NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI

STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

OBJECTIVE
The Objective of this oil flushing is to ensure cleanliness of seal oil
piping before connecting to the generator seals.

CC APPROVED PROCEDURE : COS-COMM-SIM-commg-PRO/016

VOLUME OF SEAL OIL SYSTEM: 1.5 m3

SEAL OIL SPECIFICATIONS

MI < 100 ppm
MO < 100 ppm

TOTAL NO. OF DAYS : 20 days

NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

WHY SEAL OIL SYSTEM?

To prevent H2 escape from Generator body by maintaining a continuous oil

film between Generator body and Rotor journals at both the ends..
NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

LUBE OIL (SEAL OIL) SPECIFICATIONS

CLEANING OF SEAL OIL SYSTEM PIPING

Pre-requisites

Ensure Erection of all Seal oil system pipelines as per schematic diagram.

Ensure availability of Instrument Air at gas unit.

Instrument Air pressure required for blowing pipelines is > 6kg/cm2

CLEANING PROCESS

Normally both of these are employed for effective cleaning of pipelines.

NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

Air Blowing
Cardboard Blasting

AIR BLOWING

Continuous flow of Air through the pipeline till no dust / loose foreign
material comes out from the other end.

CARDBOARD BLASTING
 NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

One end of pipeline is blanked with Cardboard sheet (approx. 3mm thick)
with the help of a flange, and is pressurised with air till cardboard bursts. This
is repeated till no dust, rust or foreign particles are observed at outlet.

GEN SEAL OIL LINES CARD BLASTING DETAILS

SNO DATE START TIME STOP TIME PRESSURE NO. OF LOCATION OF
(KSC) CARDS CARDBOARDS (CB)
1 21.01.11 10.30 AM 10.37 AM 3.2 3 Pump common suction flange
2 21.01.11 11.45 AM 11.52 AM 2.8 2 Pump common suction flange
3 22.01.11 10.45 AM 10.57 AM 3.1 3 Valve rack air side line flange
4 23.01.11 11.30 AM 11.37 AM 3.5 4 Valve rack air side line flange
5 23.01.11 03.30 PM 03.39 PM 3.0 3 Valve rack H2 side line flange
6 24.01.11 09.30 AM 09.38 AM 4.4 4 Valve rack H2 side line flange
7 24.01.11 10.55 AM 11.05 AM 3.3 3 Valve rack RING RELIEF side line
flange
8 24.01.11 04.15 PM 04.23 PM 3.1 3 Valve rack RING RELIEF side line
flange
NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

SIMPLIFIED DRAWING OF SEAL OIL SYSTEM

SYSTEM COMPONENTS (AIR SIDE)

Seal Oil Storage Tank

Seal Oil Pumps ( 3X100%)2 AC & 1 DC

 NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

Seal Oil Coolers (2x100%)

Filters

Diff. Pressure Regulators A1 & A2

H2 Side Seal Oil Circuit

Seal Oil Tank

Seal Oil Pump (1x100%)

Seal Oil Coolers (2x100%)

Filters

Differential Pressure Valve C

Pressure Equalising Valves TE & EE

NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

SEAL OIL SYSTEM
NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

DIFFERENTIAL PRESSURE REGULATOR

Gas pressure and the impulse oil pressure act in opposite directions.
Valve stem moves UP or DOWN whenever there is unbalanced
Valve cone arrangement is such that it closes further for a down
movement of the valve stem.
Dp to be maintained is set by pre- loading of the main bellows. The pre-
loading is adjusted with a Compression spring linked to the valve stem
by means of an adjusting nut.
NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

PRESSURE EQUALISING VALVE

Separate pressure equalizing valves for TE & EE Seals, to control

constant differential pressure between the Air side and the H2 side oil.
Air side and H2 side Seal oil act in opposite directions, the valve stem
moves up or down when these pressures are unbalanced.
Valve opens further with a down movement of the valve stem.
NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

Setting of desired DP is done by corrosponding pre-loading of control

piston
NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

OIL FLUSHING OF SEAL OIL SYSTEM

Pre requisites

Erection of interconnected piping is complete as per scheme.

Proper slope (min. 40mm/m) on all Seal Oil drain pipes as per drawing.
Temporary connections provided as per schematic.
Flow Meters removed and temporary spool pieces provided.
Stem of adjustable orifice removed.
Equalizing valves removed and temporary spool pieces provided.
Erection of Seal Oil Pump Unit, Skid, Valve Rack, Interconnected piping
etc.
Physical Cleaning of SOST & SOT
Oil Flushing of Seal Oil pipelines
Trial Run of Motors completed
Float Valves in SOT Removed
Regulating Valves A1, A2 & C removed & temporary spool piece
provided
Arrangement for Heating of Seal Oil up to 70oC.

Flushing of Air Side Seal Oil Circuit

Open shut off valves in circuit given in procedure
Charge Air Side Seal Oil Coolers with oil, one at a time
Keep one cooler in service
Momentarily Start & Stop Seal Oil pump 1 to bleed air from piping until
Pr gauges indicate constant pressure.
Set 3-way valves in rack, such that no oil flows through flow indicators
Carry out flushing of Air Side circuit.
NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

During the process oil flow is maintained in following manner

Filling & Flushing of H2 Side Seal Oil Circuit

Open shut off valves in circuit given in procedure
Fill oil from Air side circuit by opening SOT makeup supply valve. Open
plug provided on prechamber and fill oil till it reaches prechamber level
Charge H2 Side Seal Oil Coolers with oil, one at a time
Keep one cooler in service
Start & Stop Seal Oil pump 1 to bleed air from piping until H2 side gauges
in eq. rack indicate constant pressure
Set 3-way valves in rack, such that no oil flows through flow indicators
Carry out flushing of H2 Side circuit.

During the process oil flow is maintained in following manner

NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

Precautions during flushing

Ensure No leakages are there at flange joints, tapping joints etc

Maintain Seal Oil Temperature around 60-70oC
Provide thermal shocks, by suddenly reducing oil temperature to 35-
40oC. During this tap pipelines, specially over bends & welded joints
with a small hammer.
DP across the filters should be observed, and changeover to be done if it
exceeds 0.8kg/cm2.
Changeover filter after every 2 hr during flushing.
Open filter and clean mesh element using clean cloth & blower.
Frequency of filter changeover to be decided depending upon quantum
& type of debris collected.
Take a sample of return oil and analyse it for the presence of moisture
and mechanical impurities.
 NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

Completion Criteria

Oil flushing process can be declared completed on following basis

No foreign particle / material present at filter elements

Moisture content in return oil is NIL and impurities not more than
0.05%.

Restoration of Seal Oil System

Remove temporary piping and restore original connections

Remove blanks provided, if any
Connect back impulse lines
Reassemble valves A, A2, C, Orifice, Equalising valves
Clean both filters and reassemble
Verfication of logic & control scheme of Seal Oil Pumps as per SLC
Mounting & connection of all instrumentation as per scheme.
Check functioning of low level detectors in SOT & SOST before oil filling
Filling of fresh oil in SOST
Ensure full open condition of regulating valves A1, A2 & C by Loosening
of Springs

Filling & Operation of Air Side Circuit

Fill Air Side oil circuit, charge coolers & filters with oil
Charge coolers with Cooling water on both sides
Keep one vapour exhauster in service and second on standby
Start Pump-1
With Pump running, perform venting of

Pressure signal lines to measuring devices
 NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

Main bellows of DPRV A1,A2.

Filling & Operation of H2 Side Circuit

During filling of Air Side, SOT gets simultaneously filled via float valve
Fill H2 Side oil circuit, charge coolers & filters with oil
Charge coolers with Cooling water on both sides
Start H2 side Pump & stop to bleed air
With Pump running, perform venting of Pressure gauges, Reg. valve C
and Equalising valves.

Setting of DPRV A1

Adjust nut of A1 valve so that Seal Oil pressure is 1.5kg/cm2 at Seals.

Fill Air and adjust nut again to maintain 1.5kg/cm2 above air pressure till
rated casing pressure value.

Setting of Orifice MKW71BP501

This orifice is adjusted to keep Ring Relief oil pressure above seal oil

Pressure.

Adjust such that, ring relief oil pressure is approx 1kg/cm2 higher than

seal oil pressure.

 NTPC SIMHADRI SUPER THERMAL POWER PROJECT SIMHADRI
STAGE 2 (2X500MW)
O&M COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

Setting of DPRV C

Adjust C valve nut, such that H2 side Seal Oil pump discharge pr higher

than air side discharge pr by 1kg/cm2 is achieved.

Setting of DPRV A2

This is adjusted after Setting completion of valve A1 & C

Purge out air and record Seal Oil pressure value with A1 valve
Stop the pump
Take A2 in service and isolate A1 valve
Start pump, adjust A2 nut to achieve A1 values
Normalise A1 valve.