No
Description
37 micron filter cartridges in LO
37micron filter cartridges IN JO
MOT level indicator
MOT level high switch
MOT level low switch
AOP discharge pressure indicators
EOP discharge pressure indicator
Lube oil inlet to cooler1 local temperature
indicator.
Lube oil inlet to cooler 2 local temperature
indicators.
Lube oil outlet from cooler 1 local temperature
indicator.
Lube oil outlet from cooler 2 local temperature
indicators.
Lube oil temperature after cooler - temperature
element
Differential pressure indicator for lube oil filters
Differential pressure switch for lube oil filters
Lube oil header pressure indicator
Lube oil header pressure transmitter
Lube oil header pressure low - switch
Lube oil header pressure low-low - switch
Lube oil header pressure low-low switch
Installed
Yes/No

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TG OIL SYSTEM
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.

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Lube oil header pressure low-low switch

MOP discharge header pressure low - switch
MOP discharge header pressure indicator
MOP suction pressure - indicator
Lube oil pressure to thrust bearing - indicator
Lube oil pressure to turbine bearing 1 test
indicator
Lube oil pressure to turbine bearing 2- test
indicator
indicator
indicator
Return oil temperature indicator - bearing 1
pedestal
pedestal
pedestal
pedestal
pedestal
pedestal
pedestal
Lube oil pressure test indicator exciter rear
bearing
Refer for Tag no, set points & other details :INSTRUMENT LIST, DRG.NO. 4
13300 98 001, REV02 NPC DOC. TAPP
Checklist STG-LO-03
ON SITE CALIBRATION OF DEVICES

PS: WR NAGPUR
TG OIL SYSTEM
Sl.
no.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Device
MOT level indicator
MOT level high switch
MOT level low switch
AOP discharge pressure
indicators
EOP discharge pressure
indicator
Lube oil inlet to cooler local
temperature indicator.
Lube oil inlet to cooler local
Lube oil outlet from cooler local
Lube oil outlet from cooler local
Lube oil temperature after
cooler - temperature element
Differential pressure indicator
for lube oil filters
Differential pressure switch for
lube oil filters
Lube oil header pressure
indicator
Lube oil header pressure
transmitter
Lube oil header pressure low
switch
Lube oil header pressure lowlow switch
MOP discharge header
pressure low switch
MOP discharge header
pressure indicator

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Tag no
Date:
Range / Set
Point
Checked
OK / NOT
OK

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23.
24.
25.
26.
27.
28.

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MOP suction pressure indicator

Lube oil pressure to thrust
bearing indicator
Return oil temperature
indicators
Oil pressure to barring gear
indicator
Oil pressure to barring gear low
switch
COP disch. Pressure indicator (
8-bar and 32 bar)
Refer for Tag no, set points & other details :INSTRUMENT LIST, DRG.NO. 4 13300
98 001, REV02 NPC DOC. TAPP

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Checklist STG-LO-04
MAIN OIL TANK READINESS
Tank Description: Main Oil Tank
P&ID Number:
Fluid Stored: Turbine Oil
Capacity: 63.0 m3
No
Date:
Description
1. Check identification agrees with details on

drawing no.
Tag Number
Title
Capacity
2. Check that access is safe for operational
purposes.
3. Check that tank and nozzles correctly
fabricated as per approved drawing
4. All appurtenances (such as strainers, level
gauges, valves, vents and drains) are
connected properly.
5. The interior of tank is clean and free from all
loose scale, sand and debris.
6. Tank painted internally and externally as per
specifications
7. Ladder is installed- if applicable
8. All manhole covers and flanged joints are
made up complete with gaskets and bolts
tightened.
9. Commissioning of Level instruments including
Indicators as per check list
10. Tanks drain valve locked / closed.
11. Fire detection & Protection system for the
Tank ready if applicable
12. Earthling Connection for tank done
Tank is ready for receiving the fluid
Result
Remarks

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Checklist STG-LO-05
LUBE OIL SAMPLE TEST RESULTS
Grade: Servo prime 46 or Turbine oil 46
Sample taken on:
Sample taken from:
Size of sample:
Tested at:
Results received on date:
Sl
Test
Unit
Kinematic viscosity at
40degC
Water Content
Solid content
CST
Desired
va
lu
e
41.4 50.6
Gm/100 gm
gm/100gm
0.1
0.05
2
3
Test Value
Remarks

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Checklist STG-LO-06
OIL VAPOUR FANS COMMISSIONING
Equipment tag number.
System Description.
P&ID No..
Manufacturers Name.
Name Plate details

Sl.
No
Date
Remarks
Description
1 Bearing lubricated as recommended

2 Rotor free in its bearings
3 Review motor winding insulation resistance
values
4 Check Motor earthling
5 Power supply switchgear checked and
ready for charging
6 Cabling completed
7 Fan bumped and rotation proved
8 Instrumentation & protection devices
checked
9 Holding-down bolts fitted securely
10 Demister drain provided (Yes/No)
Fan is ready for commissioning
Oil Vapor Fan Trial Data
TIME
DATA
Motor
Current
Vibration at
Motor CE
Vibration at
Motor FE
Vibration at
fan body
UNIT
Amps
Microns /
mm/sec
Microns /
mm/sec
Microns /
mm/sec
Legend: CE Coupling End, FE- Free End

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Checklist STG-LO-07
OIL PURIFIER COMMISSIONING
Ref: Vendor drg. No.
Sl
Activity
No
1.
Components and instrumentation
checked as per drawings
2.
control panel charged
3.
All alarms, interlocks &
protections checked as per
Vendor drg No. SEN003880
4.
Purifier trial run for 4 hours
completed
Checked OK / Not
OK
Remarks
Checklist STG-LO-08
AUXILIARY OIL PUMPs COMMISSIONING
Equipment tag number .
System Description.
P&ID Number
Manufacturers Name
Name Plate details

Date
No
Description

values
4 Check Motor earthing
5 Power supply switchgear checked and ready
for charging
6 Pump bumped and rotation proved
checked (Check Auto Start of AOP by
simulating low header pressure)
Remarks

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Pump set is ready for trial run.
Auxiliary Oil pump Trial Data

TIME
DATA
UNIT
Motor
Amps
Current
Pump
Kg/cm2
discharge
pressure
Vibration at
Microns /
Motor CE
mm/sec
Vibration at
Microns /
Motor FE
mm/sec
Checklist STG-LO-09
OIL FLOW DRAIN OIL VIEWING WINDOW
Date:
SL
No
1.
2.
3.
4.
5.
6.
7.
Sight Glass location

Pedestal 1
Pedestal 2
Pedestal 3
Pedestal 4
Pedestal 5
Pedestal 6
Pedestal 7
Flow Observed
Yes/No

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Checklist STG-LO-10
OIL SYSTEM ALARM SCHEDULE
Date:
Ref: BHEL SOE List :
Sl
No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Tag No
Service
Status
LO main tank
level
LO main tank
level
LO Pr across
filter
MOP/AOP
Discharge Pr
LO Header Pr
L.O. Header Pr
LO Header Pr
Jacking Oil Pr
Lub. oil after
cooler
Turbine TB Nonactive temp
High
Alarm
Low
Alarm
High
Alarm
Low
Standby AOP
start
Alarm
AC EOP Start
AOP start
Alarm
Alarm
Low
V Low
Low
Low
Hi
Set
Point
Remark
Hi
Alarm
11.
Hi
Alarm
12.
Hi
Alarm
13.

Turbine TB
active temp
Turbine TB
active temp
Turbine TB
active temp
Hi
Alarm
Hi
Alarm
Hi
Alarm
Hi
Alarm
14.
15.
16.
Checked
OK/NOT
OK

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17.
Turbine TB
Hi
Alarm
active temp
18.
Turbine FJB
Hi
Alarm
temp
19.
Turbine Bearing
Hi
Alarm
1temp
20.
Turbine Bearing
Hi
Alarm
2temp
21.
Turbine Bearing
Hi
Alarm
3 temp
22.
Turbine Bearing
Hi
Alarm
4 temp
23.
Turbine Bearing
Hi
Alarm
5 temp
24.
Turbine Bearing
Hi
Alarm
6 temp
25.
Turbine Bearing
Hi
Alarm
7 temp
26.
Turbine axial
Hi
Alarm
displacement
27.
Turbine axial
Hi
Alarm
displacement
28.
AOP not on Auto
Alarm
Refer for Tag no , set points & other details :INSTRUMENT LIST, DRG.NO. 4 13300
98 001, REV02 NPC DOC. TAPP.
Checklist STG-LO-11
EMERGENCY OIL PUMP
Date:
SL
No
1
2
3
4
5
6
7
Pump in Operation
Value
Emergency Oil Pump

discharge pressure set at
voltage
Current drawn
Pump speed
Field resistance value
Armature resistance value
Status of pressure switches
OK / NOT OK
Unit
Kg/cm2
Volts
Amps
rpm
Ohms
Ohms

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OK / NOT OK
Auto start of EOP
9
10
OK / NOT OK
OK / NOT OK
Checklist STG-LO-12
FEEDBACK OF THERMOCOUPLES AND PRESSURE TRANSMITTERS

SL
NO
Device
Status in STG control

system
1
2
Refer for Tag no , set points & other details :INSTRUMENT LIST, DRG.NO. 4
13300 98 001, REV02 NPC DOC. TAPP.
Checklist STG-LO-13
TEMPERATURE CONTROL VALVE
SL
NO
1
2
Activity
Remarks
Valve operation
Temperature control
setting
OK / NOT OK
45 degC
Checklist STG-JO-01
INSTALLATION OF DEVICES
Date:
SL
No
1
2
3
4
5
6
7
8
9
10
11
Tag No
Description
AC JOP 1 discharge pressure
AC JOP 2 discharge pressure
JOP discharge header pressure transmitter
JOP header pressure low - switch
JOP header pressure low - switch
JOP pressure at bearing 1
Installed
Yes/No

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12
Checklist STG-JO-02
ON SITE CALIBRATION OF DEVICES
Sl
no
1
Tag no
Date:
Range /
set point
Device
Calibrated
yes/no
JOP discharge header

transmitter
JOP discharge header pressure
low
JOP Discharge header to
Turning gear interlock
2
3
Checklist STG-JO-03
JACKING OIL PUMPs MOTOR
System Description.
P&ID Number
Manufacturers Name
Name Plate details

SL
No
1
2
3
4
5
Description
Foundation bolts tightened
Check driven equipment fitted in right
direction
Bearing lubricated with specified lubricant
Check free rotation of the shaft manually in
uncoupled condition
Verify winding insulation resistance value
Date:
Remarks

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TG OIL SYSTEM
6
7
8
9
10
11
12
13
14

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Check Motor earthing

Power supply switchgear ready for charging
Verify cabling completion
Protective devices checked
Local start-stop push buttons provided (if
applicable)
Motor coupling guard provided
Set up temporary instrumentation for
recording of no-load running current
Start motor (bump test) and confirm the
direction of rotation
Run motor for 4 hrs. Note the readings of
motor current
Motor is ready for coupling with the driven equipment.

JOP Motor Trial Data
TIME
DATA
Motor
Current
Vibration at
Motor CE
Vibration at
Motor FE
UNIT
Amps
Microns /
mm/sec
Microns /
mm/sec
Checklist STG-JO-04
JACKING OIL PUMP COMMISSIONING
System Description.
P&ID Number
Manufacturers Name
Name Plate details

Date

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TG OIL SYSTEM
No

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Description
Remarks
1
2
3
4
Bearing lubricated as recommended

Rotor free in its bearings
Pump bumped and rotation confirmed
Instrumentation & protection devices
checked
6 Piping connection checked
7 Relief valve released completely
Pump set is ready for trial run.. Set Jacking Oil Header Pressure at 150 kg/cm2.
Jacking Oil pumps Trial Data
Relief valve set value after pump starting
Kg/cm2
TIME
DATA
Motor
Current
Pump disch.
Pressure
JOP header
pressure
Vibration at
Motor CE
Vibration at
Motor FE
UNIT
Amps
Kg/cm2
Kg/cm2
Microns /
mm/sec
Microns /
mm/sec

Status of Jacking Oil System devices
Sl
no
1
2
Tag no
Device
JOP discharge header pressure

switch
JOP Discharge header to Turning
gear interlock
Set Point
Status in
STG
control
system

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Refer for Tag no , set points & other details :INSTRUMENT LIST, DRG.NO. 4
13300 98 001, REV02 NPC DOC. TAPP
Checklist STG-CO-01
CONTROL OIL PUMPs COMMISSIONING
System Description.
P&ID Number
Manufacturers Name
Name Plate details

Date
No
Description
Remarks

values
4 Check Motor earthing
5 Power supply switchgear checked and ready
for charging
6 Pump bumped and rotation proved
checked (Check Auto Start of AOP by
simulating low header pressure)
Pump set is ready for trial run.
Control Oil pump Trial Data
TIME
DATA
Motor
Current
Pump
discharge
pressure
Vibration at
Motor CE
Vibration at
Motor FE
UNIT
Amps
Kg/cm2
Microns /
mm/sec
Microns /
mm/sec

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8.0
Reference
a. Turbine O&M manual
b. PIDs E7474-93051 /93452/93453
c. Instrument list, drg.no. 4 13300 98 001, REV02 NPC DOC. TAPP
9.0
Verification process
Verification points are included in 4.0 general methods
Verification requirements- all functional requirements have been listed in
general method. Cleanliness of all the bearing pedestals and tanks
(MOT/SOST/SOT/DOT/COT) will be ensured before start of flushing
activity and after flushing before normalization.

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APPENDIX-1
VERIFICATION TABLE
COMMISSIONING PROCEDURE OF TG OIL & JACKING OIL SYSTEM & FLUSHING OF
ALL OIL SYSTEM
COMMISSIONING PROCEDURE NO. TAPP-3&4- 41300-CP-1

SL.
NO
ACTIVITY
VERIFIED
ACCEPTANCE
CRITERIA
VERIFYING
AGENCY
CERTIFICATION BY VERIFYING AGENCY

PROCEDURE
VERIFICATION
Pl refer
4.0
Pl refer 4.0
INSPECTION
WITNESS
FUNCTION
-AL TEST
RESULT
VERIFICATION
GENERAL
REMARKS

PS: WR NAGPUR
TG OIL SYSTEM

ISSUE NO:01
REV NO: ZERO

Page 51 of 52
Temporary looping of seal oil system
TO AIR
SIDE
DRAIN
RING RELIEF
AIR & H2
SIDE SEAL
OIL
BYPASS
AIR & H2
SIDE SEAL
OIL
BYPASS
H2 SIDE
DRP
BYPASS
SOST
FROM L.O.
HRADER
AIR SIDE
SEAL OIL
H2 SIDE
SEAL OIL
SEAL OIL RACK

BYPASS

Bharat Heavy Electricals Limited (A Govt. of India Undertaking) Tarapur Atomic Power Project - 3&4

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Bharat Heavy Electricals Limited (A Govt. of India Undertaking) Tarapur Atomic Power Project - 3&4

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BHARAT HEAVY ELECTRICALS LIMITED

PROCEDURE NO: TAPP3&4-41300-CP-1

REV NO: ZERO

DATE OF ISSUE: NOV. 2003