Station: NTPC-Vindhyachal BHEL Ref No.

PS-DC-186-500-0018
Sheet 1 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL. NO LIST OF CONTENTS

1.0 PLANT DETAILS

2.0 OBJECTIVE

3.0 PROPOSAL

4.0 SERVICES REQUIRED

5.0 SAFETY PERECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 COMPLETION CRITERIA

10.0 APPENDICES
Station: NTPC-Vindhyachal BHEL Ref No.PS-DC-186-500-0018
Sheet 2 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS
1.0 PLANT DETAILS

1.1 500 MW Generator consists of the following components.

a. STATOR

Stator Frame
End Shields
Stator Core
Stator winding
Hydrogen coolers

b. ROTOR

Rotor Shaft
Rotor windings
Rotor Retaining Rings
Field Connections

c. BEARINGS

d. SHAFT SEALS

1.2 The two pole generator is designed with direct water cooling for
the stator winding, phase connectors and bushings and direct
Hydrogen cooling for rotor winding. Generator losses, such as
iron losses, windage losses and stray losses are also dissipated
through hydrogen. The generator frame is pressure – resistant,
gastight and equipped with major components mentioned above.
The hydrogen coolers are arranged vertically inside the turbine
end stator end field.

Signatures

NTPC BHEL
Station: NTPC-Vindhyachal BHEL Ref No.PS-DC-186-500-0018
Sheet 3 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS

1.3 The Generator is provided with the following auxiliaries which are
essential for generator operation.

1.4 They are

Seal oil systems

Gas Systems
Primary Water System
Excitation System

Respective Testing Schedules / O & M manuals are to be

referred for commissioning, operation and maintenance of these
systems.

1.5 Technical Specification of Generator are given below.

Generator Type THDF 115/59
Main Exciter Type ELR 70/90 – 30/6-20
Pilot Exciter Type ELP 50/42-30/16
Generator Apparent Power 588 MVA
Generator Active Power 500 MW
Current 16.166 KA
Voltage 21KV + 1.05KV
Speed 3000 RPM
Frequency 50HZ
Power Factor 0.85 (Lag)
Hydrogen Pressure 3.5 bar
Rated Field Voltage 340 V
Rated Field Current 4040 A

Signatures

NTPC BHEL
Station: NTPC-Vindhyachal BHEL Ref No.PS-DC-186-500-0018
Sheet 4 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS
2.0 OBJECTIVE

The objective of the test is to ensure.

2.1 Gas tightness of gas pipe lines in assembled condition including

valves and instrumentation.

2.2 Gas tightness of various joints on generator stator, terminal

bushings, primary water system, hydrogen coolers etc.

2.3 Effectiveness of the seal oil system at operating pressure.

3.0 PROPOSAL

The objective will be achieved through the following proposals.

3.1 Testing of pipe between CO2 Bottle Rack and Hydrogen Unit at a
pressure of 4.8 bar of Nitrogen gas for 2 Hrs.

Signatures

NTPC BHEL
Station: NTPC-Vindhyachal BHEL Ref No.PS-DC-186-500-0018
Sheet 5 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS

3.2 Testing of pipe between Hydrogen Bottle rack and Hydrogen Unit
at a pressure of 4.8 bar of Nitrogen gas for 2 Hrs.

3.3 Testing of Pipe between Nitrogen Bottle rack and P.W. Tank at a
pressure of 5.0 bar of Nitrogen gas for 2 Hrs.

3.4 Leakage Test of Generator along with Gas System using air at
4.0 bar for 72 Hrs

4.0 SERVICES REQUIRED

4.1 Availability of Instrument air

4.2 Availability of Nitrogen gas

4.3 Availability of

Test pressure gauge of range 0-6 KSC with least scale

division of 0.01 KSC
Mercury Manometer with mm scale
Generator winding Temp Indicator/Recorder in UCB.
Water ‘U’ Manometer

4.4 Availability of man power with required tools

4.5 Availability of lighting/communication

4.6 Availability of Soap Solution for test.

5.0 SAFETY PRECAUTIONS

5.1 Debris in the test area cleared.

5.2 Approach/Stair Case/Platforms wherever required are made

available.

Signatures

NTPC BHEL
Station: NTPC-Vindhyachal BHEL Ref No.PS-DC-186-500-0018
Sheet 6 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS

5.3 Display of board “No cutting/welding” at all floors made

5.4 Portable fire extinguishers are available in the test area.

6.0 EMERGENCY PROCEDURES

6.1 The test team should be well aware of procedures to be adopted

in case of any abnormality in the activity.

6.2 The test team should know well about the procedures to be
adopted in case of damage to machinery or injury to personnel
connected to the activity.

7.0 STATE OF THE PLANT

7.1 Assembly of generator and fixing of end shields and manhole

covers completed.

7.2 Seal oil system commissioned and put into operation for
continuous running.

7.3 Assembly of gas system piping is completed.

7.4 Generator terminal bushings are connected.

7.5 H2 gas coolers not be charged with water.

7.6 Stator winding filled with primary water and primary water tank
kept pressure less. All the valves closed in P.W. System.
Connect a ‘U’ Tube manometer in Waste gas line of P.W. Tank
after valve MKF91 AA 505 and close valve MKF91 AA 506. Open
valve MKF91 AA 513 and AA 505. It is also required to observe
for any leakage into primary water system through stator
windings during air leakage test.

Signatures

NTPC BHEL
Station: NTPC-Vindhyachal BHEL Ref No.PS-DC-186-500-0018
Sheet 7 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS

7.7 Instrument air supply connected before valve MKG25 AA 501. Air
for filling should be free from moisture, oil and any mechanical
impurity.

7.8 Precision pressure gauge of class 0.6 for pressure measurement

fixed at MKG25 CP001.

7.9 A mercury ‘U’ manometer connected in one line of mechanical

purity indicator MKG05 CP501 for air pressure measurement and
for observing the leakage rate. Other pipe line blanked and
valves MKG05 AA 501 and AA 502. Kept open.

7.10 Soap solution kept ready to check the leakages during test.

7.11 All the instruments in gas system are mounted as per scheme.

7.12 All the valves provided in H2 Unit are kept open so that all the
lines are pressurized during air filling. All valves connected to
vents are kept closed.

7.13 Valves provided in Generator oil drain lines are opened as

follows: (Liquid detector rack)

MKA 21 AA 501, MKA 22 AA 501, MKA 23 AA 501, MKA 24 AA

501, MKA 23 AA 511, MKA 24 AA 511.

7.14 Vent valves provided in oil drain lines are closed viz., MKA21 AA
502, MKA 22 AA 502, MKA 23 AA 502, MKA 23 AA 512, MKA 24
AA 502.

7.15 Valves provided in gas impulse line for valve A1, A2 in seal Oil
system are opened.

Signatures

NTPC BHEL
Station: NTPC-Vindhyachal BHEL Ref No.PS-DC-186-500-0018
Sheet 8 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS

7.16 Values MKG69 AA 504 and MKG69 AA 501 are opened to take
dryers in service.

7.17 Air leakage test done in stands still condition of generator.

8.0 METHOD

Testing of Pipe between CO2 Bottle Rack and H2 Unit

8.1
Disconnect pipe lines at isolating flanges Nos. 96 and 97. Keep
valve MKG 59 AA 507 open. Blank one end of this pipe line by a
temporary flange. Pressurize the pipe line by N2 gas to a Pr. Of
4.8 bar and observe the leakage rate for 2 hrs. There should not
be any pressure drop. (Subject to temperature condition
remaining same).

Connect back the pipe lines on system after successful

completion of test.

Testing of Pipe between H2 Bottle Rack and H2 Unit.

8.2
Disconnect pipe lines at isolating flange Nos. 94 and 95. Blank
one end of this pipe line by a temporary flange. Pressurise this
pipe by N2 gas to a pressure of 4.8 bar. Observe the leakage rate
for 2 Hrs. There should not be any pressure drop in pipe line.
Check for any leakage during this period by means of soap
solution at all welding joints and rectify any leakage. Connect
back the pipe lines in system after successful completion of test.

Signatures

NTPC BHEL
Station: NTPC-Vindhyachal BHEL Ref No.PS-DC-186-500-0018
Sheet 9 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS

8.3 Testing of Pipe Between N2 Bottle Rack and P.W. Tank

Disconnect pipe lines at isolating flange No. 312 and primary

water tank. Blank one end of this pipe line by a temporary flange.
Keep valve (MKP91 AA 502 open. Pressurise this pipe by N2 gas
to a Pr. Of 5 bar. Observe the leakage rate for 2 Hrs. There
should not be any pressure drop in pipe line. Check for any
leakage during this test by means of soap solution at all weld
joints and rectify any leakage. Connect back the pipe lines in
system after successful completion of test.

8.4 Leakage Test of Generator along with Gas System using Air.

8.4.1 Air Filling in Generator Casing

Open valve MKG25 AA 501 and fill air in generator and gas
piping upto pressure of 4 Bar. During filling observe the
performance of pressure regulating valve of seal oil system and
maintain the H2 and air side seal oil Pressure as recommended.
Close valve MKG25 AA 501 as soon as pressure in the casing
reaches 4 bar.

8.4.2 Checks during Air Leakage Test

I During the air leakage test, apply Soap Solution at all joints for
checking leakages in following areas:

Joint and bolt heads on Stator body

Weld joints on generator body

Joints of terminal bushings, manhole covers, H2 coolers

etc. Gas piping welding joints and flanged joints.

Signatures

NTPC BHEL
Station: NTPC-Vindhyachal BHEL Ref No.PS-DC-186-500-0018
Sheet 10 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS

Passing of valves in the system to atmosphere and

passing through valve glands.

Gas drier shell.

Seal oil Tank Flanged joints.

Impulse line connection for pressure regulating valve in

seal oil system

Connecting joints of all measuring instruments provided in

gas system.

Passing of valves provided in oil/water detector lines.

Sealing joints provided for taking out the stator winding

Temp. terminals.

If any leakage is observed the generator should be depressurised

and same should be attended and test should be repeated.

Ii Record half hourly reading on the mercury manometer provided

in H2 unit for this test. Record ambient and generator temperature
as measured from RTD’s.

Signatures

NTPC BHEL
Station: NTPC-Vindhyachal BHEL Ref No.PS-DC-186-500-0018
Sheet 11 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS

Iii Observe for any pressure rise in P.W. tank during test by means
of Water ‘U’ manometer provided for this purpose. If any increase
is observed, stator winding system should be checked for
leakage.

IV Continue the test till the rate is well within specified limit. If no
leakage is observed, pressure drop should be checked for 72 hrs.
continuously.

8.4.3 Calculation of Leakage Rate

Loss of air is determined as follows:

V – 0.2694x24 VG (P1+Pb1 - P2 + Pb2)

Z 273+T1 273 + T2

Where V = Loss of air in M3 at N.T.P./ 24 Hrs.

0.2694 = 273o K / 1013.25 m bar

Z = Duration of leakage test, Hrs.

VG = Generator volume, m3

P1 = Gauge Pressure within the system at beginning of

leakage test, in m bar.

P2 = Gauge Pressure within the system at the end of

leakage test, in m bar.

Signatures

NTPC BHEL
Station: NTPC-Vindhyachal BHEL Ref No.PS-DC-186-500-0018
Sheet 12 of 12
NTPC Ref no VIN/1/TS/2/007
Plant area: TURBO GENERATOR
PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS

Pb1 = Barometer reading at beginning of leakage test, in m

bar.

Pb2 = Barometer reading at the end of leakage test m bar.

T1 = Temperature of the gaseous atmosphere at beginning

of leakage test 0C.

T2 = Temp. of the gaseous atmosphere at end of leakage

Test 0C.

9.0 COMPLETION CRITERIA

Leakage test should be carried out for 72 hrs at 4 bar and

average air loss should be calculated. The permissible air loss for
a gas tight system is below 2.4m3 at N.T.P. / 24 Hrs.

If air loss is higher, checks should be carried out for detecting the
leakage areas.

10.0 APPENDICES

The following system drawings to be referred from O & M manual

Gas System

P.W. System

Seal Oil System

Generator Instrumentation Scheme

Waste Fluid System

Waste Gas System

Signatures

NTPC BHEL
PROCEDURE FOR GENERATOR AIR
TIGHTNESS TEST