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Station: NTPC Simhadri

BHEL Ref No. PS-DC-186-5 6! NTPC Ref No. S"#$1$TS$%$ 5 !

Sheet 1 of %

P&ant area : T'RB"NE PR(CED'RE )(R *ENER!T(R SE!L ("L "NT"!L C"RC'L!T"(N S&. No. 1. %. +. ,. 5. 6. -. 8. .. 1 . PL!NT DET!"LS (B/ECT"0E PR(P(S!LS SER0"CES RE1'"RED S!)ET2 PREC!'T"(NS E#ER*ENC2 PR(CED'RE ST!TE () THE PL!NT #ETH(D C(#PLET"(N CR"TER"! !PPEND"CES a3 63 Dra4in5 Lo5 Sheet7

Station: NTPC - Simhadri P&ant area : T'RB"NE

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet % of %

PR(CED'RE )(R *ENER!T(R SE!L ("L "NT"!L C"RC'L!T"(N S&. No. 1. 1.1 PL!NT DET!"LS ST!T'S

Generators cooled by H2 are provided with seal oil system for preventing the leakage of H 2 to atmosphere for the formation of explosive mixture and to reduce the consumption of H2. This system consists of tank, pumps, ( oth !.".and #."$ coolers, filters and pressure regulators to maintain the oil pressure at the seal body of generator. Turbine oil is used for this purpose. #" pump is meant to supply oil to the seals during the failure of !" power supply during emergency conditions.
%or Technical &pecifications, the respective ' ( ) manuals are to be referred. The drawings enclosed at section *+.+ are a$ &chematic for oil flushing of &eal 'il ,iping. #rg.-o. ./,&/T&0/++12/++ "ontrol 3alue rack of &eal 'il &ystem. #rg.-o../,&/T&0/++1./++

1.%

1.+

1., 1.5

b$

Si5nat8re7 NTPC BHEL

Station: NTPC - Simhadri P&ant area : T'RB"NE

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet + of %

PR(CED'RE )(R *ENER!T(R SE!L ("L "NT"!L C"RC'L!T"(N S&. No. %. (B/ECT"0E ST!T'S

To commission the seal oil system and establish the oil flow through the generator seals.

Si5nat8re7 NTPC BHEL

Station: NTPC Simhadri P&ant area : T'RB"NE

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet , of %

PR(CED'RE )(R *ENER!T(R SE!L ("L "NT"!L C"RC'L!T"(N S&. No. +. PR(P(S!L "ommissioning of seal oil system is carried out in the following stages/ ST!T'S

*$ %illing and operation of air side seal oil circuit. 2$ %illing and operation of H2 side seal oil circuit 2$ &etting of seal oil pressures. .$ "hecking of functioning of pressure switches and level detectors. 4$ )easurement of seal oil flow.

Si5nat8re7 NTPC BHEL

Station: NTPC - Simhadri P&ant area : T'RB"NE

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet 5 of %

PR(CED'RE )(R *ENER!T(R SE!L ("L "NT"!L C"RC'L!T"(N S&. No. ,. ,.1 ,.% SER0"CES RE1'"RED 5estoration of oil piping and normali6ation after oil flushing. %illing of seal oil storage tank with fresh oil and running of !vailability of service air and thinner7petrol for filter cleaning. !vailability of sufficient skilled manpower for supervision 7 execution of the process. !vailability of portable fire extinguishen at oil flushing area. !vailability of proper lighting and communication facility. ST!T'S

,.+

,., ,.5

Si5nat8re7 NTPC BHEL

Station: NTPC Simhadri

BHEL Ref No. PS-DC-186-5

Sheet 6 of %

NTPC Ref No. S"#$1$TS$%$ P&ant area : T'RB"NE

PR(CED'RE )(R *ENER!T(R SE!L ("L "NT"!L C"RC'L!T"(N S&. No. 5. 5.1 S!)ET2 PREC!'T"(NS: 5eadiness of stair cases, platforms, hand rails for &eal 'il Tank and re8uired approaches as decided at site are made available. &afety and protection e8uipments like hand gloves, helmet etc are available during the process. ,recautions taken to avoid spillage of oil and contamination of oil. &ervice water source available near the activity area. 9nsure the availability of first aid kit near the process area. uckels containing sand are available at process area. :elding7cutting shall not be carried out in lub;oil flushing areas, once oil has been filled in &eal 'il Tank. <oad on ,umps shall not exceed full load current of the motor. ,rovision for emergency stopping of oil pumps from local7=" has to be made. "ordoning of lub;oil flushing area wherever re8uired. #isplay of caution sign boards, danger tags are provided at locations in the test area. 5ound the clock monitoring of oil flushing activity. ST!T'S

5.% 5.+ 5., 5.5 5.6 5.5.8 5.. 5.1 5.11 5.1%

Si5nat8re7 NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-5

Sheet - of %

NTPC Ref No. S"#$1$TS$%$ P&ant area : T'RB"NE

PR(CED'RE )(R *ENER!T(R SE!L ("L "NT"!L C"RC'L!T"(N S&. No. 6. 6.1 ST!T'S

E#ER*ENC2 PR(CED'RES: The teams for this operation shall be aware of the procedure of oil flushing and act at the time of any emergency. They shall be aware of operation of fire extinguishers. They shall be aware of how to act in case of any personal in>uries. They shall know to stop the pumps 8uickly in case of any leakage and then inform the concerned higher official. They shall be aware of re;establishing the operation in case of system stoppage due to failure of power supply.

6.%

6.+

6.,

6.5

Si5nat8re7 NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet 8 of %

P&ant area : T'RB"NE PR(CED'RE )(R *ENER!T(R SE!L ("L "NT"!L C"RC'L!T"(N S&. No. -. -.1 -.1.1 -.1.% ST!TE () THE PL!NT 5estoration of oil piping and normali6ation after oil flushing. 3erification of logic and control scheme of seal oil pumps as per control diagram. %illing of seal oil storage tank with fresh oil and running of !vailability of service air and thinner7petrol for filter cleaning. !vailability of sufficient skilled manpower for supervision 7 execution of the process. 9nsure the cleanliness of both filters provided in air side and H2 side seal oil circuit. 9nsure that all the shut off and gate valves are closed. <oosening of spring of pressure regulating valves !*,!2 and " to ensure these are in fully open condition. ST!T'S

-.1.+

-.1.,

-.1.5 -.1.6

Si5nat8re7 NTPC BHEL

Station: NTPC Simhadri

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet . of %

P&ant area : T'RB"NE PR(CED'RE )(R H2DR!'L"C TEST !ND ("L )L'SH"N* () *ENER!T(R SE!L ("L S2STE# S&. No. ST!T'S

-.1.6

,hysical cleaning of seal oil storage tank and seal oil tank after flushing. !vailability of power and control supply for motors and starting panels. Trial run of following motors and coupled with respective pumps. a. b. c. !ir side seal oil pump motor (!"$ 9mergency air side seal oil pump motor (#"$ H2 side seal oil pump motor (!"$ 2 nos. * no. * no.

-.1.-

-.1.8

Si5nat8re7 NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-5

Sheet 1 of %

NTPC Ref No. S"#$1$TS$%$

P&ant area : T'RB"NE PR(CED'RE )(R H2DR!'L"C TEST !ND ("L )L'SH"N* () *ENER!T(R SE!L ("L S2STE# S&. No. ST!T'S

Si5nat8re7 NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-5

Sheet 11 of %

NTPC Ref No. S"#$1$TS$%$ 5 PR(CED'RE )(R H2DR!'L"C TEST !ND ("L )L'SH"N* () *ENER!T(R SE!L ("L S2STE# S&. No. 8. 8.1 ST!T'S

#ETH(D
)"LL"N* !ND (PER!T"(N () !"R S"DE SE!L ("L C"RC'"T:

Si5nat8re7 NTPC BHEL

Station: NTPC Simhadri

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet 1% of %

P&ant area : T'RB"NE PR(CED'RE )(R H2DR!'L"C TEST !ND ("L )L'SH"N* () *ENER!T(R SE!L ("L S2STE# S&. No. 8.1 8.1.1 ST!T'S

)"LL"N* () !"R S"DE SE!L ("L C"RC'"T 'pen following shut off and gate valves in air side oil circuit. )?: +* !! 4+2 !t seal oil storage tank )?: ** !! 4+* before seal oil pump (*$. )?: 2* !! 4+* before seal oil pump (2$ )?: 2* !! 4+* before stand by seal oil pump (2$ )?: 2* !! ++* after seal oil pump (*$ )?: 2* !! ++2 after seal oil pump (2$ )?: 2* !! ++2 after stand by seal oil pump (*$ )?: ** !! 4+. before !* valve )?: ** !! 4+4 after !* valve )?: 2* !! 4+. before !2 valve )?: 2* !! 4+4 after !2 valve )?: ** !! ++. after seal oil pumps (*$ ( (2$ )?: 2* !! ++. after stand by seal oil pumps (2$ )?: +2 !! 4+2 before float valve, oil inlet )?: +2 !! 4+* after float valve, oil drains (.$ )?: +2 !! 4+4@ for oil level gauge )?: +2 !! 4+1@ )?: A* , 4+* ad>ustable orifice )?: A1 !! 4*2@ seal ring relief oil )?: A1 !! 422@

Si5nat8re7 NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet 1+ of %

P&ant area : T'RB"NE PR(CED'RE )(R H2DR!'L"C TEST !ND ("L )L'SH"N* () *ENER!T(R SE!L ("L S2STE# S&. No. ST!T'S

8.1.%

"harge the seal oil coolers on oil side with rotary transfer valve assembly in centre position. :hen the coolers are filled with seal oil, turn rotary transfer valve on one side i.e. 5ight hand or left hand side to bring one cooler in service and other on standby. "harge both seal oil filters as done in case of coolers and keep one seal oil filter in service by keeping rotary transfer valve on one side. &tart and stop seal oil pump * for a short time to bleed air from piping until pressure gauges )?: A* ", 4** and ", 42* indicate a constant pressure. &et three way valves )?: A* !! 4** and !! 42* and )?: A1 !! 4** and !! 42* to position where no oil passes through the volume flow indicator.

8.1.+

8.1.,

8.1.5

Si5nat8re7 NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet 1, of %

P&ant area : T'RB"NE PR(CED'RE )(R H2DR!'L"C TEST !ND ("L )L'SH"N* () *ENER!T(R SE!L ("L S2STE# S&. No. ST!T'S

8.%
8.%.1

)"LL"N* () H% S"DE SE!L ("L C"RC'"T #uring filling of the air side circuit, the seal oil tank is simultaneously filled with seal oil by valve )?:+2 !! 4+2. 'il level in this tank will continue to rise above the sight glass till it reaches the level of seal oil storage tank and will get drained through siphon action. 'pen following shut off and gate valves of H2 side seal oil circuit. )?:*2 !! 4+* before H2 side seal oil pump )?:*2 !! ++2 before H2 side seal oil pump )?:*2 !! 4*+ before B"C valve )?:*2 !! 4+2

8.%.%

Si5nat8re7

NTPC

BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet 15 of %

P&ant area : T'RB"NE PR(CED'RE )(R H2DR!'L"C TEST !ND ("L )L'SH"N* () *ENER!T(R SE!L ("L S2STE# S&. No. ST!T'S

8.%.+

"harge both seal oil coolers on oil side with rotary transfer valve assembly in its center position. :hen both cooler are filled with seal oil, turn rotary transfer valve on one side i.e. 5ight or <eft hand to bring one cooler in service. "harge both seal oil filters as done in case of coolers and keep one filter in service. <oosen the ad>usting nut of pressure e8ualising valve )?:A2 !! +2*. &tart and stop H2 side seal oil pump to bleed the air from piping until the pressure gauges )?:A2 ", 4** and ", 42* indicates a constant reading. &et three way valves )?:A2 !! 4** and !! 42* to position, where no oil passes through volume flow indicator. Hydraulic test of the seal oil piping (excluding rack$ shall be carried out at a pressure of *2 kg.7cm2.

8.%.,

8.%.5

8.%.6

8.%.-

Si5nat8re7 NTPC BHEL

Station: NTPC Simhadri

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet 16 of %

P&ant area : T'RB"NE PR(CED'RE )(R H2DR!'L"C TEST !ND ("L )L'SH"N* () *ENER!T(R SE!L ("L S2STE# S&. No. ST!T'S

8.,.

("L )L'SH"N* () S2STE# 'il flushing of seal oil circuit is carried out in three different stages. i. ii. iii. %lushing of air side circuit %lushing of H2 side circuit %lushing of oil impulse lines

8.,.1

%lushing of !ir &ide &eal 'il "ircuit. %lushing of air side seal oil circuit is carried out by one of the !" seal oil pumps provided in the system. #uring this process, oil flow is maintained through seal oil cooler, filter, valve !*, !2, inlet seal oil pipes/ bearing drain pipes to seal oil storage tank. ,arallel to this, inlet ring relief oil pipes are also flushed in this circuit.

Si5nat8re7 NTPC BHEL

Station: NTPC Simhadri

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet 1- of %

P&ant area : T'RB"NE PR(CED'RE )(R H2DR!'L"C TEST !ND ("L )L'SH"N* () *ENER!T(R SE!L ("L S2STE# S&. No. ST!T'S

8.,.%

%lushing of H2 side &eal 'il "ircuit. %lushing of this circuit is carried out by H 2 side seal oil pump provided in the system. #uring this process, oil flow is maintained through H 2 side seal oil cooler, filter, valve B"C, Dnlet H2 side seal oil pipes, H2 side drain pipes, prechambers, seal oil tank. %lushing of 'il Dmpulse <ines %lushing of all oil impulse lines provided in the system for various pressure gauages, pressure regulators should be done by opening their root valves and then flushing through their isolating valves opened to vent. 'il should be collected in the bucket at the root of isolating valves. #uring flushing ensure that there is no oil leak in the system. Df leaks are observed stop flushing and attend to the leaks. )aintain oil temperature around 14;A+ +".

8.,.+

8.,.,

8.,.5

8.,.6

Give thermal stocks as done in Turbine lub oil system flushing. (5efer ,rocedure ,&;#"E*F1; 4++;+++.7-T," 5ef -o. &D)7*7T&727++*$ "hangeover the filter after every one hour and clear. "leaning of filter to be carried out by following steps. a$ "lean the filter element in ?erosene 7 #iesel 'il. b$ Then clean the filter element with clean markin cloth.

8.,.-

Si5nat8re7 NTPC BHEL

Station: NTPC Simhadri

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet 18 of %

P&ant area : T'RB"NE PR(CED'RE )(R H2DR!'L"C TEST !ND ("L )L'SH"N* () *ENER!T(R SE!L ("L S2STE# S&. No. ST!T'S

c$ "lean and dry the filter with compressed air. (!ir pressure to be reduced sufficiently for air blowing filter$ 8.,.8 8.,.. Take sample of return oil and analyses if for the presence of moisture ( mechanical impurities. Hydraulic test of the lines (excluding seal oil rack$ shall be carried out at a pressure of *2 kg7cm2 along with lub;oil system. 5estoration of &eal 'il &ystem 8.5. 8.5.1 8.5.% (n 9om:&etion of oi& f&87hin5: #rain the entire system. 5emove the temporary piping and restore original connections.

8.5.+ 5emove the blanks provided, if any. 8.5., 8.5.5


8.5.6

"onnect back the impulse lines. 5eassemble the float valves )?:'2 !! ++* and !! ++2 in seal oil tank. "lean both the filters and reassemble.

Si5nat8re7 NTPC BHEL

Station: NTPC Simhadri

BHEL Ref No. PS-DC-186-5 NTPC Ref No. S"#$1$TS$%$ 5

Sheet 1. of %

P&ant area : T'RB"NE PR(CED'RE )(R H2DR!'L"C TEST !ND ("L )L'SH"N* () *ENER!T(R SE!L ("L S2STE# S&. No. ST!T'S

..

C(#PLET"(N CR"TER"! The charging of seal oil system is said to be completed once the oil flow is established through both sides of the generator seals and the pressure regulators are put in to service.

Si5nat8re7 NTPC BHEL

Sheet 20 of 20

SEAL OIL PUMP NO. 1 / 2


Oil temperature Sl.No Date/Time Pump Dis.Pr. #ef. $ooler After $ooler Thermal Sho ! "emar!s

Si5nat8re7 NTPC BHEL

P"O$EDU"E %O" &'D"AULI$ TEST AND OIL %LUS&IN( O% (ENE"ATO" SEAL OIL S'STEM