Gen Air Test (Rgm)

8/18/2019 Gen Air Test (Rgm)

1/15

Station: NTPC-

RAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1TS200!S"eet 1 of 12

P#ant a$ea: TURB% GENERAT%R

PR%CEDURE &%R GENERAT%R A'R T'GHTNESS TEST

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LIST OF CONTENTS

PLANT DETAILS

OBJECTIVE

PROPOSAL

SERVICES REQUIRED

SAFETY PERECAUTIONS

EER!ENCY PROCEDURE

STATE OF T"E PLANT

ET"OD

COPLETION CRITERIA


2/15

Station: NTPC-

RAMAGUNDAM





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PLANT DETAILS

500 MW Generator consists of the following components.

a. STATOR

Stator Frame

n! Shiel!s

Stator "ore

Stator win!ing

#$!rogen coolers

%. ROTOR

Rotor Shaft

Rotor win!ings

Rotor Retaining Rings

Fiel! "onnections

c. &AR'(GS

!. S#AFT SA)S

The two pole generator is !esigne! with !irect water cooling for the stator win!ing* phase connectors an! %+shings an! !irect#$!rogen cooling for rotor win!ing. Generator losses* s+ch asiron losses* win!age losses an! stra$ losses are also !issipate!thro+gh h$!rogen. The generator frame is press+re , resistant*gastight an! e-+ippe! with maor components mentione! a%o/e.

The h$!rogen coolers are arrange! /erticall$ insi!e the t+r%ineen! stator en! fiel!.

STATUS

Si(nat)$e*

NTPC BHEL


3/15


4/15

Station: NTPC-

RAMAGUNDAM


NTPC Ref no RGM1TS200!S"eet + of 12



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The Generator is pro/i!e! with the following a+iliaries which areessential for generator operation.

The$ are

Seal oil s$stems

Gas S$stems

3rimar$ Water S$stem

citation S$stem

Respecti/e Testing Sche!+les 4 O M man+als are to %e referre!for commissioning* operation an! maintenance of these s$stems.

Technical Specification of Generator are gi/en %elow.Generator T$pe T#6F 115457

Main citor T$pe )R 80470 , 049:20

3ilot citor T$pe )3 5042:0419

Generator Apparent 3ower 5;; M


5/15


6/15

Station: NTPC-

RAMAGUNDAM





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SERVICES REQUIRED

A/aila%ilit$ of 'nstr+ment air

A/aila%ilit$ of (itrogen gas

A/aila%ilit$ of

Test press+re ga+ge of range 0:9 =S" with least scale

!i/ision of 0.01 =S" Merc+r$ Manometer with mm scale

Generator win!ing Temp 'n!icator4Recor!er in C"&.

Water DCE Manometer

A/aila%ilit$ of man power with re-+ire! tools

A/aila%ilit$ of lighting4comm+nication

A/aila%ilit$ of Soap Sol+tion for test.

SAFETY PRECAUTIONS

6e%ris in the test area cleare!.

Approach4Stair "ase43latforms where/er re-+ire! are ma!ea/aila%le.

6ispla$ of %oar! (o c+tting4wel!ing at all floors ma!e

3orta%le fire eting+ishers are a/aila%le in the test area.

STATUS

Si(nat)$e*

NTPC BHEL


7/15

Station: NTPC-

RAMAGUNDAM


NTPC Ref no RGM1TS200!S"eet of 12



SL.NO

6.0

9.1

9.2

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8.1

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EER!ENCY PROCEDURES

The test team sho+l! %e well aware of proce!+res to %e a!opte!in case of an$ a%normalit$ in the acti/it$.

The test team sho+l! Bnow well a%o+t the proce!+res to %ea!opte! in case of !amage to machiner$ or in+r$ to personnelconnecte! to the acti/it$.

STATE OF T"E PLANT

Assem%l$ of generator an! fiing of en! shiel!s an! manholeco/ers complete!.

Seal oil s$stem commissione! an! p+t into operation for contin+o+s r+nning.

Assem%l$ of gas s$stem piping is complete!.

Generator terminal %+shings are connecte!.

#2 gas coolers not %e charge! with water.

Stator win!ing fille! with primar$ water an! primar$ water tanBBept press+re less. All the /al/es close! in 3.W. S$stem. "onnecta DCE T+%e manometer in Waste gas line of 3.W. TanB after /al/eM=F71 AA 505 an! close /al/e M=F71 AA 509. Open /al/eM=F71 AA 51 an! AA 505. 't is also re-+ire! to o%ser/e for an$leaBage into primar$ water s$stem thro+gh stator win!ings !+ringair leaBage test.

STATUS

Si(nat)$e*

NTPC BHEL


8/15

Station: NTPC-

RAMAGUNDAM


NTPC Ref no RGM1TS200!S"eet ! of 12



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8.;

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8.15

'nstr+ment air s+ppl$ connecte! %efore /al/e M=G25 AA 501. Air for filling sho+l! %e free from moist+re* oil an! an$ mechanicalimp+rit$.

3recision press+re ga+ge of class 0.9 for press+re meas+rementfie! at M=G25 "3001.

A merc+r$ DCE manometer connecte! in one line of mechanicalp+rit$ in!icator M=G05 "3501 for air press+re meas+rement an!for o%ser/ing the leaBage rate. Other pipe line %lanBe! an!/al/es M=G05 AA 501 an! AA 502. =ept open.

Soap sol+tion Bept rea!$ to checB the leaBages !+ring test.

All the instr+ments in gas s$stem are mo+nte! as per scheme.

All the /al/es pro/i!e! in #2 Cnit are Bept open so that all thelines are press+irse! !+ring air filling. All /al/es connecte! to/ents are Bept close!.


9/15

Station: NTPC-

RAMAGUNDAM





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10/15

Station: NTPC-

RAMAGUNDAM


NTPC Ref no RGM1TS200!S"eet of 12



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Testing of 3ipe &etween (2 &ottle RacB an! 3.W. TanB

6isconnect pipe lines at isolating flange (o. 12 an! primar$water tanB. &lanB one en! of this pipe line %$ a temporar$ flange.=eep /al/e @M=371 AA 502 open. 3ress+rise this pipe %$ (2 gasto a 3r. Of 5 %ar. O%ser/e the leaBage rate for 2 #rs. Theresho+l! not %e an$ press+re !rop in pipe line. "hecB for an$leaBage !+ring this test %$ means of soap sol+tion at all wel!

oints an! rectif$ an$ leaBage. "onnect %acB the pipe lines ins$stem after s+ccessf+l completion of test.

)eaBage Test of Generator along with Gas S$stem +sing Air.

Air Filling in Generator "asing

Open /al/e M=G25 AA 501 an! fill air in generator an! gaspiping +pto press+re of &ar. 6+ring filling o%ser/e theperformance of press+re reg+lating /al/e of seal oil s$stem an!maintain the #2 an! air si!e seal oil 3ress+re as recommen!e!."lose /al/e M=G25 AA 501 as soon as press+re in the casingreaches %ar.

"hecBs !+ring Air )eaBage Test

6+ring the air leaBage test* appl$ Soap Sol+tion at all oints for checBing leaBages in following areasH

Joint an! %olt hea!s on Stator %o!$

Wel! oints on generator %o!$

Joints of terminal %+shings* manhole co/ers* #2 coolers

etc. Gas piping wel!ing oints an! flange! oints.

STATUS

Si(nat)$e*

NTPC BHEL


11/15

Station: NTPC-

RAMAGUNDAM





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3assing of /al/es in the s$stem to atmosphere an!

passing thro+gh /al/e glan!s.

Gas !rier shell.

Seal oil TanB Flange! oints.

'mp+lse line connection for press+re reg+lating /al/e in

seal oil s$stem

"onnecting oints of all meas+ring instr+ments pro/i!e! in

gas s$stem.

3assing of /al/es pro/i!e! in oil4water !etector lines.

Sealing oints pro/i!e! for taBing o+t the stator win!ing

Temp. terminals.

'f an$ leaBage is o%ser/e! the generator sho+l! %e !epress+rise!an! same sho+l! %e atten!e! an! test sho+l! %e repeate!.

Recor! half ho+rl$ rea!ing on the merc+r$ manometer pro/i!e!in #2 +nit for this test. Recor! am%ient an! generator temperat+reas meas+re! from RT6Es.

STATUS

Si(nat)$e*

NTPC BHEL


12/15

Station: NTPC-

RAMAGUNDAM





SL.NO

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O%ser/e for an$ press+re rise in 3.W. tanB !+ring test %$ meansof Water DCE manometer pro/i!e! for this p+rpose. 'f an$ increaseis o%ser/e!* stator win!ing s$stem sho+l! %e checBe! for leaBage.

"ontin+e the test till the rate is well within specifie! limit. 'f noleaBage is o%ser/e!* press+re !rop sho+l! %e checBe! for 82 hrs.contin+o+sl$.

"alc+lation of )eaBage Rate

)oss of air is !etermine! as followsH

< , 0.2972 3%1 : 32 > 3%2

? 28>T1 28 > T2

Where < K )oss of air in M at (.T.3.4 2 #rs.

0.297 K 28o = 4 101.25 m %ar

? K 6+ration of leaBage test* #rs.


13/15

Station: NTPC-

RAMAGUNDAM





SL.NO

9.0

3%1 K &arometer rea!ing at %eginning of leaBage test* in m%ar.

3%2 K &arometer rea!ing at the en! of leaBage test m %ar.

T1 K Temperat+re of the gaseo+s atmosphere at %eginningof leaBage test 0".

T2 K Temp. of the gaseo+s atmosphere at en! of leaBageTest 0".

COPLETION CRITERIA

)eaBage test sho+l! %e carrie! o+t for 82 hrs at %ar an!a/erage air loss sho+l! %e calc+late!. The permissi%le air loss for a gas tight s$stem is %elow 2.m at (.T.3. 4 2 #rs.

'f air loss is higher* checBs sho+l! %e carrie! o+t for !etecting theleaBage areas.

STATUS

Si(nat)$e*

NTPC BHEL


14/15

3RO"6CR FOR G(RATOR A'RT'G#T(SS TST


15/15

PROJECT #S RAA!UNDA 500 $

PROCEDURE !ENERATOR AIR TI!"TNESS TEST

PURPOSE OF

DOCUETFOR E%ECUTION # INFORATION

DOCUENT PS&TS%&183&00&03

"op$ (oH

'ss+e! to H

00 =J M=S =3TM 18.07.200

Re/.(o. 3repare! %$ Re/iewe! %$ Appro/e! %$ 6ate

B"ARAT "EAVY ELECTRICALS LIITEDPSSR#TEC"NICAL SERVICES

474' A(() S)*)+' N)(,)()-'

C/(()+ 600 035.

Documents

Gen Air Test (Rgm)