gen seal oil sys

8/20/2019 Gen Seal Oil Sys

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Station: NTPC – Simhadri BHEL Ref No. PS-DC-186-5-6NTPC Ref No. S!"#1#TS#$#5

Sheet 1 of $

P%ant area : T&RB!NE

PR'CED&RE ('R H)DR*&L!C TEST *ND '!L (L&SH!N+ '( +ENER*T'R

SE*L '!L S)STE"

S%. No.

1.

$.

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5.

6.

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8.

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1.

PL*NT DET*!LS

'B0ECT!E

PR'P'S*LS

SER!CES RE2&!RED

S*(ET) PREC*&T!'NS

E"ER+ENC) PR'CED&RE

ST*TE '( THE PL*NT

"ETH'D

C'"PLET!'N CR!TER!*

*PPEND!CES

a3 Dra4in

3 Lo Sheet7

Station: NTPC - Simhadri BHEL Ref No. PS-DC-186-5-6 Sheet $ of $


2/21

NTPC Ref No. S!"#1#TS#$#5


PR'CED&RE ('R H)DR*&L!C TEST *ND '!L (L&SH!N+ '( +ENER*T'RSE*L '!L S)STE"

S%. No.

1.

1.1

1.$

1.,

1.

1.5

PL*NT DET*!LS

Generators cooled by H2 are provided with sealoil system for preventing the leakage of H2 toatmosphere for the formation of explosivemixture and to reduce the consumption of H2.

This system consists of tank, pumps, (oth !.".and #."$ coolers, filters and pressureregulators to maintain the oil pressure at the sealbody of generator. Turbine oil is used for thispurpose.

#" pump is meant to supply oil to the sealsduring the failure of !" power supply duringemergency conditions.

%or Technical &pecifications, the respective ' )manuals are to be referred.

The drawings enclosed at section *+.+ are

a$ &chematic for oil flushing of &eal 'il iping. #rg.-o. /&/T&0/++1/++

b$ "ontrol 3alue rack of &eal 'il &ystem.#rg.-o./&/T&0/++1/++

ST*T&S

Sinatre7

NTPC BHEL


3/21

Station: NTPC - Simhadri BHEL Ref No. PS-DC-186-5-6

NTPC Ref No. S!"#1#TS#$#5Sheet , of $



SE*L '!L S)STE"

S%. No.

$. 'B0ECT!E

The ob4ective of this oil flushing is to ensure thecleanliness of seal oil piping before connecting itto the various racks of seal oil system.

ST*T&S

Sinatre7

NTPC BHEL


4/21

Station: NTPC – Simhadri BHEL Ref No. PS-DC-186-5-6

NTPC Ref No. S!"#1#TS#$#5Sheet of $



S%. No.

,.

,.1

,.$

TEST!N+ PR'P'S*L

The oil flushing of &eal 'il &ystem is proposedto be carried out in two stages.

Stae ! 'il %lushing of &eal 'il iping (&eal 'il

rack excluded$

The oil flushing is carried out by taking the lub oilfrom lub oil supplu line near bearing -o. asshown in enclosed circuit.

The oil flushing is carried out in two parts.

P*RT – ! : includes seal oil air side supply pipeline and ring relief supply pipe lines.

P*RT – !! : includes the seal oil H2 side supplypipe line.

Stae !! 'il %lushing of &eal 'il &ystemincluding the various components of &eal 'ilrack and the system piping.

#uring flushing thermal shocks on seal oil is

given 5efer rocedure for Hydraulic test andflushing of Turbine lub6oil and 7acking 'il&ystem. H89 5ef.-o.&6#"6*:16;++6+++

(-T".5ef.-o. &


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SER!CES RE2&!RED

!vailability of 8lectrical heating arrangement for heating the"> to turbine oil cooler for thermal shock operation duringoil flushing.

!vailability of laboratory facility for analysis of oil sample.

!vailability of service air and thinner=petrol for filtercleaning. !vailability of sufficient skilled manpower for supervision =execution of the process. !vailability of re?uired ?uantity of Turbine oil

!vailability of portable fire extinguishen at oil flushing area.

!vailability of proper lighting and communication facility.

ST*T&S

Sinatre7

NTPC BHEL


6/21


NTPC Ref No. S!"#1#TS#$#5Sheet 6 of $



SE*L '!L S)STE"

S%. No.

5.

5.1

5.$

5.,

5.

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5.6

5.

5.8

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5.1

5.11

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S*(ET) PREC*&T!'NS:

5eadiness of stair cases, platforms, hand rails for &eal 'ilTank and re?uired approaches as decided at site are madeavailable.

&afety and protection e?uipments like hand gloves, helmet etcare available during the process.

recautions taken to avoid spillage of oil and contamination of oil.

&ervice water source available near the activity area.

8nsure the availability of first aid kit near the process area.

uckels containing sand are available at process area.

>elding=cutting shall not be carried out in lub6oil flushingareas, once oil has been filled in &eal 'il Tank.

9oad on umps shall not exceed full load current of the motor.

rovision for emergency stopping of oil pumps from local=@"has to be made.

"ordoning of lub6oil flushing area wherever re?uired.

#isplay of caution sign boards, danger tags are provided atlocations in the test area.

5ound the clock monitoring of oil flushing activity.

ST*T&S

Sinatre7

NTPC BHEL


7/21


NTPC Ref No. S!"#1#TS#$#5Sheet of $



SE*L '!L S)STE"

S%. No.

6.

6.1

6.$

6.,

6.

6.5

E"ER+ENC) PR'CED&RES:

The teams for this operation shall be aware ofthe procedure of oil flushing and act at the timeof any emergency.

They shall be aware of operation of fireextinguishers.

They shall be aware of how to act in case of anypersonal in4uries.

They shall know to stop the pumps ?uickly in

case of any leakage and then inform theconcerned higher official.

They shall be aware of re6establishing theoperation in case of system stoppage due tofailure of power supply.

ST*T&S

Sinatre7

NTPC BHEL

Station: NTPC - Simhadri BHEL Ref No. PS-DC-186-5-6 Sheet 8 of $


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ST*TE '( THE PL*NT

efore starting the flushing, the completion offollowing 4obs should be ensured.

8rection of interconnected piping is completed.

rovide temporary connection wherever re?uiredas per enclosed circuit.

The temporary pipes should be acid cleaned andneutralised before installation.

8nsure that flange 4oints are tightened withgasket in position.

The pressure regulating valve )A> B !! +**and )A> B !! +2* have been removed andspool pieces have been placed.

ST*T&S

Sinatre7

NTPC BHEL


9/21


NTPC Ref No. S!"#1#TS#$#5Sheet / of $



SE*L '!L S)STE"

S%. No.

.1.6

.1.

.1.8

.1./

.1.1

8rection of seal oil pump unit, seal oil unit, sealoil valve rack, measuring instrument rack, sealoil storage tank and interconnected pipings iscompleted.

hysical cleaning of seal oil storage tank andseal oil tank.

!vailability of power and control supply formotors and starting panels.

Trial run of following motors and coupled with

respective pumps.

a. !ir side seal oil pump motor (!"$ 2 nos.

b. 8mergency air side sealoil pump motor (#"$ * no.

c. H2 side seal oil pump motor (!"$ * no.

#isconnect air side seal oil inlet pipes at the seal

body on both sides of generator and connect it tobearing drains by a temporary piping.

ST*T&S

Sinatre7

NTPC BHEL


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S%. No.

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#isconnect H2 side seal oil inlet and outlet pipesat seal body on both sides of generator andinterconnect it by a temporary piping.

#isconnect ring relief oil inlet pipe at seal bodyon both sides of generator and interconnect by atemporary piping into air side seal oil drain pipes.

Take out both float valves from seal oil tank.)A> +++*.

Aeep the springs of regulating valves !*, !2 andC"D at completely released condition.

)ake necessary arrangement for heating seal oilupto 1; E B+o" during oil flushing process.

%ire fighting system of TG 9ub6oil and generator &ealoil system made available before commencement of flushing.

!cid cleaning of pipe line normally not envisaged.However, if traces of pitting observed in any of thepipe line, acid cleaning of the pipe line to be carried

out (5efer rocedure -o.&6#"6*:16;++6++*=-T" 5ef.-o.&


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S%. No.

8. "ETH'D

&eal oil system is filled with oil by taking the oilsupply from seal oil storage tank. To ensure oil

level in seal oil storage tank, lub oil pump shouldbe kept running during this process or oil shouldbe filled manually in this tank. &eal oil system isfilled up in two stages as follows (ensure that allshut off and gate valves are closed$.

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Sinatre7

NTPC BHEL


12/21


NTPC Ref No. S!"#1#TS#$#5Sheet 1$ of $



S%. No.

8.1

8.1.1

(!LL!N+ '( *!R S!DE SE*L '!L C!RC&!T

'pen following shut off and gate valves in airside oil circuit.

)A> +* !! ;+ !t seal oil storage tank

)A> ** !! ;+* before seal oil pump (*$.

)A> 2* !! ;+* before seal oil pump (2$

)A> * !! ;+* before stand by sealoil pump ($

)A> 2* !! ++* after seal oil pump (*$

)A> 2* !! ++2 after seal oil pump (2$

)A> * !! ++ after stand by seal

oil pump (*$)A> ** !! ;+ before !* valve

)A> ** !! ;+; after !* valve

)A> * !! ;+ before !2 valve

)A> * !! ;+; after !2 valve

)A> ** !! ++ after seal oil pumps (*$ (2$

)A> * !! ++ after stand by seal oil pumps($

)A> + !! ;+2 before float valve, oil inlet

)A> + !! ;+* after float valve, oil drains ($

)A> + !! ;+;F for oil level gauge

)A> + !! ;+1F

)A> B* ;+* ad4ustable orifice

)A> B1 !! ;*F seal ring relief oil

)A> B1 !! ;2F

ST*T&S

Sinatre7

NTPC BHEL


13/21


NTPC Ref No. S!"#1#TS#$#5Sheet 1, of $



SE*L '!L S)STE"

S%. No.

8.1.$

8.1.,

8.1.

8.1.5

"harge the seal oil coolers on oil side with rotarytransfer valve assembly in centre position. >henthe coolers are filled with seal oil, turn rotarytransfer valve on one side i.e. 5ight hand or lefthand side to bring one cooler in service andother on standby.

"harge both seal oil filters as done in case ofcoolers and keep one seal oil filter in service bykeeping rotary transfer valve on one side.

&tart and stop seal oil pump * for a short time tobleed air from piping until pressure gauges )A>B* " ;** and " ;2* indicate a constantpressure.

&et three way valves )A> B* !! ;** and !!;2* and )A> B1 !! ;** and !! ;2* to positionwhere no oil passes through the volume flowindicator.

ST*T&S

Sinatre7

NTPC BHEL

Station: NTPC - Simhadri BHEL Ref No. PS-DC-186-5-6 Sheet 1 of $


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8.$

8.$.1

8.$.$

(!LL!N+ '( H$ S!DE SE*L '!L C!RC&!T

#uring filling of the air side circuit, the seal oiltank is simultaneously filled with seal oil by valve)A>+ !! ;+2. 'il level in this tank willcontinue to rise above the sight glass till it

reaches the level of seal oil storage tank and willget drained through siphon action.

'pen following shut off and gate valves of H2side seal oil circuit.

)A>* !! ;+* before H2 side seal oil pump

)A>* !! ++ before H2 side seal oil pump

)A>* !! ;*+ before C"D valve

)A>* !! ;+

ST*T&S

Sinatre7

NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-5-6

NTPC Ref No. S!"#1#TS#$#5 Sheet 15 of $


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S%. No.

8.$.,

8.$.

8.$.5

8.$.6

8.$.

"harge both seal oil coolers on oil side withrotary transfer valve assembly in its centerposition. >hen both cooler are filled with sealoil, turn rotary transfer valve on one side i.e.5ight or 9eft hand to bring one cooler in service.

"harge both seal oil filters as done in case ofcoolers and keep one filter in service.

9oosen the ad4usting nut of pressure e?ualisingvalve )A>B !! +2*.

&tart and stop H2 side seal oil pump to bleed theair from piping until the pressure gauges)A>B " ;** and " ;2* indicates aconstant reading. &et three way valves )A>B

!! ;** and !! ;2* to position, where no oilpasses through volume flow indicator.

Hydraulic test of the seal oil piping (excludingrack$ shall be carried out at a pressure of *2kg.=cm2.

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Sinatre7

NTPC BHEL



Sheet 16 of $



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S%. No.

8..

8..1

'!L (L&SH!N+ '( S)STE"

'il flushing of seal oil circuit is carried out inthree different stages.

i. %lushing of air side circuitii. %lushing of H2 side circuitiii. %lushing of oil impulse lines

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

ST*T&S

Sinatre7

NTPC BHEL






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S%. No.

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%lushing of H2 side &eal 'il "ircuit. %lushing of

this circuit is carried out by H2 side seal oil pumpprovided in the system. #uring this process, oilflow is maintained through H2 side seal oil cooler,filter, valve C"D,


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c$ "lean and dry the filter with compressed air.(!ir pressure to be reduced sufficiently for airblowing filter$

Take sample of return oil and analyses if for thepresence of moisture mechanical impurities.

Hydraulic test of the lines (excluding seal oilrack$ shall be carried out at a pressure of *2kg=cm2 along with lub6oil system.

5estoration of &eal 'il &ystem

'n 9om%etion of oi% f%7hin:

#rain the entire system.

5emove the temporary piping and restoreoriginal connections.

5emove the blanks provided, if any.

"onnect back the impulse lines.

5eassemble the float valves )A>' !! ++*and !! ++2 in seal oil tank.

"lean both the filters and reassemble.

ST*T&S

Sinatre7

NTPC BHEL


NTPC Ref No. S!"#1#TS#$#5Sheet 1/ of $




19/21

S%. No.

/. C'"PLET!'N CR!TER!*

'il flushing for each stage may be declaredcompleted on the following basis.

-o foreign particle and material present at

thefiltering elements after 2 hours offlushing.

)oisture content in return oil should be less

than +.+* (*++ ppm$ and mech.


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Sl.No Date/Time Pump Dis.Pr.

Oil temperatureThermal

Sho! "emar!s#ef.

$ooler

After

$ooler

Sinatre7

NTPC BHEL


21/21

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

gen seal oil sys

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