Seal Oil Flushing

Station: NTPC-Vindhyachal Plant area : TURBINE
BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005
Sheet 1 of 20
PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM 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 PROPOSALS SERVICES REQUIRED SAFETY PRECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES a) b) Drawing Log Sheets
Station: NTPC-Vindhyachal
Sheet 2 of 20
Plant area : TURBINE PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM Sl. No. 1.0 1.1 PLANT DETAILS STATUS
Generators cooled by H2 are provided with seal oil system for preventing the leakage of H2 to atmosphere for the formation of explosive mixture and to reduce the consumption of H2. This system consists of tank, pumps, (Both A.C. and D.C) coolers, filters and pressure regulators to maintain the oil pressure at the seal body of generator. Turbine oil is used for this purpose. DC pump is meant to supply oil to the seals during the failure of AC power supply during emergency conditions.
For Technical Specifications, the respective O & M manuals are to be referred. The drawings enclosed at section 10.0 are a) Schematic for oil flushing of Seal Oil Piping. Drg.No. 4:PS:TSX:0063:00 Control Value rack of Seal Oil System. Drg.No.4:PS:TSX:0064:00
1.2
1.3
1.4 1.5
b)
Signatures NTPC BHEL
BHEL Ref No. PS-DC-186-500-0006 Sheet 3 of 20 Station:NTPC Vindhyachal NTPC Ref No. VIN/1/TS/2/005 Plant area : TURBINE PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM Sl. No. 2.0 OBJECTIVE STATUS
The objective of this oil flushing is to ensure the cleanliness of seal oil piping before connecting it to the various racks of seal oil system.
Station:NTPC-Vindhyachal
Sheet 4 of 20
Plant area : TURBINE PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM Sl. No. 3.0 TESTING PROPOSAL STATUS
The oil flushing of Seal Oil System is proposed to be carried out in two stages.
3.1
Stage I Oil Flushing of Seal Oil Piping (Seal Oil rack excluded) The oil flushing is carried out by taking the lub oil from lub oil supply line near bearing No.4 as shown in enclosed circuit. The oil flushing is carried out in two parts. PART I : includes seal oil air side supply pipe line and ring relief supply pipe lines. PART II : includes the seal oil H2 side supply pipe line.
3.2
Stage II Oil Flushing of Seal Oil System including the various components of Seal Oil rack and the system piping. During flushing thermal shocks on seal oil is given Refer Procedure for Hydraulic test and flushing of Turbine lub-oil and Jacking Oil System. BHEL Ref.No.PS-DC-186-500-0004 (NTPC.Ref.No. SIM/1/TS/2/001) All weld joints should be hammered to remove any loose weld slag.
Sheet 5 of 20
Plant area : TURBINE PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM Sl. No. 4.0 4.1 SERVICES REQUIRED Availability of Electrical heating arrangement for heating the CW to turbine oil cooler for thermal shock operation during oil flushing. Availability of laboratory facility for analysis of oil sample. Availability of service air and thinner/petrol for filter cleaning. Availability of sufficient skilled manpower for supervision / execution of the process. Availability of required quantity of Turbine oil Availability of portable fire extinguisher at oil flushing area. Availability of proper lighting and communication facility. STATUS
4.2 4.3 4.4 4.5 4.6 4.7
Station: NTPCVindhyachal
Sheet 6 of 20
Plant area : TURBINE PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM Sl. No. 5.0 5.1 SAFETY PRECAUTIONS: Readiness of stair cases, platforms, hand rails for Seal Oil Tank and required approaches as decided at site are made available. Safety and protection equipments like hand gloves, helmet etc are available during the process. Precautions taken to avoid spillage of oil and contamination of oil. Service water source available near the activity area. Ensure the availability of first aid kit near the process area. Buckets containing sand are available at process area. Welding/cutting shall not be carried out in lub-oil flushing areas, once oil has been filled in Seal Oil Tank. Load on Pumps shall not exceed full load current of the motor. Provision for emergency stopping of oil pumps from local/UCB has to be made. Cordoning of lub-oil flushing area wherever required. Display of caution sign boards, danger tags are provided at locations in the test area. Round the clock monitoring of oil flushing activity. STATUS
5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12
Sheet 7 of 20
Plant area : TURBINE PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM Sl. No. 6.0 6.1 STATUS
EMERGENCY PROCEDURES: The teams for this operation shall be aware of the procedure of oil flushing and act at the time of any emergency. They shall be aware of operation of fire extinguishers. They shall be aware of how to act in case of any personal injuries. They shall know to stop the pumps quickly in case of any leakage and then inform the concerned higher official. They shall be aware of re-establishing the operation in case of system stoppage due to failure of power supply.
6.2
6.3
6.4
6.5
Sheet 8 of 20
Plant area : TURBINE PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM Sl. No. 7.0 7.1 STATE OF THE PLANT STATUS
Before starting the flushing, the completion of following jobs should be ensured. Erection of interconnected piping is completed. Provide temporary connection wherever required as per enclosed circuit. The temporary pipes should be acid cleaned and neutralized before installation. Ensure that flange joints are tightened with gasket in position. The pressure regulating valve MKW 73 AA 011 and MKW 73 AA 021 have been removed and spool pieces have been placed.
7.1.1 7.1.2 7.1.3
7.1.4 7.1.5
Sheet 9 of 20
Plant area : TURBINE PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM Sl. No. STATUS
7.1.6
Erection of seal oil pump unit, seal oil unit, seal oil valve rack, measuring instrument rack, seal oil storage tank and interconnected piping is completed.
7.1.7
Physical cleaning of seal oil storage tank and seal oil tank. Availability of power and control supply for motors and starting panels. Trial run of following motors and coupled with respective pumps. a. Air side seal oil pump motor (AC) 2 nos.
7.1.8
7.1.9
b. Emergency airside seal oil pumps motor (DC) 1 no. c. H2 side seal oil pump motor (AC) 1 no.
7.1.10
Disconnect airside seal oil inlet pipes at the seal body on both sides of generator and connect it to bearing drains by a temporary piping.
Sheet 10 of 20
Plant area: TURBINE PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM Sl. No. 7.1.12 STATUS
Disconnect H2 side seal oil inlet and outlet pipes at seal body on both sides of generator and interconnect it by a temporary piping. Disconnect ring relief oil inlet pipe at seal body on both sides of generator and interconnect by a temporary piping into air side seal oil drain pipes. Take out both float valves from seal oil tank. MKW 03BB001. Keep the springs of regulating valves A1, A2 and C at completely released condition. Make necessary arrangement for heating seal oil unto 65 70oC during oil flushing process.
Fire fighting system of TG Lub-oil and generator Seal oil system made available before commencement of flushing. Acid cleaning of pipeline normally not envisaged. However, if traces of pitting observed in any of the pipe line, acid cleaning of the pipe line to be carried out (Refer Procedure No.PS-DC-186-500-0013B/NTPC Ref.No.SIM/1/TS/2/001 for acid cleaning)
7.1.13
7.1.14
7.1.15
7.1.16 7.1.17
7.1.18
Sheet 11 of 20 NTPC Ref No. VIN/1/TS/2/005 PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM STATUS
BHEL Ref No. PS-DC-186-500-0006
Sl. No. 8.0
METHOD Seal oil system is filled with oil by taking the oil supply from seal oil storage tank. To ensure oil level in seal oil storage tank, lub oil pump should be kept running during this process or oil should be filled manually in this tank. Seal oil system is filled up in two stages as follows (ensure that all shut off and gate valves are closed).
Station: NTPC- Vindhyachal
Sheet 12 of 20
Plant area : TURBINE PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM Sl. No. 8.1 8.1.1 STATUS
FILLING OF AIR SIDE SEAL OIL CIRCUIT Open following shut off and gate valves in air side oil circuit. MKW 01 AA 503 At seal oil storage tank MKW 11 AA 501 before seal oil pump (1). MKW 21 AA 501 before seal oil pump (2) MKW 31 AA 501 before stand by seal oil pump (3) MKW 21 AA 001 after seal oil pump (1) MKW 21 AA 002 after seal oil pump (2) MKW 31 AA 003 after stand by seal oil pump (1) MKW 11 AA 504 before A1 valve MKW 11 AA 505 after A1 valve MKW 31 AA 504 before A2 valve MKW 31 AA 505 after A2 valve MKW 11 AA 004 after seal oil pumps (1) & (2) MKW 31 AA 004 after stand by seal oil pumps (3) MKW 03 AA 502 before float valve, oil inlet MKW 03 AA 501 after float valve, oil drains (4) MKW 03 AA 505} for oil level gauge MKW 03 AA 506} MKW 71 BP 501 adjustable orifice MKW 76 AA 513} seal ring relief oil MKW 76 AA 523}
Sheet 13 of 20
8.1.2
Charge the seal oil coolers on oil side with rotary transfer valve assembly in centre position. When the coolers are filled with seal oil, turn rotary transfer valve on one side i.e. Right hand or left hand side to bring one cooler in service and other on standby. Charge both seal oil filters as done in case of coolers and keep one seal oil filter in service by keeping rotary transfer valve on one side. Start and stop seal oil pump 1 for a short time to bleed air from piping until pressure gauges MKW 71 CP 511 and CP 521 indicate a constant pressure. Set three way valves MKW 71 AA 511 and AA 521 and MKW 76 AA 511 and AA 521 to position where no oil passes through the volume flow indicator.
8.1.3
8.1.4
8.1.5
Sheet 14 of 20
8.2
8.2.1
FILLING OF H2 SIDE SEAL OIL CIRCUIT During filling of the air side circuit, the seal oil tank is simultaneously filled with seal oil by valve MKW03 AA 502. Oil level in this tank will continue to rise above the sight glass till it reaches the level of seal oil storage tank and will get drained through siphon action. Open following shut off and gate valves of H2 side seal oil circuit. MKW13 AA 501 before H2 side seal oil pump MKW13 AA 003 before H2 side seal oil pump MKW13 AA 510 before C valve MKW13 AA 503
8.2.2
Sheet 15 of 20
8.2.3
Charge both seal oil coolers on oil side with rotary transfer valve assembly in its center position. When both cooler are filled with seal oil, turn rotary transfer valve on one side i.e. Right or Left hand to bring one cooler in service. Charge both seal oil filters as done in case of coolers and keep one filter in service. Loosen the adjusting nut of pressure equalizing valve MKW73 AA 021. Start and stop H2 side seal oil pump to bleed the air from piping until the pressure gauges MKW73 CP 511 and CP 521 indicates a constant reading. Set three way valves MKW73 AA 511 and AA 521 to position, where no oil passes through volume flow indicator. Hydraulic test of the seal oil piping (excluding rack) shall be carried out at a pressure of 12 kg./cm2.
8.2.4
8.2.5
8.2.6
8.2.7
Sheet 16 of 20
8.4.0
OIL FLUSHING OF SYSTEM Oil flushing of seal oil circuit is carried out in three different stages. i. ii. iii. Flushing of air side circuit Flushing of H2 side circuit Flushing of oil impulse lines
8.4.1
Flushing of Air Side Seal Oil Circuit. Flushing of air side seal oil circuit is carried out by one of the AC seal oil pumps provided in the system. During this process, oil flow is maintained through seal oil cooler, filter, valve A1, A2, inlet seal oil pipes: bearing drain pipes to seal oil storage tank. Parallel to this, inlet ring relief oil pipes are also flushed in this circuit.
Sheet 17 of 20
8.4.2
Flushing of H2 side Seal Oil Circuit. Flushing of this circuit is carried out by H2 side seal oil pump provided in the system. During this process, oil flow is maintained through H2 side seal oil cooler, filter, valve C, Inlet H2 side seal oil pipes, H2 side drain pipes, prechambers, seal oil tank. Flushing of Oil Impulse Lines Flushing of all oil impulse lines provided in the system for various pressure gauges, pressure regulators should be done by opening their root valves and then flushing through their isolating valves opened to vent. Oil should be collected in the bucket at the root of isolating valves.
8.4.3
8.4.4
During flushing ensure that there is no oil leak in the system. If leaks are observed stop flushing and attend to the leaks. Maintain oil temperature around 65-700C. Give thermal stocks as done in Turbine lub oil system flushing. (Refer Procedure PS-DC_186500-0004/NTPC Ref No. SIM/1/TS/2/001) Changeover the filter after every one hour and clear. Cleaning of filter to be carried out by following steps. a) Clean the filter element in Kerosene / Diesel Oil. b) Then clean the filter element with clean marking cloth.
8.4.5 8.4.6
8.4.7
Sheet 18 of 20
c) Clean and dry the filter with compressed air. (Air pressure to be reduced sufficiently for air blowing filter) 8.4.8 8.4.9 Take sample of return oil and analyses if for the presence of moisture & mechanical impurities. Hydraulic test of the lines (excluding seal oil rack) shall be carried out at a pressure of 12 kg/cm2 along with lub-oil system. Restoration of Seal Oil System 8.5.0 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5
8.5.6
On completion of oil flushing: Drain the entire system. Remove the temporary piping and restore original connections. Remove the blanks provided, if any. Connect back the impulse lines. Reassemble the float valves MKWO3 AA 001 and AA 002 in seal oil tank. Clean both the filters and reassemble.
Sheet 19 of 20
9.0
COMPLETION CRITERIA Oil flushing for each stage may be declared completed on the following basis. No foreign particle and material present at the filtering elements after 24 hours of flushing. Moisture content in return oil should be less than 0.01% (100 ppm) and mech. Impurities should be less than 0.01% (100 ppm). For lab analysis of oil samples for mechanical impurities, filter of size 0.45 micron shall be used.
Sheet 20 of 20
SEAL OIL PUMP NO. 1 / 2

Oil temperature Sl.No Date/Time Pump Dis.Pr. Bef. Cooler After Cooler Thermal Shock Remarks

Seal Oil Flushing

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Station: NTPC-Vindhyachal Plant area : TURBINE

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

4.2 4.3 4.4 4.5 4.6 4.7

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

7.1.1 7.1.2 7.1.3

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006

Sl. No. 8.0

Signatures NTPC BHEL

Station: NTPC- Vindhyachal

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

BHEL Ref No. PS-DC-186-500-0006 NTPC Ref No. VIN/1/TS/2/005

Signatures NTPC BHEL

SEAL OIL PUMP NO. 1 / 2

Signatures NTPC BHEL

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