NTPC LIMITED KHARGONE SUPER THERMAL POWER PROJECT (2 × 660 MW)

(A GOVERNMENT OF INDIA
ENTERPRISE) LARSEN & TOUBRO LTD.
COMMENT SHEET
DOC TITLE FLUSHING PROCEDURE FOR SEAL OIL SYSTEM
L&T DOC NO. LM1013GAA015
NTPC DOC NO. 9578-001-110-PVM-W-133
Reviewed By
Review Date / Location

L&T's Clarification (Response /

NTPC Comment L&T's Clarification (Response / NTPC Comment NTPC Comment L&T's Clarification (Response / NTPC Comment L&T's Clarification (Response / Resolution) on NTPC NTPC Comment L&T's Clarification (Response / Resolution) on NTPC NTPC Comment L&T's Clarification (Response / Resolution) on NTPC NTPC Comment L&T's Clarification (Response / Resolution) on NTPC
Resolution) on NTPC Rev. No. Remarks Item Status
Page No. / Clause ( NTPC Rev No.00) Resolution) on NTPC Rev. No. 00 ( NTPC Rev No.01) ( NTPC Rev No.02) Resolution) on NTPC Rev. No. 02 ( NTPC Rev No.03) Rev. No. 03 ( NTPC Rev No.04) Rev. No. 04 ( NTPC Rev No.04) Rev. No. 04 ( NTPC Rev No.05) Rev. No. 05
Sl. No. 01
No. / Sheet No.
NTPC Transmittal No. : 23596 dt. 22- NTPC Transmittal No. : NTPC Transmittal No. : 26193 dt. NTPC Transmittal No. : 27158/
Date of response:10/03/2018 Date of response:07/05/2018 Date of response:16/06/2018 Date of response:20/08/2018 NTPC Transmittal No. : 27158/ 06/08/2018 Date of response:20/08/2018 NTPC Transmittal No. : :27532/ 05/09/2018 Date of response:10/09/2018 NTPC Transmittal No. : 27789 dt. 25-09-2018 Date of response:26/09/2018
JAN-2018 25313 dt. 30-MAR-2018 22/05/2018 06/08/2018
A. The procedure is to be written under - Noted and incorporated.
----- -----
the following subheadings
----- ----- 1. Plant Details - Noted and incorporated.
----- ----- 2. Objectives - Noted and incorporated.
----- ----- 3. Proposal - Noted and incorporated.
----- ----- 4. Services Required - Noted and incorporated.
----- ----- 5. Safety Precautions - Noted and incorporated.
----- ----- 6. Emergency Procedures - Noted and incorporated.
----- ----- 7. State of the Plant - Noted and incorporated.
----- ----- 8. Method - Noted and incorporated.
----- ----- 9. Completion Criteria - Noted and incorporated.
----- ----- 10. Appendices - Noted and incorporated.
----- ----- i. Log Sheets - Noted and incorporated.
----- ----- ii. Drawings - Noted and incorporated.
B. Matter is to be typed in the enclosed - Noted and incorporated.
----- -----
format.
C. Size of the front is to be 12 and of - Noted and incorporated.
----- -----
Times New Roman
----- ----- D. Spacing between line is to be 1.5 - Noted and incorporated.
E. Printing is to be done in single side of Noted
----- -----
the page and NOT on both sides.
F. Main clauses for example 1.0, 2.0, 3.0 - Noted and incorporated.
etc. to be in Bold and sub clauses like 1.1,
----- -----
1.2, 1.3 etc. to be in normal.

G. Finalized procedure to be submitted in Noted

----- -----
four sets of Hard copies.
- Resubmission of procedure as per
customer requirements.
Cover page: Mention full name, designation of
persons prepared, Reviewed, and Approved.
Also please mention the name , designation - Incorporated as per NTPC request in
and signature of the authorized person page no.1.
QSTGM.Also mention NTPC OS Doc no in the -Incorporated as per NTPC request in the
cover page as “COS_COMM-KG-Commg- header of each page.
PRO/016” and mention in headers of each
page.
CLAUSE 1.0: Requested to delete as it is not - Noted and incorporated in page no.4 as
necessary. per NTPC request.
CLAUSE 2.0 : Requested to delete as
description of the objective why the process is - Noted and incorporated in page no.5 as
required not the intent for issuance of the per NTPC request.
document.
yes, Pipes are fabricated at site.FQP
CLAUSE 2.0: Are the pipes fabricated at site
NTPC Document No: 9578-001-110-QVE-
?? Please furnish approved FQP for the same.
G-618 (PAGE 23 OF 24)

CLAUSE 2.0: Is there relevance of these

- Seprately and suitably placed in the
sentence with the subject “Objective”? it not
document at page no.11
then place them suitably or delete.,

- As per OEM standard practice,

CLAUSE 3.0: Suggested to introduce card
board busting before going for oil flushing.
CLAUSE 3.0: Please mention stage before
flushing and all other places as applicable.
compressed dry air blow out shall be
perfromed for cleaning inside pipes before
proceeding for the air leak test and
flushing.
- Stages Mentioned as per NTPC request
wherever applicable.

- Mentioned separately as per NTPC

CLAUSE 3.0: Please mention stages
request.
separately. Electrical heater – provide
-Refer attachment -1 for the Schematic
schematic arrangement and rating of heater.
arrangement of heating skid.

CLAUSE 4.0: Requested to mention the list of

services required not the process as per the - List of Services Mentioned as per NTPC
subject title. Also relocate the points mentioned request in page no-6.
under this clause suitably.
CLAUSE 5.0: Add the following clauses
1. Job Safety Analysis should be done before
start of the process.
2. Welding / cutting should not be carried out in
the oil flushing area once oil has been filled in
seal oil tank.
3. Load on pumps should not exceed full load
current of motor.
- noted and incorporated as per NTPC
4. Provision of emergency stopping of oil
request in page no.6.
pumps from local / control room should be
made.
5. Buckets containing sand should be available
near the process.
6. First aid kit should be available near process
area.
7. Precaution should be taken to avoid spillage
and contamination of oil.
CLAUSE 6.0: It should be modified with “
Emergency Procedures”
- Noted and incorporated as per NTPC
The description mentioned under this clause
request in page no.7
are to be modified suitably to mention “
Emergency Procedures”
CLAUSE 7.0: Mention the followings
1.0 Condition of pipes before dispatch whether -1.0 Noted and incorporated as per
acid cleaned or not. NTPC request in page 7.
2.0 Add “ Joint inspections pipes is to be done 2.0 Joints are already inspected at shop.
at site before going for assembly and welding Hence further inspection is not envisaged.
works.” 3.0 Preparations are already mentioned in
3.0 Mention the preparation required before CLAUSE 3.0,page no.5.
carrying out each stage of oil flushing.
CLAUSE 7.0: Modify as “ All seal oil piping
- Noted and incorporated as per NTPC
erection must be completed as per drawing,
request in page no.7
engg specification and quality plan.”

- Flushing method and Cicuit is

CLAUSE 8.0: Please mention flushing circuit
against each stage of flushing
Please mention temperatures of thermal
shock.
Carry out hydro test of pipe.
mentioned in Clause 8.0, page no.12,13
and flushing schedule in page15 and 16.
- As per flushing schedule mentioned in
page no 15 and 16 cold oil circulation and
hot oil circulation with hammering
considered.Thermal shock is not
envisaged because seal oil supply pipe is
considered as stainless steel.
-As per OEM practices Air leak test is
carried out at site.Refer page no.7 for the
pipe erection procedure and filed quality
plan document no.

CLAUSE 9.0: Please adopt completion criteria

- As per OEM standard, Completion
as per approved data sheet / contractual
citeria are already covered in Clause 9.0.
agreement. Please provide relevant document
CLAUSE 10.0: Add
“ System is filled with fresh oil ( Mention type of - Noted and incorporated in cluase no.10.
oil as per approved data sheet)
Incorporate maximum flushing oil temeprature Noted and incorporated in clause no.3 of
during heat cycle page no.6
Mention the NAS level of the oil after Noted and incorporated in page no.11 of
completion of 3rd stage flushing lcause no.10
Add next coarse of activites to be perfromed Noted and incorporated in page no.11 of
after completion of 3 rd stage flushing lcause no.10

Procedure is to be resubmitted by agency

based on discussion held at EOC, Revised asper NTPC discussuion at NTPC-NOIDA office.
Noida on 23-07 and 24-07-18 with L & T

Procedure is to be resubmitted by agency based on discussion

held at EOC, Revised asper NTPC discussuion at NTPC-NOIDA office.
Noida on 23-07 and 24-07-18 with L & T
Hydro test to be done with working media ( Seal oil ) as per
Noted & revised in Clause no: 3.2
ASME code as done in the case of TG lube oil system
1. There is no difference between stage 1 and stage 2. Please
1. Refer Clause no: 3.3 for the difference mentioned.
clarify or rectify.
2.Refer page number 12,13 ,Figure .1 and Figure.2 for the
2. Please mention circuit of flushing as done for TG lube oil
flushing schematic.
flushing.
Pl furnish approved data sheet for our reference of seal oil pipe Please refer page no 16,17 and 18 of document no: 9578-001-
, where the design pressure mentioned. 110-PVM-W-053A for design pressure.
Is it 1st or 2nd ? Noted & revised.
Please mention about thermal shock.
Noted & revised in clause no: 9 (Applicable only in 2nd stage
Upto what temperature would be reduced during thermal
flushing)
shock?
Please mention NAS 7 as completion criteria as done in the
Noted & revised in Clause no: 10
case of TG lube oil flushing
After which stage? Please clarify and mention properly. Noted & revised in Clause no: 11
Heating of flushing oil shall be carried with help of temporary
flushing skid and cooling of flushing oil shall be done by using
Pl enclose a sketch of thermal shock arrangement.
natural cooling method. Refer attachment-1 for the flushing oil
heating arrangement.
1.0 Even after commented earlier the word "Pneumatic" still
remains. It to be replaced with Hydraulic. Before "test" Revised as per comment.
Hydraulic is to be mentioned.

# Sensitivity : This Document is Classified as "LNT Internal Use". Page 1 of 1

 2 × 660 MW KHARGONE SUPER THERMAL
L&T – MHPS Turbine Generators Pvt Ltd.
POWER PROJECT
Doc. No.: LM1013GAA015
Rev. No.: 06
PROCEDURE FOR FLUSHING OF SEAL
Date: 21.09.2018
OIL SYSTEM
Larsen & Toubro Ltd.

REVISION SUMMARY SHEET

Rev Details / Description Date

No.
00 First Submission 07.12.2017

01 Second Submission 10.03.2018

02 Third Submission 07.05.2018

03 Fourth Submission 13.06.2018

04 5th Submission 20.08.2018

05 6th Submission 10.09.2018

06 7th Submission 21.09.2018

Page 2
 NTPC KHARGONE NTPC DOC NO: COS-COMM-KG-COMMG-PRO/016 Page3
2X660MW L&T DOC NO : LM1013GAA015
PLANT AREA : TURBINE GENERATOR
PROCEDURE FOR FLUSHING OF SEAL OIL SYSTEM

Table of Contents

1.0 Plant Details 4

2.0 Objective 5

3.0 Proposal 5

4.0 Services required 5-6

5.0 Safety Precautions 6

6.0 Emergency Procedures 6-7

7.0 State of the Plant 7

8.0 Pressure Test 7-8

9.0 Methods 8-10

10.0 Completion Criteria 10-11

11.0 Restoration of Seal Oil System after completion of 3rd stage flushing 11

12.0 General Information 11

13.0 Appendices 11

Fig. 1: 1st and 2nd stage Flushing Diagram 12

Fig. 2: 3rd stage Flushing Diagram 13

Fig. 3: Temporary Piping connection for bearing oil pipe line flushing of 14
generator

Table 1: Working Schedule for Flushing 15-16

Table 2: Standard Flushing Procedure 16

Table 3: Parts List of Flushing Circuit 17-19

LM1013SO01 (9578-001-110-PVE-L-008): Turbine Generator Seal Oil 20

Diagram

Attachment-1 21
 NTPC KHARGONE NTPC DOC NO: COS-COMM-KG-COMMG-PRO/016 Page4
2X660MW L&T DOC NO : LM1013GAA015
PLANT AREA : TURBINE GENERATOR
PROCEDURE FOR FLUSHING OF SEAL OIL SYSTEM

1.0 Plant Details

 Stator Frame
The stator frame is of special pressure-proof design that can withstand pressure of 8.2 Bar-g, twice
the maximum gas pressure, 4.0 Bar-g. Generator stator frame comprises of stator core, stator coils,
end windings, manifold, blower shroud, shroud support, two hydrogen gas coolers, bearing
brackets at both end in which bearing, Gland seal bracket & Seal rings are assembled. Lead box is
assembled at bottom of stator frame.
 Rotor
It comprises of rotor body, rotor coils, retaining ring, slip ring fan. The rotor body is machined
from single piece forging. In order to support the rotor coil end, retaining rings are shrink fitted to
both end of the rotor body.
 Bearings
Tilting pad type bearings are used in order to keep high stability of rotor and low metal
temperature during operation. The bottom half of the bearing consists of a shell with spherical
seat, containing two pivoted pads with centre lines located 45 degrees each side of the vertical
centre line. Spherical seat keeps the bearing and shaft free from undue stress due to the deflection
of shaft or misalignment.
 Shaft seals
Generator is filled with pressurised hydrogen gas and seals are used to prevent H2 gas leakage.
The seal is provided by floating ring having close clearance around the rotor. Oil is fed into the
gap under pressure higher than hydrogen pressure inside generator.
 Bearing Oil Supply
Generator bearings are fed from the turbine lube oil system.
 Gas Supply
Gas unit includes all devices needed to regulate the filling and emptying of generator, provides
automatic control of gas supply to sustain pressure and purity during normal operation.
 Demineralised Water Supply
A special unit supplies a continuous flow of cooling water to the stator winding. It contains the
equipment to supply demineralised water to generator at the necessary temperature and quality.
 Seal Oil Supply
Seal oil supply unit contains the equipment necessary to supply oil to the shaft seals at proper
temperature, pressure and purity.
 NTPC KHARGONE NTPC DOC NO: COS-COMM-KG-COMMG-PRO/016 Page5
2X660MW L&T DOC NO : LM1013GAA015
PLANT AREA : TURBINE GENERATOR
PROCEDURE FOR FLUSHING OF SEAL OIL SYSTEM

2.0 Objective
Any mechanical impurity left out inside the seal oil system shall be removed before starting
operation of turbine & generator. The objective is flush seal oil system sufficiently to remove
foreign material.
3.0 Proposal

3.1 Carry out air blow inside seal oil pipes and temporary bypass pipes by using dry compressed
air.

3.2 Carry out Pressure test of seal oil pipes by using oil (ISO VG-32).

3.3 a. Line up the seal oil system piping as per fig.1 & fig.2 to carryout flushing.

b. Flushing procedure is divided into 3 stages:

Stage1: Flushing of seal oil system pipes shall be carried out with flushing skid and criteria

shall be achieved as mentioned in clause no:10.

Stage2: Flushing of seal oil system pipes shall be carried out with flushing skid, Heating &

cooling cycle shall be applied and criteria shall be achieved as mentioned clause no: 10.

Stage3: Flushing of seal oil system pipes shall be carried out with Seal Oil Unit.

3.4 a. Extra turbulence can be created by switching OFF and ON of the running pump of
temporary skid during Stage1 & Stage2 flushing.

b. Extra turbulence can be created by switching OFF and ON any of the pumps of Seal Oil Unit
during 3rd Stage flushing.

3.5 Suitable hammering or vibration arrangement shall be made for field welded Seal Oil piping
joints.

3.6 Suitable heating arrangement shall be made for creating cooling and heating cycles.

3.7 Flushing shall be carried out with Lube oil from approved source and oil grade shall be ISO
VG 32.

3.8 Hammering, cooling & heating should not be applied during 3rd flushing.

4.0 Services required

 For air blow inside seal oil pipes and Pressure test, dry compressed air line shall be
available.
 Flushing equipment such as the Flushing Unit, temporary bypass hoses and manifolds etc
shall be available at site.
 Required manpower shall be available to carry out the inspection of the Flushing Unit.
 NTPC KHARGONE NTPC DOC NO: COS-COMM-KG-COMMG-PRO/016 Page6
2X660MW L&T DOC NO : LM1013GAA015
PLANT AREA : TURBINE GENERATOR
PROCEDURE FOR FLUSHING OF SEAL OIL SYSTEM

 Required tools, tackles & spares shall be available.

 Permanente Power supply, proper lighting and required communication equipment shall be
available.
 Heating and cooling arrangement for creating heating & cooling cycles during flushing.

5.0 Safety Precaution

 Job Safety Analysis should be done before start of the process. Check list shall be prepared
& jointly signed.
 Welding / cutting should not be carried out in the oil flushing area once oil has been filled
in seal oil tank.
 Load on pumps should not exceed full load current of motor.
 Provision of emergency stopping of oil pumps from local / control room should be made.
 Buckets containing sand should be available near the process.
 First aid kit should be available near process area.
 Precaution should be taken to avoid spillage and contamination of oil.
 Ensure any scaffolding required is correctly erected and safe for use.
 Wear a safety harness when working above ground.
 Wear protective eyeglasses and gloves.
 Ensure all temporary hoses and connections are secure and adequately supported.
 Ensure sufficient fire extinguishers are available and located in the correct positions near the
flushing area.
 Barrier tape, fencing and warning notices should be erected.
 Take care of removed materials and equipment for flushing system (In order to prevent
damaging).
 Oil temperature during flushing should not go beyond 65°C.

6.0 Emergency Procedures

The following instructions need to be followed in case of an emergency situation which
could arise as a result of:
 The group members should be aware of operating instruction of portable fire extinguishers.
 The test team should know about the procedure to be adopted in case of oil leakage or injury
to the personnel connected to the activity.
 Emergency telephone number of fire and hospital shall be prominently displayed.

 Over pressurization/bursting:
In the event of bursting of the pressured line, stop the pumps immediately. Ascertain the
point of bursting and replace the part.
 NTPC KHARGONE NTPC DOC NO: COS-COMM-KG-COMMG-PRO/016 Page7
2X660MW L&T DOC NO : LM1013GAA015
PLANT AREA : TURBINE GENERATOR
PROCEDURE FOR FLUSHING OF SEAL OIL SYSTEM

 In the case of improper transport of the flushing unit or seal Oil Unit, pressurized or
functional components may become damaged. Ensure that these components do not come
into contact with the attachment devices or lifting tools during transport. Ensure that no
unauthorized persons are within the hazard zone.

7.0 State of the Plant

 All seal oil piping is sent acid cleaned, end capped and preserved with Cortec M-531.
 All Seal Oil Piping Erection must be completed as per drawing, Engg. Specification
(NTPC doc no: 9578-001-110-PVE-E-001, Page -161,164) and quality plan (9578-001-
110-QVE-G-618 (PAGE 23 OF 24).
 Flushing skid should be in working condition for 1st & 2nd stage Flushing.
 Seal oil Unit should be in working condition for 3rd stage Flushing.
 Install flushing equipment such as the Flushing Unit, temporary bypass hose and
manifold etc at site.
 Connect & line up the temporary bypass circuit for flushing at site and put blind plate at
flange portion of the Oil Supply unit and H2 side oil return pipes of brackets according
to the Fig.1.
 Carry out the inspection of the Flushing Unit.
 Apply the 150 meshes stainless steel strainers to the temporary strainer boxes as shown
in Fig.1.
 Following valves shall be closed. (01MKW91AA421/02MKW91AA421)
 Inspect the electrical heater of flushing unit for insulation resistance with 500V Megger.
Minimum insulation resistance value shall be 1M Ω.
 Put flushing oil in the oil tank of Flushing Unit through the 150 Meshes strainer.
Prepare the flushing oil approximately 1200L-1500L.
 Carry out the load test operation of Flushing Unit pump motor set. Be careful about oil
leakage from connected portions of pipes.

8.0 Pressure Test

 Pressure test of Seal oil pipe shall be carried before start of the Seal oil flushing as per
below procedure.
8.1 Setup:
 All permanent piping and equipment shall be installed along with pipe supports.
 Necessary temporary piping connections and blinds shall be made ready. Blinds shall
be selected by considering the test pressure.
 Temporary pressure gauge of suitable ranges shall be used during the testing.
 Equipment not subjected to pressure test shall be isolated from the system.
 NTPC KHARGONE NTPC DOC NO: COS-COMM-KG-COMMG-PRO/016 Page8
2X660MW L&T DOC NO : LM1013GAA015
PLANT AREA : TURBINE GENERATOR
PROCEDURE FOR FLUSHING OF SEAL OIL SYSTEM

 Venting arrangement shall be made available with isolation valves.

8.2 Seal oil piping Hydraulic pressure test
 Connect the temporary hydraulic test pump to Seal oil system piping.
 Raise the Hydraulic test pressure in Seal oil system piping as per Fig.1, attachment-2 &
as mentioned in Table-A.
 Venting of total system is carried out.
 Hold the pressure for 10 min. Check for the leakages.
 If any leakage is found the system is to be depressurized and attend the leakages.
 Above procedure shall be followed till the leakage criteria shall be achieved as per
Table-A.
Table-A

Seal oil piping Hydraulic test pressure

Design Working Test
Sr. Test pressure No./ Duration Pressure drop
Pressure Pressure Pressure
No Description (min) criteria
(kg/cm2) (kg/cm2) (kg/cm2)
No pressure
1 TP-SO-MEL-01/Seal Oil 17 11 25.5 10
drop/No leakage
No pressure
2 TP-SO-MEL-02/Seal Oil 15.7 7.5 23.6 10
drop/No leakage
No pressure
3 TP-SO-MEL-03/Seal Oil 9.5 4 14.5 10
drop/No leakage
No pressure
4 TP-SO-MEL-04/Seal Oil 1.3 0.9 2 10
drop/No leakage

9.0 Methods

 1st Stage Flushing

a. After final assembly of all pipes as per NTPC Document No: 9578-001-110-PVE-E-001,
proceed for interconnection of pipes as per Fig.1 (Page 12 of 20) for 1st stage flushing.
b. The 1st stage oil flushing of the Seal Oil System is carried by using the Flushing Unit.
c. Carryout, hammering for the pipe corner and welding portion of the pipe to improves the
flushing effect.
d. Proceed for 2nd stage flushing after conclusion of 1st stage flushing as per clause no.10.
e. The 1st stage flushing is carried out in accordance with the following procedure, Table. 1,
Table.2, Fig.1 and LM1013SO01 (9578-001-110-PVE-L-008)
 Check valve condition.

a. Open (Temporary Valve): V1, V2 and V3 (As shown in Fig.1)

b. Open (The flushing unit valve).

NTPC KHARGONE NTPC DOC NO: COS-COMM-KG-COMMG-PRO/016 Page9
2X660MW L&T DOC NO : LM1013GAA015
PLANT AREA : TURBINE GENERATOR
PROCEDURE FOR FLUSHING OF SEAL OIL SYSTEM

 Operate the oil pump and raise the oil pressure gradually to about 2.5 to 3.0 kg/cm2 by
adjusting (bypass) valve of Flushing Unit.
 Check the following items during oil circulation.

a. Oil leakage from pipe connections.

b. The oil level of flushing unit tank.

 The oil flow adjusted by Open/Close valves (if oil flow is not sufficiently).
 In the beginning period, the interval of circulation and inspection are carried out for short
period (As shown in Table.1)
 After performing the above work, replacement for the strainer (120 Meshes) and
hammering (As shown in Table 1and table 2) are carried out.
 The following confirmation and recording are carried out every 60 minutes during 1st
flushing.

a. Oil pressure of flushing pump outlet

b. Oil level of flushing oil tank
c. Oil temperature
d. Oil circulation time
 2nd Stage Flushing
a. 2nd stage oil flushing for the Seal Oil System is carried by using the Flushing Unit.
b. Heating and cooling cycle should be carried out by using electrical heater in the flushing
unit. Heat cycle target value of oil temperature is approximately 65°C.Oil temperature shall
be reduced to 30 – 35 °C during cooling cycle and shall be achieved by natural cooling
method.
c. Carryout, hammering of the pipe corner and welding portion of the pipe to improves the
flushing effect.
d. Proceed for 3rd stage flushing after conclusion of 2nd stage flushing as per clause 10.
e. The 2nd stage flushing is carried out similar to 1st flushing oil flushing procedure.
f. In order to get effective oil flow, the flushing circuits are divided into two. One is H2 Side
and another is Air Side according to Table.2. In each case of valve condition is as follows.
(Refer to Fig.-1)
 In-case of H2 Side: V1 is closed, V2 and V3 are opened
 In-case of Air Side: V1 is opened, V2 and V3 are closed
 Prior to 2nd. Stage Flushing start, drain the 1st stage flushing oil from pipes, manifold
and oil tank and clean them, if necessary.
 NTPC KHARGONE NTPC DOC NO: COS-COMM-KG-COMMG-PRO/016 Page10
2X660MW L&T DOC NO : LM1013GAA015
PLANT AREA : TURBINE GENERATOR
PROCEDURE FOR FLUSHING OF SEAL OIL SYSTEM

 Reuse the oil used in 1st stage flushing by putting in the temporary oil tank through the
200 meshes strainer.
 Install 150 meshes strainer in strainer box.
 Carry out the oil circulation and inspection of the strainer (as shown in Table 1)
 Carry out heat cycle. Heat cycle target value of oil temperature is approximately 65°C.
 3rd Stage Flushing
a. The 3rd stage flushing is carried out as shown in Table.1, Table.2, Fig.2, and LM1013SO01
(9578-001-110-PVE-L-008).
b. In this stage, also flushing circuit is divided into two. In each case of valve condition is as
follows. (Refer to Fig.-2)
 Drain flushing oil from oil tank in Flushing Unit, pipes and, manifold.
 Remove the temporary bypass pipe, manifold, and flushing Unit as shown in Fig.1.
 Inspect and clean the drain regulator tank inside and pipe connections.
 Set the temporary valve V4, V5, V6, V7 and flushing strainers (special tool) with valve
according to the Fig.2.
 Prepare turbine oil used for operation of turbine generator approximately 600L-800L for
flushing.
 Remove filter elements mounted in Air side and H2 side Seal oil filters and the pressure
equalizing valves "01MKW91AA085 / 02MKW91AA085 and 01MKW91AA086 /
02MKW91AA086” as shown in LM1013SO01 (9578-001-110-PVE-L-008).
 Put the turbine oil used for operation of turbine generator in the Seal Oil Supply Unit.
 Check the valve condition in the seal oil unit for open or close condition according to the
drawing LM1013SO01 (9578-001-110-PVE-L-008) and Fig-2.
 Operate the seal oil pump and raise the seal oil pressure gradually to 1.5 to 2.0 kg/cm2 by
adjusting 01MKW91AA081/02MKW91AA081 (Pressure differential regulator) and
01MKW91AA122 / 02MKW91AA122 (Bypass valve of H2 side oil pump).
 During circulating oil, station surveillance should be carried out to confirm the oil leakage
from pipe connections.
 During above item, check the oil level of drain regulator and keep the oil level higher than
normal level.
 Carry out flushing through the seal oil cooler at the end of 3rd flushing.
 Hammering is not applied in the 3rd flushing.
 3rd stage flushing shall be concluded after achieving criteria mention in clause no.10.

10.0 Completion Criteria

As per QSTGM standard, it is allowable to finish each flushing if the following items are satisfied.
 NTPC KHARGONE NTPC DOC NO: COS-COMM-KG-COMMG-PRO/016 Page11
2X660MW L&T DOC NO : LM1013GAA015
PLANT AREA : TURBINE GENERATOR
PROCEDURE FOR FLUSHING OF SEAL OIL SYSTEM

 1st Stage Flushing

 No large foreign substance (such as gaskets, welding rods, cloths, etc.) collects in the
strainer.
 The collected foreign substances are not more than 1.0 gram per every 8 Hours
(Repeat the Cycle 4~5 times to conclude the 1st flushing).
 2nd Stage Flushing
 The collected foreign substances are not more than 0.1 gram per every 8 Hours
(Repeat the Cycle 4~5 times to conclude the 2nd flushing).
 The maximum size of solid substance must be not larger than 0.12 mm in diameter.
 If diameter of solid foreign substance is not larger than 0.2mm, it must be soft enough
so that can be crushed to size not exceeding 0.2mm in diameter.
 3rd Stage Flushing
 The maximum size of solid substance must be smaller than 0.12 mm in diameter.
 There should not be any metallic particles in the flushing collection. If any particle
found larger than 0.12 mm from the flushing collection, then same should be crushable
to size that will not be exceeding 0.12mm in diameter.
 In case of soft material such as fiber, the diameter which is rolled in to ball must be
smaller than 1.6 mm.
 After achievement of above criteria NAS level shall be checked at least for 2
consecutive times at an interval of 8 hr flushing cycle and that oil NAS level should
not be poorer than NAS 7.

11.0 Restoration of Seal Oil System after completion of 3rd stage flushing

 Flushing oil is drained from drain regulator tank, loop seal oil tank & pipes and clean
the tanks.
 Restore the pipes to the proper position after cleaning.
 Install filter elements in the H2 Side and Air side seal oil filters.
 Install the pressure equalizing valves in the Seal Oil System.
 Ensure that the system is filled with fresh Turbine Oil ISO VG 32.
 Run Seal Oil unit system for 8 hours cycle and proceed for commissioning as per
NTPC Document NO: 9578-001-110-PVE-X-005A (Page No: 557 to 591) and 9578-
001-110-PVE-E-002(Page no:31 to 43).

12.0 General Information

 All flushing materials shall be prepared & procured by L&T.
 The flushing schedule included in this document, is given for guidance.

13.0 Appendices
Fig1. 1st and 2nd stage flushing diagram

Page 12
 Fig2. 3rd stage flushing diagram

AA421

AA081

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 RV-3
NB40

MHPS 699990

Page 20
Attachment-1

Stage 1 & 2
Attachment-1

Stage 3
 Attachment-2

RV-3
NB40

MHPS 699990