Gen Air Test

Station: NTPC- RAMAGUNDAM

COMMISSIONING PROTOCOL

4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR, RAIGARH PS-WR

UNIT UNIT NO. 1 PLANT AREA: TG PROCESS: GENERATOR AIR TIGHTNESS TEST

Station: JPL - RAIGARH OPJSTPP (4X250MW)BHEL Ref No. _____________________

JPL Ref no ________________________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

LIST OF CONTENTS

PLANT DETAILS

OBJECTIVE

PROPOSAL

SERVICES REQUIRED

SAFETY PERECAUTIONS

EMERGENCY PROCEDURE

STATE OF THE PLANT

METHOD

COMPLETION CRITERIA








SL.NO

1.0

1.1

1.2

PLANT DETAILS

250 MW Generator consists of the following components.

a. STATOR

Stator Frame

End Shields

Stator Core and winding assembly

Baffle and labyrinth rings

Terminal bushings

Hydrogen coolers

b. ROTOR

Rotor Shaft

Rotor windings

Rotor Retaining Rings

Field Connections

Sliprings and brush gear

c. BEARINGS

d. SHAFT SEALS

The two pole generator is designed with direct hydrogen cooling of the rotor. The heat losses arising in the generator are dissipated to the secondary coolant (DMCW) through hydrogen.STATUS

Signatures

JPL BHEL








1.3

1.4

1.5

The Generator is provided with the following auxiliaries which are essential for generator operation.

They are

Bearing oil supply system

Seal oil systems

Gas Systems

Excitation System

Respective Testing Schedules / O & M manuals are to be referred for commissioning, operation and maintenance of these systems.

Technical Specification of Generator are given below.

Generator Type THRI 108/44 TOTALLY IMPREGNATED

Main Excitor Type ELR 70/62 30/6-10

Pilot Excitor Type ELP 50/29-30/16

Generator Apparent Power 294.1 MVA

Generator Active Power 250 MW

Current 10.291 KA

Voltage 16.5 KV + 825KV

Speed 3000 RPM

Freqency 50HZ

Power Factor 0.85 (Lag)

Hydrogen Pressure 4.0 kg/cm2 (g)

Rated Field Voltage 300 V

Rated Field Current 2497 A STATUS

Signatures

JPL BHEL








2.0

2.1

2.2

2.3

3.0

3.1

3.2

3.3

3.4

OBJECTIVE

The objective of the test is to ensure.

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.

PROPOSAL

The objective will be achieved through the following proposals.

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

Testing of pipe between Hydrogen Bottle rack and Hydrogen Unit at a pressure of 4.8 bar of Air 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.-NOT APPILICABLE TO JPL

Leakage Test of Generator along with Gas System using air at 4.0 bar for 72 Hrs

STATUS

Signatures

JPL BHEL








4.0

4.1

4.2

4.3

4.4

4.5

4.6

5.0

5.1

5.2

5.3

5.4SERVICES REQUIRED

Availability of Instrument air

Availability of Nitrogen gas- NOT APPILICABLE TO JPLAvailability 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

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.

Display of board No cutting/welding at all floors made

Portable fire extinguishers are available in the test area.

STATUS

Signatures

JPL BHEL








6.0

6.1

6.2

7.0

7.1

7.2

7.3

7.4

7.5

7.6

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 NOT APPLICABLE TO JPL

STATUS

Signatures

JPL BHEL








7.7

7.8

7.9

7.10

7.11

7.12

7.13

7.14

7.15

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.

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.

Signatures

JPL BHEL








7.16

7.17

8.0

8.1

8.2

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 pipelines 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 pipeline by Air to a Pr. Of _______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 pipelines on system after successful completion of test.

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 _____ 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

JPL BHEL








8.3

8.4

8.4.1

8.4.2

I

Testing of Pipe Between N2 Bottle Rack and P.W. Tank-NOT APPILICABLE TO JPLDisconnect 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.

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 ____ 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 ____ bar.

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

JPL BHEL








Ii

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.

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

JPL BHEL








Iii

IV

8.4.3

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

Where V = Loss of air in M3 at N.T.P./ 24 Hrs.

0.2694 = 273o K / 1013.25 m bar

Z = Duration of leakage test, Hrs.

VG = Generator volume, m3

P1 = Gauge Pressure within the system at beginning of leakage test, in m bar.

P2 = Gauge Pressure within the system at the end of leakage test, in m bar.

STATUS

Signatures

JPL BHEL








9.0

Pb1 = Barometer reading at beginning of leakage test, in m bar.

Pb2 = Barometer reading at the end of leakage test m bar.

T1 = Temperature of the gaseous atmosphere at beginning of leakage test 0C.

T2 = 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.

STATUS

Signatures

JPL BHEL





PROJECTM/S JINDAL POWER LIMITED (4 * 250 MW)

PROCEDUREGENERATOR AIR TIGHTNESS TEST




PROTOCOL ON THE GENERATOR AIR TIGHTNESS TEST The generator air tightness test of 250 MW TG, Unit no # 1 at O.P.Jindal Super Thermal Power Station, Tamnar, Raigarh was carried out between ___________ and ______________. The Chronological log of activities of the operations, quantity of chemicals added and test results obtained during the process are given in the annexure I.

The pressure at the start of activities was ________ kg/cm2 and the pressure at the end of activity was ________ kg/cm2. The loss in air (leakage rate) during this period was observed as ____________ m3, which is less than normal __________ m3 as desired. The readings at different intervals are attached as separate sheet.

The generator air tightness test was satisfactorily completed on ____________.

Signature:

BHEL JPL

BHARAT HEAVY ELECTRICALS LTD., POWER SECTOR WESTERN REGION_1242907340.bin

Documents

Gen Air Test