Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 1 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL. NO 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES LIST OF CONTENTS

Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 2 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL.NO 1.0 1.1 STATUS

PLANT DETAILS 500 MW Generator consists of the following components. a. STATOR Stator Frame End Shields Stator Core Stator winding Hydrogen coolers b. ROTOR Rotor Shaft Rotor windings Rotor Retaining Rings Field Connections c. BEARINGS d. SHAFT SEALS

1.2

The two pole generator is designed with direct water cooling for the stator winding, phase connectors and bushings and direct Hydrogen cooling for rotor winding. Generator losses, such as iron losses, windage losses and stray losses are also dissipated through hydrogen. The generator frame is pressure resistant, gastight and equipped with major components mentioned above. The hydrogen coolers are arranged vertically inside the turbine end stator end field.

Signatures NTPC BHEL

Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 3 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL.NO 1.3 1.4 The Generator is provided with the following auxiliaries which are essential for generator operation. They are Seal oil systems Gas Systems Primary Water System Excitation System Respective Testing Schedules / O & M manuals are to be referred for commissioning, operation and maintenance of these systems. 1.5 Technical Specification of Generator are given below. Generator Type THDF 115/59 Main Exciter Type Pilot Exciter Type Generator Apparent Power Generator Active Power Current Voltage Speed Frequency Power Factor Hydrogen Pressure Rated Field Voltage Rated Field Current ELR 70/90 30/6-20 ELP 50/42-30/16 588 MVA 500 MW 16.166 KA 21KV + 1.05KV 3000 RPM 50HZ 0.85 (Lag) 3.5 bar 340 V 4040 A STATUS

Signatures NTPC BHEL

Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 4 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL.NO 2.0 STATUS

OBJECTIVE The objective of the test is to ensure.

2.1 2.2 2.3

Gas tightness of gas pipe lines in assembled condition including valves and instrumentation. Gas tightness of various joints on generator stator, terminal bushings, primary water system, hydrogen coolers etc. Effectiveness of the seal oil system at operating pressure.

3.0

PROPOSAL The objective will be achieved through the following proposals.

3.1

Testing of pipe between CO2 Bottle Rack and Hydrogen Unit at a pressure of 4.8 bar of Nitrogen gas for 2 Hrs.

Signatures NTPC BHEL

Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 5 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL.NO 3.2 3.3 3.4 4.0 4.1 4.2 4.3 Testing of pipe between Hydrogen Bottle rack and Hydrogen Unit at a pressure of 4.8 bar of Nitrogen gas for 2 Hrs. Testing of Pipe between Nitrogen Bottle rack and P.W. Tank at a pressure of 5.0 bar of Nitrogen gas for 2 Hrs. Leakage Test of Generator along with Gas System using air at 4.0 bar for 72 Hrs SERVICES REQUIRED Availability of Instrument air Availability of Nitrogen gas Availability of Test pressure gauge of range 0-6 KSC with least scale division of 0.01 KSC Mercury Manometer with mm scale Generator winding Temp Indicator/Recorder in UCB. Water U Manometer 4.4 4.5 4.6 5.0 5.1 5.2 Signatures NTPC BHEL Availability of man power with required tools Availability of lighting/communication Availability of Soap Solution for test. SAFETY PRECAUTIONS Debris in the test area cleared. Approach/Stair Case/Platforms wherever required are made available. STATUS

Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 6 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL.NO 5.3 5.4 6.0 6.1 6.2 Display of board No cutting/welding at all floors made Portable fire extinguishers are available in the test area. EMERGENCY PROCEDURES The test team should be well aware of procedures to be adopted in case of any abnormality in the activity. The test team should know well about the procedures to be adopted in case of damage to machinery or injury to personnel connected to the activity. STATE OF THE PLANT Assembly of generator and fixing of end shields and manhole covers completed. Seal oil system commissioned and put into operation for continuous running. Assembly of gas system piping is completed. Generator terminal bushings are connected. H2 gas coolers not be charged with water. Stator winding filled with primary water and primary water tank kept pressure less. All the valves closed in P.W. System. Connect a U Tube manometer in Waste gas line of P.W. Tank after valve MKF91 AA 505 and close valve MKF91 AA 506. Open valve MKF91 AA 513 and AA 505. It is also required to observe for any leakage into primary water system through stator windings during air leakage test. STATUS

7.0 7.1 7.2 7.3 7.4 7.5 7.6

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Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 7 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL.NO 7.7 Instrument air supply connected before valve MKG25 AA 501. Air for filling should be free from moisture, oil and any mechanical impurity. Precision pressure gauge of class 0.6 for pressure measurement fixed at MKG25 CP001. A mercury U manometer connected in one line of mechanical purity indicator MKG05 CP501 for air pressure measurement and for observing the leakage rate. Other pipe line blanked and valves MKG05 AA 501 and AA 502. Kept open. Soap solution kept ready to check the leakages during test. All the instruments in gas system are mounted as per scheme. All the valves provided in H2 Unit are kept open so that all the lines are pressurized during air filling. All valves connected to vents are kept closed. Valves provided in Generator oil drain lines are opened as follows: (Liquid detector rack) MKA 21 AA 501, MKA 22 AA 501, MKA 23 AA 501, MKA 24 AA 501, MKA 23 AA 511, MKA 24 AA 511. 7.14 Vent valves provided in oil drain lines are closed viz., MKA21 AA 502, MKA 22 AA 502, MKA 23 AA 502, MKA 23 AA 512, MKA 24 AA 502. Valves provided in gas impulse line for valve A1, A2 in seal Oil system are opened. STATUS

7.8 7.9

7.10 7.11 7.12

7.13

7.15

Signatures NTPC BHEL

Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 8 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL.NO 7.16 7.17 8.0 8.1 Values MKG69 AA 504 and MKG69 AA 501 are opened to take dryers in service. Air leakage test done in stands still condition of generator. METHOD Testing of Pipe between CO2 Bottle Rack and H2 Unit Disconnect pipe lines at isolating flanges Nos. 96 and 97. Keep valve MKG 59 AA 507 open. Blank one end of this pipe line by a temporary flange. Pressurize the pipe line by N2 gas to a Pr. Of 4.8 bar and observe the leakage rate for 2 hrs. There should not be any pressure drop. (Subject to temperature condition remaining same). Connect back the pipe lines on system after successful completion of test. 8.2 Testing of Pipe between H2 Bottle Rack and H2 Unit. Disconnect pipe lines at isolating flange Nos. 94 and 95. Blank one end of this pipe line by a temporary flange. Pressurise this pipe by N2 gas to a pressure of 4.8 bar. Observe the leakage rate for 2 Hrs. There should not be any pressure drop in pipe line. Check for any leakage during this period by means of soap solution at all welding joints and rectify any leakage. Connect back the pipe lines in system after successful completion of test. STATUS

Signatures NTPC BHEL

Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 9 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL.NO 8.3 Testing of Pipe Between N2 Bottle Rack and P.W. Tank Disconnect pipe lines at isolating flange No. 312 and primary water tank. Blank one end of this pipe line by a temporary flange. Keep valve (MKP91 AA 502 open. Pressurise this pipe by N2 gas to a Pr. Of 5 bar. Observe the leakage rate for 2 Hrs. There should not be any pressure drop in pipe line. Check for any leakage during this test by means of soap solution at all weld joints and rectify any leakage. Connect back the pipe lines in system after successful completion of test. 8.4 8.4.1 Leakage Test of Generator along with Gas System using Air. Air Filling in Generator Casing Open valve MKG25 AA 501 and fill air in generator and gas piping upto pressure of 4 Bar. During filling observe the performance of pressure regulating valve of seal oil system and maintain the H2 and air side seal oil Pressure as recommended. Close valve MKG25 AA 501 as soon as pressure in the casing reaches 4 bar. 8.4.2 I Checks during Air Leakage Test During the air leakage test, apply Soap Solution at all joints for checking leakages in following areas: Joint and bolt heads on Stator body Weld joints on generator body Joints of terminal bushings, manhole covers, H2 coolers etc. Gas piping welding joints and flanged joints. STATUS

Signatures NTPC BHEL

Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 10 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL.NO Passing of valves in the system to atmosphere and passing through valve glands. Gas drier shell. Seal oil Tank Flanged joints. Impulse line connection for pressure regulating valve in seal oil system Connecting joints of all measuring instruments provided in gas system. Passing of valves provided in oil/water detector lines. Sealing joints provided for taking out the stator winding Temp. terminals. If any leakage is observed the generator should be depressurised and same should be attended and test should be repeated. Ii Record half hourly reading on the mercury manometer provided in H2 unit for this test. Record ambient and generator temperature as measured from RTDs. STATUS

Signatures NTPC BHEL

Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 11 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL.NO Iii Observe for any pressure rise in P.W. tank during test by means of Water U manometer provided for this purpose. If any increase is observed, stator winding system should be checked for leakage. Continue the test till the rate is well within specified limit. If no leakage is observed, pressure drop should be checked for 72 hrs. continuously. Calculation of Leakage Rate Loss of air is determined as follows: V 0.2694x24 VG (P1+Pb1 - P2 + Pb2) Z 273+T1 273 + T2 STATUS

IV

8.4.3

Where V = Loss of air in M3 at N.T.P./ 24 Hrs. 0.2694 = 273o K / 1013.25 m bar Z VG P1 P2 = Duration of leakage test, Hrs. = Generator volume, m3 = Gauge Pressure within the system at beginning of leakage test, in m bar. = Gauge Pressure within the system at the end of leakage test, in m bar.

Signatures NTPC BHEL

Station: NTPC-Vindhyachal

BHEL Ref No.PS-DC-186-500-0018 NTPC Ref no VIN/1/TS/2/007

Sheet 12 of 12

Plant area: TURBO GENERATOR PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST SL.NO Pb1 Pb2 T1 T2 9.0 = Barometer reading at beginning of leakage test, in m bar. STATUS

= Barometer reading at the end of leakage test m bar. = Temperature of the gaseous atmosphere at beginning of leakage test 0C. = Temp. of the gaseous atmosphere at end of leakage Test 0C.

COMPLETION CRITERIA Leakage test should be carried out for 72 hrs at 4 bar and average air loss should be calculated. The permissible air loss for a gas tight system is below 2.4m3 at N.T.P. / 24 Hrs. If air loss is higher, checks should be carried out for detecting the leakage areas.

10.0

APPENDICES The following system drawings to be referred from O & M manual Gas System P.W. System Seal Oil System Generator Instrumentation Scheme Waste Fluid System Waste Gas System

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PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST