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NTPC

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

SEAL OIL SYSTEM

SIMHADRI

OBJECTIVE The Objective of this oil flushing is to ensure cleanliness of seal oil piping
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 m 3
SEAL OIL SPECIFICATIONS
MI < 100 ppm
MO < 100 ppm
TOTAL NO. OF DAYS : 20 days

NTPC

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

SEAL OIL SYSTEM

SIMHADRI

WHY SEAL OIL SYSTEM?

To prevent H 2 escape from Generator body by maintaining a continuous oil film between Generator body and Rotor journals at both the ends

escape from Generator body by maintaining a continuous oil film between Generator body and Rotor journals

NTPC

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

SEAL OIL SYSTEM

SIMHADRI

NTPC SIMHADRI SUPER THERMAL POWER PROJECT STAGE 2 (2X500MW) O&M – COMMISSIONING DEPARTMENT SEAL OIL SYSTEM
SEAL OIL SYSTEM CLEANING PROCESS SIMHADRI employed for effective cleaning of pipe lines.
SEAL OIL SYSTEM CLEANING PROCESS SIMHADRI employed for effective cleaning of pipe lines.

SEAL OIL SYSTEM

CLEANING PROCESS

SIMHADRI
SIMHADRI

employed for effective cleaning of pipe lines.

NTPC

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

SEAL OIL SYSTEM

Air Blowing

Cardboard Blasting

AIR BLOWING

SIMHADRI

Continuous flow of Air through the pipeline till no dust / loose foreign material comes
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 STAGE 2 (2X500MW) O&M – COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

SIMHADRI

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.
GEN SEAL OIL LINES CARD BLASTING DETAILS
SNO
DATE
START TIME
STOP TIME
PRESSURE
NO. OF
(KSC)
CARDS
LOCATION OF
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 H 2 side line flange
6 24.01.11
09.30
AM
09.38
AM
4.4
4
Valve rack H 2 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 STAGE 2 (2X500MW) O&M – COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

SIMHADRI

SIMPLIFIED DRAWING OF SEAL OIL SYSTEM

OIL SYSTEM SIMHADRI SIMPLIFIED DRAWING OF SEAL OIL SYSTEM SYSTEM COMPONENTS (AIR SIDE) • Seal Oil

SYSTEM COMPONENTS (AIR SIDE)

• Seal Oil Storage Tank

• Seal Oil Pumps ( 3X100%)2 AC & 1 DC

NTPC

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

SEAL OIL SYSTEM

• Seal Oil Coolers (2x100%)

Filters

Diff. Pressure Regulators ‘A1’ & ‘A2’

SIMHADRI

H 2 Side Seal Oil Circuit Seal Oil Tank Seal Oil Pump (1x100%) Seal Oil
H 2 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 STAGE 2 (2X500MW) O&M – COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

SEAL OIL SYSTEM

SIMHADRI

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

NTPC

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

SEAL OIL SYSTEM

SIMHADRI

DIFFERENTIAL PRESSURE REGULATOR • Gas pressure and the impulse oil pressure act in opposite directions.
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 STAGE 2 (2X500MW) O&M – COMMISSIONING DEPARTMENT

SIMHADRI

SEAL OIL SYSTEM

– COMMISSIONING DEPARTMENT SIMHADRI SEAL OIL SYSTEM PRESSURE EQUALISING VALVE • Separate pressure

PRESSURE EQUALISING VALVE

Separate pressure equalizing valves for TE & EE Seals, to control constant differential pressure between the Air side and the H 2 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 STAGE 2 (2X500MW) O&M – COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

SIMHADRI

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

DEPARTMENT SEAL OIL SYSTEM SIMHADRI • Setting of desired DP is done by corrosponding pre-loading of

NTPC

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

SEAL OIL SYSTEM

SIMHADRI

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.
• 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 70 o C.
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 STAGE 2 (2X500MW) O&M – COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

SIMHADRI

During the process oil flow is maintained in following manner

the process oil flow is maintained in following manner Filling & Flushing of H 2 Side
Filling & Flushing of H 2 Side Seal Oil Circuit • Open shut off valves
Filling & Flushing of H 2 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

Start & Stop Seal Oil pump 1 to bleed air from piping until H 2 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 H 2 Side circuit.

Keep one cooler in service

During the process oil flow is maintained in following manner

NTPC

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

SEAL OIL SYSTEM

SIMHADRI

Precautions during flushing • Ensure No leakages are there at flange joints, tapping joints etc
Precautions during flushing
Ensure No leakages are there at flange joints, tapping joints etc
Maintain Seal Oil Temperature around 60-70 o C
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/cm 2 .
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 STAGE 2 (2X500MW) O&M – COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

Completion Criteria

SIMHADRI

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 •
• 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 STAGE 2 (2X500MW) O&M – COMMISSIONING DEPARTMENT

SEAL OIL SYSTEM

Main bellows of DPRV A1,A2.

Filling & Operation of H 2 Side Circuit

SIMHADRI

During filling of Air Side, SOT gets simultaneously filled via float valve

Fill H 2 Side oil circuit, charge coolers & filters with oil

Charge coolers with Cooling water on both sides

• Start H 2 side Pump & stop to bleed air • With Pump running,
• Start H 2 side Pump & stop to bleed air
• With Pump running, perform venting of Pressure gauges, Reg. valve C
and Equalising valves.
Adjust nut of A1 valve so that Seal Oil pressure is 1.5kg/cm 2 at Seals.
Fill Air and adjust nut again to maintain 1.5kg/cm 2 above air pressure till
rated casing pressure value.

Setting of DPRV A1

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/cm 2 higher than

seal oil pressure.

NTPC

Setting of DPRV ‘C’

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

SEAL OIL SYSTEM

SIMHADRI

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

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

• This is adjusted after Setting completion of valve A1 & C • Purge out
• 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.

Setting of DPRV A2