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    Generator Seal Oil System Manual

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    651 views25 pages

    Generator Seal Oil System Manual

    Uploaded by

    niraj
    Generator Seal Oil System Manual

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 25
    SEAL OIL SYSTEM TIRODA THERMAL POWER ies OPERATION AND PROJECT 1980 MW (2x660 MW Proven HeSr#® | MAINTENANCE MANUAL | PHASE 1+ 1*660 MW Phase) D> pose Project: TIRODA THERMAL POWER PROJECT 1980 MW. (2x660 MW Phase | + 1*660 MW Phase II) Tiroda, Gondia District, Maharashtra Ef ‘Owner: ADANI POWER MAHARASHTRA LIMITED x TIRODA, MAHARASHTRA ADANI GROUP Owner's Consultant: FICHTNER Consulting Engineers (India) Private Limited and BLACK & VEATCH ‘Owner's Engineer: APML DOCNO. Revision SEAL OIL SYSTEM OPERATION AND MAINTENANCE MANUAL _ SSN Heras Tap VENDOR DOC. No. TRIYQUAASORS64. Revision o @ bees | Leeitiesaman beeen te en NRHN EOP Tb BU GEERATER OS PROJECT DOC. TITLE | APPROVAL STATUS 0 [2010.06.15 | mi perl Bow a3 2 @ sion [inmats | sion InmaLs | SIGN | INITIALS Rev DATE = _| PREPARED CHECKED APPROVED eee [Document no. TRrvaoAd6oF Sea Page 1 of 25 | Boa up ‘SEAL OIL SYSTEM TIRODA THERMAL POWER tif 25 OPERATION AND PROJECT 1980 MW (2660 MW SIAISHA GESTS | MAINTENANCE MANUAL | PHASE 1 + 1x660 MW Phase Il) CONTENTS CLAUSE NO DESCRIPTION PAGE NO 1 DESCRIPTION OF THE SEAL OIL SYSTEM... sd 1.1 General. ve 1.2. Functional Description. seo 1.3. Generator Gland Seals .. 4 14 Oil Supply...... 5 1 1 Le 1 1 1 2.2 Receiving nec 2.3 Handling, .5 Defoaming Tanks....... 6 Seal Oil Pumps. 7 Regulator Valves... 8 Pressure Equalizing Valves.....0.00somne 9 Seal Oil Coolers 10 Pressure Reducing Valve... 11 Hydrogen-Side and Air-Side Scal Oil Filters... 12 Hydrogen Side Drain Regulator 13. Seal Oil System Backup Sources. 14 Air Side DC Motor Time Starter...... 1B 13. Generator Bearing Drain Loop Seal Oil Tank 13 RECEIVING, HANDLING AND STORAGE OF THE SEAL OIL SYSTEM ssssccsscseees 14 DL General nse 4 Protection during Storage ... 3. ERECTION OF THE SEAL OIL SYSTEM waesnensnson cette 1S. 3.1 General... 15 3.2 Assembly of Seal Oil System... 1S 3.3. Hydrogen Side Drain Regulator .. 1s | DOCUMENT NO.: TR/YQOA460F564 Page 2 of 25 "SEAL OiL SYSTEM TIRODA THERMAL POWER OPERATION AND. PROJECT 1980 MW (2x660 MW MAINTENANCE MANUAL | PHASE | + 1x660 MW Phase II) Hines SANGHA! ELECTRIC 3.4 Flushing of the Seal Oil System ..... 16 4 OPERATION OF THE SEAL OIL SYSTEM ...sssnensnnnennernee peceibta 4.1 Initial Operation of Oil System.. 17 42 Adjustments While Running... 19 4.3 Normal Operation 20 4.4 Operation without Hydrogen Side Seal Oil Pump... 20 4.5 Operation with Generator Shutdown... 21 4.6 Operation of Seal Oil Pumps. we 2d 5 MAINTENANCE AND INSPECTION OF THE SEAL OIL SYSTEM... aD 5.1 General. 22 5.2 Monthly Maintenance 22 5.3. Scheduled Outage Maintenance. 2D 6 SIGNALS OF SEAL OWL SYSTEM....... 24 6.1 Defoaming Tank Level-High 0. 6.2 Seal Oil Pressure-Low 24 6.3. Air Side Seal Oil Pump-Off. nnn 24 64 Seal Oil Turbine Backup Pressure-Low .... 6.5 Hydrogen Side Level-LoW -iccssecntsneuseoes 6.6 Hydrogen Side Seal Oil Pump-Off.... 6.7 Air Side Seal Oil Backup Pump-Running 6.8 Gas Side Seal Oil Backup Pump-Running ssccocseon | DOCUMENT NO.: TRYQUA460F564 Page of 25 | ip eS OPERATION AND PROJECT 1980 MW (2660 MW ~ SEAL OIL SYSTEM TIRODA THERMAL POWER SHANGHAI ELESTRIS | MAINTENANCE MANUAL PHASE | +1*660MWPhasell) | 1 DESCRIPTION OF THE SEAL OIL SYSTEM 1.1 General The Seal Oil System consists of a seal oil unit, associated piping to and from the generator, and the gland seals, which are an integral part of the generator and are located at each end of the stator frame. The purpose of the Seal Oil System is to: (1) Provide sealing oil to the gland seals maintaining a constant differential pressure of seal oil to hydrogen to prevent the escape of hydrogen gas from the generator, and control the oil pressure equalization between air side and gas side. (2). Provide lubrication to the gland seals to prevent seal wear. 3) Provide a means of minimizing the amount of air and moisture entering the generator. (4) Dissipation the heat from the seal oil due to the friction between seal rings and rotor shaft, and control the seal oil temperature in a specified limit, (5) Filtering the seal oil through the self-clean filters, without interrupting the oil flow. (6) Multi-backup in air side seal oil supplies ensuring the system safe operation. (7) 2x100% oil filters and 2100% oil coolers both in air side and in gas side. The seal oil unit is normally located on the floor beneath the generator. The unit contains the majority of assemblies that make up the Seal Oil System. 1.2 Functional Description The Seal Oil System is a self-contained system that supplies oil to the gland seal rings. It is separated into an air-side seal oil supply and a hydrogen-side seal oil supply. Each of these supplies contains a shell-and-tube type of oil cooler to maintain an acceptable oil temperature range. Edge-type filter units in both supplies prevent contaminants in the oil from damaging the system or the gland seal rings. The Seal Oil System uses motor-driven, screw oil pumps to provide the necessary oil pressure. Valves regulate the pressure oil to the gland seal rings and between the air-side sone, eae and hydrogen-side seal oil supplies Pressure and temperature devices constantly monitor the Seal Oil System sense? while operating, counmeasenne 1.3. Generator Gland Seals Since the rotor shaft ends of the hydrogen cooled turbine generator must be brought out of the gas tight enclosure, means must be provided to prevent the escape of gas along the shaft. Gland seals supplied with oil under pressure are used for this purpose. The action of these seals is shown in Fig. 1 Generator §RS55S540400%8., Gland Seal Oil is supplied to two annular grooves in the gland seal ring, From these grooves the oil flows both ways along the shaft thru the clearance [DocuMeNT No.: TRrvaoaasorse4 | Page 4 of 25 Hast ie SEAL OIL SYSTEM TIRODA THERMAL POWER fines OPERATION AND PROJECT 1980 MW (2x660 MW Shey nssils | -MAINTENANCE MANUAL | _ PHASE I + 1*660 MW Phase I) space between the shaft and the inner diameter of the gland ring. As long as the oil pressure in the circumferential groove exceeds the gas pressure in the machine, oil will flow towards the hydrogen (gas) side of the seal and prevent the escape of hydrogen from the generator. The Purpose of having two feed grooves in the gland rings to provide separate hydrogen side and air side seal oil systems, The details of this will be explained later, but it might be noted here that when the feed pressures in these two systems are properly balanced there would be no flow of oil in the clearance space between the two feed grooves. Oil supplied by the air side of the Seal Oil System flows outward along the shaft toward the bearing. This prevents release of absorbed air or moisture into the generator. Oil supplied by the hydrogen side of the system flows inward along the shaft toward the inside of the generator, This keeps the air-side seal oil from contacting the hydrogen and prevents escape of absorbed hydrogen to the outside atmosphere. Because the air-side and hydrogen-side seal oil feeds are separate, high hydrogen purity is maintained. The gland seal ring restricts and directs the flow of oil though the seal, This ring can move radially with the shaft, but is kept from rotating by a stop pin on the supporting structure. Oil leaving the gland seal rings at each end of the generator is caught in chambers on each side of the seal The air-side seal ofl drains back into the bearing drains. This oil and the lubrication oil from the generator bearings drain to the loop seal tank. The loop seal keeps hydrogen from getting into the lubrication oil reservoir if hydrogen escapes past the seals, The gas is then discharged by the loop seal vapor extractor. 14 Oil Supply The Seal Oil System P&ID shows how a gland seal ring is supplied with oil and how two separate oil feeds are used to seal the generator rotor shaft The hydrogen-side seal oil is shown being supplied to the inside groove of the generator shaft seal: after use, the oil drains into the defoaming tank. From the defoaming tanks, the oil drains to the hydrogen-side drain regulator. ‘This drain regulator is located in the seal oil unit, The drain regulator acts as a reservoir for the oil used in the hydrogen-side seal oil loop. If excess oil builds up in the regulator tank, float-operated drain valve 10MKWO6AA101 opens and releases the excess oil to the air-side oil drain. If the tank level is too low, float operated valve 10MKW06AA102 opens to allow makeup oil from the air-side pump to fill the tank to the connect level, Hydrogen-side oil from the drain regulator feeds the suction side of the motor-driven hydrogen-side seal oil pump. The oil is pumped through the hydrogen-side oil cooler and oil filter. The air-side and hydrogen-side seal oil must be kept at the same pressure (84kPa above the hydrogen gas pressure in the generator) to prevent any interchange of oil across the gland seal rings. Pressure equalizing valves 10MKW36AA101 and [OMKW3SAA\101 sense the pressure at the gland rings and adjust the hydrogen-side seal oil pressure to the seal oil pressure being maintained at the air side of that gland seal ring holding the hydrogen-side and air-side oil pressures equal results in a minimum interchange of oil at the gland seal ring. This causes the hydrogen-side seal oil to flow only to the hydrogen side of the system and the air-side seal oil to flow only to the air side, A bypass valve 1OMKW1SAA202 around the hydrogen-side pump allows part of the total output of the pump not needed by the pressure equalizing valves to return to the suction side of the pump. The air-side seal oil is fed to the outer groove in the gland ring. After flowing through the gland DOCUMENT NO.: TR/YQUA460F564 Page 5 of 25 | SEAL OIL SYSTEM TIRODA THERMAL POWER tines OPERATION AND PROJECT 1980 MW (2660 MW BANGIN EEESTES | MAINTENANCE MANUAL | PHASE I + 1x660 MW Phasol) ring outer groove, this oil drains to a common drain with the bearing lubrication oil ‘The bearing oil and air-side seal oi! are returned to the loop seal tank, where oil vapors and hydrogen gas (if present) are drawn off by the loop seal vapor extractor. The loop seal tank is the source of oil for the air-side seal oil pump. The loop seal tank also acts as a safety feature if a gland seal ring fails. Although unlikely, failure of a gland seal ring can result in sudden surge of hydrogen through the drain line. An oil-filled loop keeps hydrogen from going directly back to the reservoir. A vent to atmosphere is provided on the upstream or inlet side of this loop. Any hydrogen flowing through the bearing drain line is carried out of the system before enough pressure is built up to blow the oil out of the loop seal and allow the hydrogen to reach the lubrication oil reservoir. Some of the air-side seal oil discharge is bypassed back to the pump suction side by main differential pressure regulator 1OMKW31AA101. The regulator keeps the air-side seal oil at 84kPa above the hydrogen gas pressure in the generator during normal operation. The air-side seal oil passes through oil cooler and filter before being supplied to the grooves in the air-side seal oil gland rings at both ends of the generator. 1.5 Defoaming Tanks Oil from the hydrogen side of the gland seal rings goes to defoaming tanks. The defoaming tanks slow the oil velocity and provide a surface arca that permits hydrogen bubbles to escape, reducing oil foaming. The defoaming tanks are located in the bearing brackets of the generator. Standpipe overflow connections maintain the oil level in the defoaming tanks. There is a defoaming tank for each gland seal and a trap in the drain Line between the two tanks. The trap keeps the difference in gas pressure at the two ends of the generator from circulating oil vapors through the generator. 1.6 Seal Oil Pumps The Seal Oil System contains four motor driven pumps: air-side seal oil AC pump, hydrogen-side seal oil AC pump, air-side seal oil DC backup pump and hydrogen-side seal oil AC backup pump. Each pump consists of three components: an electric motor, a flexible coupling, and a rotary pump. The air-side seal oil pump and two hydrogen-side seal oil pumps use AC powered motors. The air-side seal oil backup pump is powered by a DC motor. The motor and pump are coupled with a flexible coupling. The pumps are positive-displacement, rotary types with three screws. The motor drives the pump screws and forces the oil through as the screws. The body of the pump is cast iron. The shaft is steel and is sealed by a mechanical seal. This seal is designed to help prevent oil leaks around the shaft Each pump is monitored by a differential pressure switch across the discharge and suction piping, Four pressure switches are mounted on the gauge panel and are set to alarm when an abnormal condition occurs. The air-side and hydrogen-side seal oil pump pressure switches, 10MKW11DPO01 and 1OMKW1SDP001, tur on an alarm when the differential pressure acrose the pump decreases to 3SkPa, indicating that the pump is off. Air-side and hydrogen-side seal oi backup pump pressure switches, 1OMKW13DP001 and 1OMKW16DP001, tum on an alarm when the differential pressure across the pump increases to 35KPa, indicating that the pump is operating High pressure seal oil backup pressure switch IOMKW1IDPOOI transfers to the non-operated state when the pressure at the scals decreases to a limit indicating that the high pressure seal oil backup pressure from the lube oil reservoir is low. This switch can also provide a contact input to DOCUMENT NO.: TR/YQOA460F 564 Page 6 of 25 | WAG} SEAL OIL SYSTEM TIRODA THERMAL POWER OPERATION AND PROJECT 1980 MW (2x60 MW MAINTENANCE MANUAL PHASE I + 1x660 MW Phase II) bipes computer. Relief valve 1OMKW11AAS01 keeps the air-side seal oil pumps from over pressurizing the air side lines. Relief valve 10MKWISAASOI prevents overpressure in the hydrogen-side seal oil lines. Both valves are set to relieve at 0.8MPa. 1.7. Regulator Valves The Seal Oil System has two differential pressure regulating valves, 1OMKW31AA101 and 10MKW32AA101. Except for how they seat, these valves are physically the same, Each valve has double-seated poppets, flanged inlet and outlet ports, and a pressure head with an intemal bellows, The differential pressure setting of the valve is adjusted by increasing or decreasing the compression of the spring. The compression offsets the pressure from the sensing lines connected to the pressure head, A cross-sectional view of a typical regulator valve is shown in Fig 2 for main and Fig 3 for backup. The functional description is given in the following paragraphs. ‘The valves are functionally shown on seal oil system P & ID. 1) Main (Bypass) Differential Pressure Regulator Valve H orem TT Ly occu ae a = gn Be ee — ja ss he unt a oamnens ou ce eas ea Fig. 2 Seal Oi Differential Pressure Regulator (main) Main differential pressure regulator valve 10MKW31AA101 keeps air-side seal oil pressure at the gland seal rings at 84kPa above the hydrogen ges pressure in the generator enclosure. The pressure head of the valve has two sensing lines connected to regulate the opening and closing of the double-seated poppets. The top connection uses the oil in the defoaming tank to sense the hydrogen gas pressure of the generator enclosure. The bottom connection on the pressure head monitors the air-side seal oil pressure. Adjusting the spring compression in the vaive allows the valve to regulate the air-side seal oil pressure at 84kPa above the hydrogen gas pressure in the generator enclosure. If the hydrogen gas pressure in the enclosure decreases, the air-side seal oil pressure in the sensing line overcomes the spring compression anid opens the valve. The valve opening causes a portion of the ait-side seal oil to be retumed to the suction side of the air-side seal oil pump. This DOCUMENT NO.: TR/YQOA460F564 Page 7 of 25 7a Buf | iy ies | SHANGHAI ELECTRIC OPERATION AND PROJECT 1980 MW (2*660 MW ‘SEAL OIL SYSTEM "_TIRODA THERMAL POWER _ MAINTENANCE MANUAL PHASE I + 1x660 MW Phase I) bypassing action reduces the air-side seal oil pressure at the gland seal rings. Since pressure equalizing valves 1OMKW35AA101 and 10MKW36AA101 adjust the hydrogen-side seal oil pressure fo match the air side, both seal oil flows will be reduced while maintaining the seal oil at the gland seals at 84kPa above the hydrogen pressure, If the hydrogen gas pressure increases, the oil in the gas sensing line acts with the spring to close the valve. This reduces the amount of air-side seal oil bypassed back to the suction side of the air-side seal oil pump and increases the amount provided to the gland seal rings from the discharge of the pump, Again, pressure equalizing valves 10MKW3SAAI01 and 10MKW36AA101 act to match air-side and hydrogen-side seal oil to keep both pressures at 84kPa above the hydrogen gas pressure in the generator enclosure, 2) Turbine Backup (Feed-through) Differential Pressure Regulator Valve Turbine backup differential pressure regulator 1OMKW32AA101 opens when the difference between the seal oil pressure at the gland seal rings and the hydrogen gas pressure in the generator enclosure decreases to 56kPa, and the Lubrication Oil System backup sources supply oil pressure to the air-side seal oil aC Fig. 3 Seal Oil Differential Pressure Regulator (backup) Backup regulator valve 1OMKW32AA101 also senses the air-side seal oil and the hydrogen gas pressure in the generator. the hydrogen gas pressure is monitored by a connection to the defoaming tank oil in the same way that main regulator valve 1OMKW31AA101 uses this oil to sense gas pressure, Once the generator is synchronized and the seal oil temperature has stabilized between 27 deg C and 50 deg C, neither regulator valve should normally require any more adjustment to maintain their set points. 1.8 Pressure Equalizing Valves The Seal Oil System has two pressure equalizing valves 10MKW3SAA101 and 10MKW36AA101. Bach valve consists of a top and bottom sections refer Fig 4. The top section is the valve body. The valve body has a double-seat poppet held in place on the valve stem by a DOCUMENT NO.: TR/YQOA460F564 Page 8 of 25 oa ap ties OPERATION AND PROJECT 1980 MW (2660 MW SnangalEcTsS | MAINTENANCE MANUAL PHASE I + 1x660 MW Phase II) i Se SEAL OIL SYSTEM | TIRODA THERMAL POWER l set crew. The flanges are bolted in place in the hydrogen-side seal oil piping, A removable cover provides access to the valve seats and poppets. The bottom section of the valve controls the top section. Two threaded pressure connections on the bottom section are provided for the hydrogen-side and air-side seal oil sensing lines. The botiom section of the valve is a cylinder housing that contains a Spring-loaded piston. The compression of the piston spring can be adjusted by a capped screw on the bottom of the valve. The two pressure connections admit oil to the bottom and top of the piston, The air-side seal oil sensing line feeds oil to the bottom of the piston. This pressure forces the piston up, opening the valve. If the pressure under the piston decreases, the spring forces the valve closed. In the Seal Oil System the valves maintain equal pressure on both sides of the gland sgamomens seal ring. Valve 1OMKW36AA101 senses Smee as the airside and hydrogen-side seal oil pressure across the gland seal ring at the exciter end of the generator. Valve 1OMKW35AA101 works the same for the gland seal ring at the turbine end. Both valves equalize the pressure by adjusting the flow of hydrogen-side seal oil, as shown in Fig 4. When the air-side seal oil pressure increases, the valve opens to provide mote oil to the hydrogen side until the differential pressure across the gland seal ring is brought back to zero, When the air-side seal oil pressure decreases, the valve closes to reduce the oil to the hydrogen-side seal oil until the differential pressure is brought back to zero. The change in pressure on the hydrogen-side seal oil of each gland seal ring always follows the change in pressure on the air-side seal oil. 1.9 Seal ‘The Seal Oil System contains four shell-and tube type of oil coolers designed to maintain an acceptable temperature range (27 to 50 deg C) while the system is in operation, The oil coolers are horizontally mounted at side of the seal oil unit. Two coolers are used in the hydrogen-side oil piping; the other two coolers are used in the air-side of the system. Under normal operating conditions, one of two oil coolers is used in each oil line. Each oil cooler consists of these main items: a shell assembly, reverse and inlet water chambers, and a removable tube bundle The stee! shell assembly contains the removable tube bundle. The inlet tube plate and reverse tube plate of the bundle assembly close the ends of the shell. The rube plate at the inlet water chamber end is fixed in position and sealed by a gasket. The reverse tube plate on the opposite end of the tube bundle is a floating plate that can move horizontally within the shell. This movement prevents damage to the cooler from thermal expansion and contraction of the tube bundle. ‘Two O-rings seal the reverse tube plate. The O-rings are seated in a retainer ring on the oil side and water side of the shell and chamber joint. Weep holes in the center of this retainer ring will Fig4 Pressure Equalizing Valve Coolers DOCUMENT NO.: TRIYQOA460F564 Page 9 of 25 Bes Hoh eeu! - SEAL Oil SYSTEM TIRODA THERMAL POWER tines OPERATION AND PROJECT 1980 MW (2x660 MW | “vase ésvss | MAINTENANCE MANUAL PHASE I+ 1%660MWPhasell) | show any O-ring leakage on the oil or water side. ‘Tubes are fitted to the tube plates by inserting the tube ends through the holes in the tube plates and expanding the tubes to form a tight seal. The tubes are designed and tested to operate at 1.0MPa on both the water side and the oil side. The maximum temperature rating of both the shell side (oil) and tube side (water) is 95 deg C. Atno time, including any cleaning operation, should the temperature exceed this maximum, The oil coolers reduce the oil temperature by passing oil over the cooling water tubes in the tube bundle. The cooling water makes two passes through each cooler. The water enters the inlet water chamber through one of the two flanged openings on the chamber. A partition inside the inlet water chamber directs flow down one half of the tubes. The cooling water then enters the reverse chamber. In the reverse chamber, the water is directed back up the remaining tubes to the other half of the inlet chamber, where it exits through the other flanged opening. Purchaser-supplied valves are needed to regulate the cooling water flow and pressure. The inlet chambers and flanges of coolers contain several plugged openings for chamber water drain and air venting, Both inlet and reverse water chambers are steel. Oil enters the coolers through flanged openings in the shell. Baffle plates inside the cooler direct the oil flow over the cooling tubes inside the shell and lengthen the path of the oil for better heat transfer. The oil being cooled makes one pass through the cooler. The RTD should be mounted at inlet and outlet of cooler to monitor the oil temperature in air side and hydrogen side seal oil lines. Each oil cooler should have shutoff valves at the oil inlet and outlet. Bypass valves are also provided for both air side and hydrogen side oil cooler. Bypass valves can direct the flow around the coolers when the shutoff valves are closed. 1.10 Pressure Reducing Valve Pressure reducing valve 1OMKW12AA101 reduces the pressure of backup seal oil coming from the lubrication oil reservoir. The oil pressure from the main oil pump, which supplies this backup oil, can exceed the 0.88MPa pressure needed for the Seal Oil System. When the turbine is operating above two-thirds speed, the oil pressure at the inlet side of the pressure reducing valve is about 2.1MPa. The outlet pressure of the valve is O.88MPa. ‘The pressure reducing valve body is steel. The seal ring, valve seats, diaphragm, and trim are stainless steel, The valve has two sections, as shown in Fig 5. The bottom section contains a doubte-seated valve with guide bushings on Fig. 3 Pressure Reducing Valve both the top and bottom sections of the stem. The valve stem is lubricated by the oil in the valve. The top section of the valve contains a diaphragm spring, and adjusting screw for setting the valve operating point. DOCUMENT NO.: TRIYQOA460F564 Page 10 of 25 HARP = SEAL OIL SYSTEM TIRODA THERMAL POWER a) Fife OPERATION AND PROJECT 1980 MW (2x60 MW Shancnay evecrais | MAINTENANCE MANUAL PHASE I + 1x660 MW PhaselI) A decrease in downstream pressure allows the diaphragm spring to open the valve. An increase in

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