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BHARAT HEAVY ELECTRICALS LIMITED

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


PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 1 of 52

BHARAT HEAVY ELECTRICALS LIMITED


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

COMMISSIONING PROCEDURE FOR


TG OIL SYSTEM
TAPP3&4- 41300-CP-1

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY ISSUED BY


BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 2 of 52

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BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 3 of 52

REVISION LOG

Revision Details Preparation Details

Prepared by
Issue Rev. Page Concurred by
Details Date Checked by
No. No. No. Approved by
Reviewed by
V.K.Kuhikar, Dy.Mgr
01 NA First Issue NOV. ‘03 NA R.M, Bagul. Engr., QA
J. Mathew, Incharge-TG

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY ISSUED BY

V.K. Kuhikar R.M Bagul J. Mathew S.K Jain


Dy.Manager Engineer, QA Incharge-TG Construction Manager
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 4 of 52

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BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 5 of 52

CONTENTS

SLNO. TITLE CLAUSE PAGE NO.

COVER SHEET 1
REVISION LOG 3
CONTENTS 5
1. PURPOSE 6
2. PRE-REQUISITES 6
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
FLOW CHARACTERISTICS OF OIL THROTTLE
15.
Nb25, Nb50, Nb65, Nb80 & Nb100 (5 PAGES)
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
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1.0 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.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
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COMMISSIONING PROCEDURE FOR
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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.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
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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.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
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COMMISSIONING PROCEDURE FOR
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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 & 0-13149-
99001& 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.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
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2.6 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.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
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e. Blind flange dummy is to be provided at flange as indicated in the scheme (1-


131480-99001 & 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.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
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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 NRV’s (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.
BHARAT HEAVY ELECTRICALS LIMITED
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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
BHARAT HEAVY ELECTRICALS LIMITED
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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 STG–LO-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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PROCEDURE NO: TAPP3&4-41300-CP-1
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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 ½ 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 ½ hour with thermal shock.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
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3.4 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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PROCEDURE NO: TAPP3&4-41300-CP-1
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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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PROCEDURE NO: TAPP3&4-41300-CP-1
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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.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
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3.10 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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PROCEDURE NO: TAPP3&4-41300-CP-1
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TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 21 of 52

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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PROCEDURE NO: TAPP3&4-41300-CP-1
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Page 22 of 52

Dotted lines show temporary lines.

Flushing of JOP lines by JOP (Jacking Oil Pump)

Scheme No. 1

BRG 2 BRG 3 BRG 4 BRG 5 BRG 6 BRG 7


BRG 1

TO DRAIN
HEADER

To Lub oil PRSS.REG.VALVE


syst.

TOMOT

JOP JOP
1 2
MOT

JACKING OIL FLUSHING


SCHEME
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Scheme No. 2

Flushing scheme for control oil system

SIGNAL SIGNAL
OIL OIL

CSDV 32 BAR UNFILTERED CSDV


STOP CONTROL
VALVE VALVE
1/2 1/2
32BAR
UNFILTERED S.M.DRAIN
32 BAR S.M.DRAIN
FILTERED

OIL FROM
PUMP DISCH

C.F.PUMP DISCIT

TEMP. HEADER Nb 80, MAN 10/20AZ001

SOL
VALVE

RACK VAC
W.I
VAL
DRAIN BREAKER
VE

SIGNAL OIL TO CSDV


TO DRAIN
DRAIN
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Scheme No. 3

Flushing scheme for control oil system


32BAR SU TRIPOIL
OIL

SEC.OIL

HP
CONTR
OL
TRIPOIL VALVE
ABOVE 1/2
ESV PISTON
1/2 32 BAR SUPPLY UNIT
UNFILTERED

32 BAR
TRIPOIL FILTERED
BELOW
PISTON

HPCV1/2 DRAIN TO
S.M.DRAIN S.M. ESV1/2
DRAIN
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Scheme No. 4

Flushing scheme for control oil system

Nb 100 TEMPORARY HEADERS IN PLACE OF HYD. CONTROL RACK

RACK
PRI.OIL DRAIN

AUX.
TRIP
SEC.OIL TO OIL TO TEST OIL TO O/S
HPCV 1/2 SOL. GOVERNOR
VALVE

S.U.OIL TO AUX. TRIP OIL TO O/S


FROM C.F. PUMP SUPPLY UNIT GOVERNOR
DISCHARGE

TRIP OIL TO AUX. S.U.OIL TO OVERSPEED


SUPPLY UNIT GOVERNOR
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Scheme No. 5

Flushing scheme for control oil system

C.F.PUMP
DISCH.
SOL
VALVE DRAIN

LPBP
VALVE

TO ACCUMULATOR

DRAIN

Scheme for hydraulic test

FROM AOP

TO SYST.

TO 32-BAR

JO JO
P P
I 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 TO DRAIN HEADER


TO JOP VALVE

DUPLEX FILTER

TO SEAL SOIL
AOP
AOP1 2
COOLER BYPASS

MOT EOP
DIRTY
SIDE MOT CLEAN SIDE
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Dirty oil and clean oil flushing scheme

TO MOT

NRV FLAP REMOVED BOUSER BYPASS


TO MOT

DIRTY OIL
TANK
CLEAN OIL DIRTY OIL
COMP. COMP.

C.O. PUMP 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
4. Flow through bearing 2= 2.7 cu. Dm/sec
5. Flow through bearing 3= 11.8 cu. Dm/sec
6. Flow through bearing 4= 12.9 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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Page 30 of 52

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 directives-


Gov/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. 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

7.0 Test report format

Schedule of Check Lists for Lube Oil System and jacking oil system

Sl. Check list Description


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

INSTALLATION OF ORIFICES
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Date:

SL Orifice Identification Orifice Orifice Installed


No Diameter. (Yes/No)
1
2
3
4

(Pl refer PIDs oil system supplied by HWR)

Checklist STG-LO-02

INSTALLATION OF DEVICES

Date:

SL. Tag No Description Installed


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


22. Lube oil header pressure low-low - switch
23. MOP discharge header pressure low - switch
24. MOP discharge header pressure indicator
25. MOP suction pressure - indicator
26. Lube oil pressure to thrust bearing - indicator
27. Lube oil pressure to turbine bearing 1 – test
indicator
28. Lube oil pressure to turbine bearing 2- test
indicator
29. Lube oil pressure to turbine bearing 3- test
indicator
30. Lube oil pressure to turbine bearing 4- test
indicator
31. Return oil temperature indicator - bearing 1
pedestal
32. Return oil temperature indicator - bearing 2
pedestal
33. Return oil temperature indicator - bearing 3
pedestal
34. Return oil temperature indicator - bearing 4
pedestal
35. Return oil temperature indicator - bearing 5
pedestal
36. Return oil temperature indicator - bearing 6
pedestal
37. Return oil temperature indicator - bearing 7
pedestal
38. 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


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Date:
Sl. Device Tag no Range / Set Checked
no. Point OK / NOT
OK
1. MOT level indicator
2. MOT level high switch
3. MOT level low switch
4. AOP discharge pressure
indicators
5. EOP discharge pressure
indicator
6. Lube oil inlet to cooler local
temperature indicator.
7. Lube oil inlet to cooler local
temperature indicator.
8. Lube oil outlet from cooler local
temperature indicator.
9. Lube oil outlet from cooler local
temperature indicator.
10. Lube oil temperature after
cooler - temperature element
11. Differential pressure indicator
for lube oil filters
12. Differential pressure switch for
lube oil filters
13. Lube oil header pressure
indicator
14. Lube oil header pressure
transmitter
15. Lube oil header pressure low –
switch
16. Lube oil header pressure low-
low – switch
17. Lube oil header pressure low-
low switch
18. Lube oil header pressure low-
low – switch
19. Lube oil header pressure low-
low switch
20. Lube oil header pressure low-
low – switch
21. MOP discharge header
pressure low – switch
22. MOP discharge header
pressure indicator
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23. MOP suction pressure -


indicator
24. Lube oil pressure to thrust
bearing – indicator
25. Return oil temperature
indicators
26. Oil pressure to barring gear –
indicator
27. Oil pressure to barring gear low
– switch
28. 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 Date:
No Description Result Remarks
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
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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 Desired Test Value Remarks


va
lu
e
1 Kinematic viscosity at CST 41.4 – 50.6
40degC
2 Water Content Gm/100 gm 0.1
3 Solid content gm/100gm 0.05
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Checklist STG-LO-06

OIL VAPOUR FANS COMMISSIONING

Equipment tag number. ……………………………


System Description………………………….
P&ID No………………………..
Manufacturer’s Name. ………………………………
Name Plate details ……………………………………
Date
Sl. Description Remarks
No
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 UNIT
Motor Amps
Current
Vibration at Microns /
Motor CE mm/sec
Vibration at Microns /
Motor FE mm/sec
Vibration at Microns /
fan body 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 Checked OK / Not Remarks
No OK
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

Checklist STG-LO-08
AUXILIARY OIL PUMPs COMMISSIONING
Equipment tag number …………………………….
System Description………………………….
P&ID Number ……………………………….
Manufacturer’s Name ……………………………….
Name Plate details ……………………………………
Date
No Description Remarks

1 Bearing lubricated as recommended


2 Rotor free in its bearings
3 Review motor winding insulation resistance
values
4 Check Motor earthing
5 Power supply switchgear checked and ready
for charging
6 Pump bumped and rotation proved
7 Instrumentation & protection devices
checked (Check Auto Start of AOP by
simulating low header pressure)
8 Holding-down bolts fitted securely
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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
Legend: CE – Coupling End, FE- Free End

Checklist STG-LO-09

OIL FLOW DRAIN OIL VIEWING WINDOW


Date:

SL Sight Glass location Flow Observed


No Yes/No
1. Pedestal 1
2. Pedestal 2
3. Pedestal 3
4. Pedestal 4
5. Pedestal 5
6. Pedestal 6
7. Pedestal 7
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Checklist STG-LO-10

OIL SYSTEM ALARM SCHEDULE

Date:
Ref: BHEL SOE List :

Sl Tag No Service Status Set Remark Checked


No Point OK/NOT
OK
1. LO main tank High Alarm
level
2. LO main tank Low Alarm
level
3. LO Pr across High Alarm
filter
4. MOP/AOP Low Standby AOP
Discharge Pr start
5. LO Header Pr Low Alarm
6. L.O. Header Pr V Low AC EOP Start
7. LO Header Pr Low AOP start
8. Jacking Oil Pr Low Alarm
9. Lub. oil after Hi Alarm
cooler
10. Turbine TB Non- Hi Alarm
active temp

11. Turbine TB Non- Hi Alarm


active temp

12. Turbine TB Non- Hi Alarm


active temp

13. Turbine TB Non- Hi Alarm


active temp
14. Turbine TB Hi Alarm
active temp
15. Turbine TB Hi Alarm
active temp
16. Turbine TB Hi Alarm
active temp
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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 Pump in Operation Value Unit


No
1 Emergency Oil Pump Kg/cm2
discharge pressure set at
2 voltage Volts
3 Current drawn Amps
4 Pump speed rpm
5 Field resistance value Ohms
6 Armature resistance value Ohms

Status of pressure switches


7 OK / NOT OK
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8 OK / NOT OK
Auto start of EOP
9 OK / NOT OK
10 OK / NOT OK
Checklist STG-LO-12

FEEDBACK OF THERMOCOUPLES AND PRESSURE TRANSMITTERS

SL Device Status in STG control


NO 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 Activity Remarks
NO
1 Valve operation OK / NOT OK
2 Temperature control 45 degC
setting

Checklist STG-JO-01

INSTALLATION OF DEVICES
Date:

SL Tag No Description Installed


No Yes/No
1 AC JOP 1 discharge pressure
2 AC JOP 2 discharge pressure
3 JOP discharge header pressure transmitter
4 JOP header pressure low - switch
5 JOP header pressure low - switch
6 JOP pressure at bearing 1
7 JOP pressure at bearing 2
8 JOP pressure at bearing 3
9 JOP pressure at bearing 4
10 JOP pressure at bearing 5
11 JOP pressure at bearing 6
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 45 of 52

12 JOP pressure at bearing 7


Refer for Tag no , set points & other details :INSTRUMENT LIST, DRG.NO. 4 13300
98 001, REV02 NPC DOC. TAPP

Checklist STG-JO-02

ON SITE CALIBRATION OF DEVICES

Date:
Sl Tag no Device Range / Calibrated
no set point yes/no
1 JOP discharge header
transmitter
2 JOP discharge header pressure
low
3 JOP Discharge header to
Turning gear interlock

Refer for Tag no , set points & other details :INSTRUMENT LIST, DRG.NO. 4 13300
98 001, REV02 NPC DOC. TAPP

Checklist STG-JO-03

JACKING OIL PUMPs MOTOR

Equipment tag number …………………………….


System Description………………………….
P&ID Number ……………………………….
Manufacturer’s Name ……………………………….
Name Plate details ……………………………………
Date:
SL Description Remarks
No
1 Foundation bolts tightened
2 Check driven equipment fitted in right
direction
3 Bearing lubricated with specified lubricant
4 Check free rotation of the shaft manually in
uncoupled condition
5 Verify winding insulation resistance value
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 46 of 52

6 Check Motor earthing


7 Power supply switchgear ready for charging
8 Verify cabling completion
9 Protective devices checked
10 Local start-stop push buttons provided (if
applicable)
11 Motor coupling guard provided
12 Set up temporary instrumentation for
recording of no-load running current
13 Start motor (bump test) and confirm the
direction of rotation
14 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 UNIT
Motor Amps
Current
Vibration at Microns /
Motor CE mm/sec
Vibration at Microns /
Motor FE mm/sec

Legend: CE – Coupling End, FE- Free End

Checklist STG-JO-04

JACKING OIL PUMP COMMISSIONING


Equipment tag number …………………………….
System Description………………………….
P&ID Number ……………………………….
Manufacturer’s Name ……………………………….
Name Plate details ……………………………………
Date
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 47 of 52

No Description Remarks

1 Bearing lubricated as recommended


2 Rotor free in its bearings
3 Pump bumped and rotation confirmed
4 Instrumentation & protection devices
checked
5 Holding-down bolts fitted securely
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 UNIT
Motor Amps
Current
Pump disch. Kg/cm2
Pressure
JOP header Kg/cm2
pressure
Vibration at Microns /
Motor CE mm/sec
Vibration at Microns /
Motor FE mm/sec

Legend: CE – Coupling End, FE- Free End

Status of Jacking Oil System devices


Sl Tag no Device Set Point Status in
no STG
control
system
1 JOP discharge header pressure –
switch
2 JOP Discharge header to Turning
gear interlock
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 48 of 52

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
Equipment tag number …………………………….
System Description………………………….
P&ID Number ……………………………….
Manufacturer’s Name ……………………………….
Name Plate details ……………………………………
Date
No Description Remarks

1 Bearing lubricated as recommended


2 Rotor free in its bearings
3 Review motor winding insulation resistance
values
4 Check Motor earthing
5 Power supply switchgear checked and ready
for charging
6 Pump bumped and rotation proved
7 Instrumentation & protection devices
checked (Check Auto Start of AOP by
simulating low header pressure)
8 Holding-down bolts fitted securely
Pump set is ready for trial run.

Control 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
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 49 of 52

Legend: CE – Coupling End, FE- Free End

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.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 50 of 52

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. ACTIVITY ACCEPTANCE VERIFYING CERTIFICATION BY VERIFYING AGENCY


NO VERIFIED CRITERIA AGENCY
FUNCTION RESULT GENERAL
PROCEDURE INSPECTION
VERIFICA-
VERIFICATION WITNESS -AL TEST REMARKS
TION

1 Pl refer Pl refer 4.0


4.0
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 51 of 52

Temporary looping of seal oil system

TO AIR
SIDE
DRAIN
RING RELIEF

AIR & H2
SIDE SEAL
OIL AIR & H2
BYPASS SIDE SEAL
OIL
BYPASS

H2 SIDE
SOST DRP
BYPASS

FROM L.O.
HRADER

AIR SIDE H2 SIDE


SEAL OIL SEAL OIL

SEAL OIL RACK


BYPASS