STANDARD OPERATING PROCEDURE

Jaypee Nigrie Super Thermal Power Plant

2 X 660 MW IPP
SOP FOR H2 AND CO2 CHARGING
Revision No.: 01
Document No.: PMPL/SOP/17 Effective Date: Page 1 of 9
Revision Date:

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Designation Designation

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR H2 AND CO2 CHARGING
Revision No.: 01
Document No.: PMPL/SOP/17 Effective Date: Page 2 of 9
Revision Date:

STANDARD OPERATING
PROCEDURE
FOR

H2 AND CO2 CHARGING

List of Contents

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR H2 AND CO2 CHARGING
Revision No.: 01
Document No.: PMPL/SOP/17 Effective Date: Page 3 of 9
Revision Date:

1. Objective
2. Scope
3. Description of the system
4. Technical Data
5. Relative Properties of Coolants
6. Replacing Air/H2 with CO2 Procedure
7. Abbreviations / Notations

References

1. Objective
For Smooth Operation of H2 & CO2 Charging.

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR H2 AND CO2 CHARGING
Revision No.: 01
Document No.: PMPL/SOP/17 Effective Date: Page 4 of 9
Revision Date:

2. Scope
This SOP is applicable for H2 & CO2 Charging.

3. Description of the system

A lot of heat will be generated in Generator rotor, stator. These windings are
to be cooled. Hydrogen is the best media to cool as its heat coefficient is more.
At the same time handling hydrogen is very hazardous. Explosion possibility
of hydrogen is more due to its wide range of Explosive limits (4.5 to 75%).
Hence it cannot be charged directly in air media or air cannot be admitted in
H2 media. Hence CO2 is used in between air and hydrogen to avoid
explosions.

4. Technical Detail

Description H2 CO2
Total no. of cylinders 125nos 38nos
offered
No of cylinders 8 cylinders per unit 20 per unit (10
connected to each in single leg cylinders in each
Modemanifold
of operation Continuous leg)
Continuous

Cylinder supply pressure 150 kg/cm2 120kg/cm2

at 30oC
Design Pressure 165kg/cm2 165kg/cm2

Usable volume of gas in 6Nm3 10Nm3

cylinder

5. Relative Properties Of Coolants

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR H2 AND CO2 CHARGING
Revision No.: 01
Document No.: PMPL/SOP/17 Effective Date: Page 5 of 9
Revision Date:

Coolants Specific Density Practical Thermal Heat

Heat Velocity Conductivity Transfer
Coefficient
Air 1 1 1 1 1
Nitrogen 1 0.966 1 1.08 1.03
CO2 1.27 1.52 1 0.64 1.13
Methane 1.22 0.55 1 1.29 1.43
Helium 5.25 0.138 1 6.4 1.18
H2@1kg/cm2 14.35 0.14 1 6.69 2.65
H2@2kg/cm2 14.35 0.22 1 6.69 3.65
H2@3kg/cm2 14.35 0.30 1 6.69 4.4
H2@4kg/cm2 14.35 0.375 1 6.69 4.85
Oil 2.09 848 0.012 5.45 21
Water 4.16 1000 0.012 21.00 50.0

6. Replacing Air/ H2 with Co2:

Prestart Checks

1. 38No of CO2 cylinders are ready in location.

2. Hot water is ready for spraying water on CO2 cylinders, valves
to remove ice.
3. Water hose is ready if hot water is not available.
4. CO2 cylinder key is ready.
5. Seal oil system is in service.
6. Sampling valve to Analyser is open.
7. CO2 vent valve is closed.
8. Hydrogen purity analyser is in service and sample inlet valve at
analyser is open. Sample vent valve after analyser is open.
9. Close Hydrogen dew point meters supply valves.
10.H2 inlet valves at H2 control panel are closed.
11.Generator Hydrogen Pressure gauge available.
12.Main impulse line valve is open.
13.H2 control panel inlet valves are closed.
14.H2 control panel outlet valve is closed
15.CO2 safety valve is in service.
16.Generator CO2 inlet valve is open.
17.Air charging valve at dryer is closed.

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR H2 AND CO2 CHARGING
Revision No.: 01
Document No.: PMPL/SOP/17 Effective Date: Page 6 of 9
Revision Date:

18.Air supply valve (opposite vacuum pumps is closed)

19.Air line flange was disconnected and dummied.
20.CO2 Vaporiser A, B modules are ON.
21.Inst air is ready with dew point.
22.Hose / Flange required for air connection is ready.

Replacement Procedure

1. Connect CO2 cylinders to CO2 manifold. 10 cylinders can be

connected at a time.
2. Open CO2 cylinders manifold valve.
3. Open CO2 manifold PRV inlet valve.
4. Open CO2 manifold PRV outlet valve.
5. Open CO2 manifold common valve.
6. Open CO2 control unit inlet valve.
7. Open CO2 filling valve
8. Open Generator CO2 inlet valve
9. Open Hydrogen / Air vent valve
10.Open Generator H2 inlet valve.
11.Open CO2 cylinders valve and charge CO2 into generator.
12.Switch ON CO2 Vaporizer.
13.Maintain CO2 pressure in generator at 0.035 MPa by controlling
vent interface valve
14.Check the concentration of CO2 in air.
15.Sample to be collected from vent line drain for doing analysis with
Orsat apparatus.
16.Continue CO2 charging till CO2 purity is >95%.
17.Keep dryer path in service to charge CO2 in the circuit.
18.Close vent interface valve (119) and maintain CO2 pressure of
0.035 MPa in generator.
19.Close CO2 cylinder valves.
20.Switch OFF vaporizer.
21.Close CO2 cylinders manifold valves.

22.Close CO2 manifold PRV inlet, outlet valve.

23.Close CO2 manifold common valve.
24.Close CO2 control unit inlet valve.
25.Close CO2 filling valve
26.Close Generator CO2 inlet valve

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR H2 AND CO2 CHARGING
Revision No.: 01
Document No.: PMPL/SOP/17 Effective Date: Page 7 of 9
Revision Date:

Replacing CO2 with hydrogen

Prestart Checks
1. CO2 System Is Ready For Charging In Case Of Emergency.
2. CO2 System Valves Are Closed.
3. Hydrogen cylinders are ready in cylinder room.
4. Non sparking tools are available for operating H2 cylinders.
5. Hydrogen cylinder key is ready.
6. Take trial of DC SOP before charging Hydrogen.
7. Fire water system is ready.
8. No hot work around the area of Generator / H2 filling station
9. Hydrogen safety valve is in service. ( After PRV )
10.Hydrogen / air vent valve is close.
11.Sampling valve to Analyser is open.
12.Hydrogen purity analyser is in service and sample inlet valve at
analyser is open. Sample vent valve after analyser is open.

Replacement Procedure
1. Charge hydrogen from cylinders room to H2 control Panel.
2. Open PRVs inlet , outlet valve.(Keep one PRV in service)
3. Open H2 control panel outlet valve.
4. Open generator H2 inlet valve.
5. Open generator CO2 inlet valve.
6. Open CO2 vent valve
7. Open H2 control panel inlet valve. (1 / 2) and charge
hydrogen.
8. Open vent interface valve
9. Maintain H2 pressure in generator 0.035 MPa by adjusting
vent valve.
10.Keep dryer path in service to replace CO2 in the circuit.
11.Check Hydrogen purity
12.Sample to be collected from vent line drain for doing analysis
with Orsat apparatus.
13.When H2 purity is >98%, stop venting. Increase H2 pressure
to 45 KPa.
14.Close Float tank bypass valve at 45-50 KPa. H2 will escape
from bypass if bypass is not closed.
15.Increase H2 pressure to 100 KPa.

16.Start seal oil pump at 100 KPa.

17.Increase hydrogen pressure to 450KPa.

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR H2 AND CO2 CHARGING
Revision No.: 01
Document No.: PMPL/SOP/17 Effective Date: Page 8 of 9
Revision Date:

18.Open dew point analysers supply valves.

Venting Of Hydrogen

1. Open Generator H2 inlet valve. Normally remains open.

2. Open H2 vent valve partly
3. Open vent interface valve partly
4. Observe seal oil float tank level. If level is high open float
bypass as float will not function at low pressure.)
5. Stop venting when H2 pressure reduces to 0.035 MPa.
6. Further venting to be done by charging CO2 only.

Charging Air

1. Ensure CO2 concentration is >95%.

2. Connect inst air line to hydrogen line. (Valve located near
column opposite vacuum pumps). Spool piece to be
connected after removing dummy.
3. Open dryer inlet valve.
4. Open dryer outlet valve.
5. Open generator CO2 inlet valve.
6. Open CO2 vent valve
7. Open air charging valve, near dryer.
8. Open inst air valve.
9. Open vent interface valve and maintain pressure around
0.035 MPa.
10.Sample to be collected from vent line drain for doing analysis
with Orsat apparatus.
11.Continue purging till CO2 is <5%.
12.Close inst. Air valve.
13.Pressure in generator becomes zero.
14.If pressure is required for leak test, close generator CO2 inlet
valve and increase pressure in generator to 350. KPa. Then
close air supply valve.

7. Abbreviations / Notations:

1. SOP: Standard Operating Procedure

2. UCE: Unit Control Engineer

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR H2 AND CO2 CHARGING
Revision No.: 01
Document No.: PMPL/SOP/17 Effective Date: Page 9 of 9
Revision Date:

3. DE: Desk Engineer

4. FE: Field Engineer
5. DCS: Distributed Control System
6. EE: Electrical Shift Engineer
7. MFT: Main Fuel Trip.
8. RB: Run Back

References
1. TG O & M manual
2. Catalogue of TG interlock & protection
3. TG P & I Drawing

Standard Operating Procedure