Seal Oil Initial

Station: NTPC – Simhadri BHEL Ref No.
PS-DC-186-500- Sheet 1 of 20
0006A
NTPC Ref No. SIM/1/TS/2/005 A
Plant area : TURBINE
PROCEDURE FOR GENERATOR SEAL OIL INTIAL CIRCULATION
Sl. No.
1.0 PLANT DETAILS
2.0 OBJECTIVE
3.0 PROPOSALS
4.0 SERVICES REQUIRED
5.0 SAFETY PRECAUTIONS
6.0 EMERGENCY PROCEDURE
7.0 STATE OF THE PLANT
8.0 METHOD
9.0 COMPLETION CRITERIA
10.0 APPENDICES
a) Drawing
b) Log Sheets
Station: NTPC - Simhadri BHEL Ref No. PS-DC-186-500-0006 Sheet 2 of 20
NTPC Ref No. SIM/1/TS/2/005
Sl. No. STATUS
1.0 PLANT DETAILS
1.1 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 H 2.
1.2 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.
1.3 DC pump is meant to supply oil to the seals

during the failure of AC power supply during
emergency conditions.
1.4 For Technical Specifications, the respective O & M
manuals are to be referred.
1.5 The drawings enclosed at section 10.0 are
a) Schematic for oil flushing of Seal Oil Piping.

Drg.No. 4:PS:TSX:0063:00
b) Control Value rack of Seal Oil System.

Drg.No.4:PS:TSX:0064:00
Signatures
NTPC BHEL
Sl. No. STATUS
2.0 OBJECTIVE
To commission the seal oil system and establish

the oil flow through the generator seals.
Signatures
NTPC BHEL
Station: NTPC – Simhadri BHEL Ref No. PS-DC-186-500-0006 Sheet 4 of 20
Sl. No. STATUS
3.0 PROPOSAL
Commissioning of seal oil system is carried out in
the following stages:
1) Filling and operation of air side seal oil

circuit.
2) Filling and operation of H2 side seal oil
circuit
3) Setting of seal oil pressures.
4) Checking of functioning of pressure
switches and level detectors.
5) Measurement of seal oil flow.
Signatures
NTPC BHEL
Sl. No. STATUS
4.0 SERVICES REQUIRED
4.1 Restoration of oil piping and normalization after oil flushing.
4.2 Filling of seal oil storage tank with fresh oil and running of
Availability of service air and thinner/petrol for filter
cleaning.
4.3 Availability of sufficient skilled manpower for supervision /

execution of the process.
4.4 Availability of portable fire extinguishen at oil flushing area.
4.5 Availability of proper lighting and communication facility.
Signatures
NTPC BHEL
Sl. No. STATUS
5.0 SAFETY PRECAUTIONS:
5.1 Readiness of stair cases, platforms, hand rails for Seal Oil
Tank and required approaches as decided at site are made
available.
5.2 Safety and protection equipments like hand gloves, helmet etc
are available during the process.
5.3 Precautions taken to avoid spillage of oil and contamination of

oil.
5.4 Service water source available near the activity area.
5.5 Ensure the availability of first aid kit near the process area.
5.6 Buckels containing sand are available at process area.
5.7 Welding/cutting shall not be carried out in lub-oil flushing

areas, once oil has been filled in Seal Oil Tank.
5.8 Load on Pumps shall not exceed full load current of the motor.
5.9 Provision for emergency stopping of oil pumps from local/UCB

has to be made.
5.10 Cordoning of lub-oil flushing area wherever required.
5.11 Display of caution sign boards, danger tags are provided at

locations in the test area.
5.12 Round the clock monitoring of oil flushing activity.
Signatures
NTPC BHEL
Sl. No. STATUS
6.0 EMERGENCY PROCEDURES:
6.1 The teams for this operation shall be aware of

the procedure of oil flushing and act at the time
of any emergency.
6.2 They shall be aware of operation of fire

extinguishers.
6.3 They shall be aware of how to act in case of any

personal injuries.
6.4 They shall know to stop the pumps quickly in

case of any leakage and then inform the
concerned higher official.
6.5 They shall be aware of re-establishing the

operation in case of system stoppage due to
failure of power supply.
Signatures
NTPC BHEL
Sl. No. STATUS
7.0 STATE OF THE PLANT
7.1 Restoration of oil piping and normalization after oil

flushing.
7.1.1 Verification of logic and control scheme of seal oil

pumps as per control diagram.
7.1.2 Filling of seal oil storage tank with fresh oil and
running of Availability of service air and thinner/petrol
for filter cleaning.
7.1.3 Availability of sufficient skilled manpower for

supervision / execution of the process.
7.1.4 Ensure the cleanliness of both filters provided in air

side and H2 side seal oil circuit.
7.1.5 Ensure that all the shut off and gate valves are
closed.
7.1.6 Loosening of spring of pressure regulating valves
A1,A2 and C to ensure these are in fully open
condition.
Signatures
NTPC BHEL
PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR
SEAL OIL SYSTEM
Sl. No. STATUS
7.1.6 Physical cleaning of seal oil storage tank and

seal oil tank after flushing.
7.1.7 Availability of power and control supply for

motors and starting panels.
7.1.8 Trial run of following motors and coupled with

respective pumps.
a. Air side seal oil pump motor (AC) 2 nos.
b. Emergency air side seal

oil pump motor (DC) 1 no.
c. H2 side seal oil pump motor (AC) 1 no.
Signatures
NTPC BHEL
SEAL OIL SYSTEM
Sl. No. STATUS
Signatures
NTPC BHEL
Station: NTPC - Simhadri BHEL Ref No. PS-DC-186-500-0006
Sheet 11 of 20
SEAL OIL SYSTEM
Sl. No. STATUS
8.0 METHOD
8.1 FILLING AND OPERATION OF AIR SIDE SEAL OIL

CIRCUIT:
Signatures
NTPC BHEL
SEAL OIL SYSTEM
Sl. No. STATUS
8.1 FILLING OF AIR SIDE SEAL OIL CIRCUIT

Open following shut off and gate valves in air
8.1.1
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}
Signatures
NTPC BHEL
SEAL OIL SYSTEM
Sl. No. STATUS
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.
8.1.3 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.
8.1.4 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.
8.1.5 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.
Signatures
NTPC BHEL

SEAL OIL SYSTEM
Sl. No. STATUS
8.2 FILLING OF H2 SIDE SEAL OIL CIRCUIT
8.2.1 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.
8.2.2 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
Signatures
NTPC BHEL

SEAL OIL SYSTEM
Sl. No. STATUS
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.
8.2.4 Charge both seal oil filters as done in case of

coolers and keep one filter in service.
8.2.5 Loosen the adjusting nut of pressure equalising

valve MKW73 AA 021.
8.2.6 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.
8.2.7 Hydraulic test of the seal oil piping (excluding

rack) shall be carried out at a pressure of 12
kg./cm2.
Signatures
NTPC BHEL
SEAL OIL SYSTEM
Sl. No. STATUS
8.4.0 OIL FLUSHING OF SYSTEM
Oil flushing of seal oil circuit is carried out in

three different stages.
i. Flushing of air side circuit

ii. Flushing of H2 side circuit
iii. 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.
Signatures
NTPC BHEL
SEAL OIL SYSTEM
Sl. No. STATUS
8.4.2 Flushing of H2 side Seal Oil Circuit. Flushing of

this circuit is carried out by H 2 side seal oil pump
provided in the system. During this process, oil
flow is maintained through H 2 side seal oil cooler,
filter, valve ‘C’, Inlet H2 side seal oil pipes, H2
side drain pipes, prechambers, seal oil tank.
8.4.3 Flushing of Oil Impulse Lines
Flushing of all oil impulse lines provided in the

system for various pressure gauages, 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.
8.4.4 During flushing ensure that there is no oil leak in

the system. If leaks are observed stop flushing
and attend to the leaks.
8.4.5 Maintain oil temperature around 65-700C.
8.4.6 Give thermal stocks as done in Turbine lub oil

system flushing. (Refer Procedure PS-DC_186-
500-0004/NTPC Ref No. SIM/1/TS/2/001)
8.4.7 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
markin cloth.
Signatures
NTPC BHEL

SEAL OIL SYSTEM
Sl. No. STATUS
c) Clean and dry the filter with compressed air.

(Air pressure to be reduced sufficiently for air
blowing filter)
8.4.8 Take sample of return oil and analyses if for the

presence of moisture & mechanical impurities.
8.4.9 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 On completion of oil flushing:
8.5.1 Drain the entire system.
8.5.2 Remove the temporary piping and restore

original connections.
8.5.3 Remove the blanks provided, if any.
8.5.4 Connect back the impulse lines.
8.5.5 Reassemble the float valves MKWO3 AA 001

and AA 002 in seal oil tank.
8.5.6 Clean both the filters and reassemble.
Signatures
NTPC BHEL

SEAL OIL SYSTEM
Sl. No. STATUS
9.0 COMPLETION CRITERIA
The charging of seal oil system is said to be

completed once the oil flow is established
through both sides of the generator seals and
the pressure regulators are put in to service.
Signatures
NTPC BHEL
Sheet 20 of 20
SEAL OIL PUMP NO. 1 / 2
Oil temperature
Thermal
Sl.No Date/Time Pump Dis.Pr. Bef. After Remarks
Shock
Cooler Cooler
Signatures
NTPC BHEL
PROCEDURE FOR HYDRAULIC TEST AND OIL
FLUSHING OF GENERATOR SEAL OIL SYSTEM

Seal Oil Initial

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Station: NTPC – Simhadri BHEL Ref No.

PROCEDURE FOR GENERATOR SEAL OIL INTIAL CIRCULATION

1.0 PLANT DETAILS

4.0 SERVICES REQUIRED

5.0 SAFETY PRECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STATE OF THE PLANT

9.0 COMPLETION CRITERIA

Sl. No. STATUS

1.0 PLANT DETAILS

1.1 Generators cooled by H2 are provided with seal

1.2 This system consists of tank, pumps, (Both

1.3 DC pump is meant to supply oil to the seals

1.5 The drawings enclosed at section 10.0 are

a) Schematic for oil flushing of Seal Oil Piping.

b) Control Value rack of Seal Oil System.

Sl. No. STATUS

To commission the seal oil system and establish

Sl. No. STATUS

1) Filling and operation of air side seal oil

Sl. No. STATUS

4.0 SERVICES REQUIRED

4.1 Restoration of oil piping and normalization after oil flushing.

4.3 Availability of sufficient skilled manpower for supervision /

4.4 Availability of portable fire extinguishen at oil flushing area.

4.5 Availability of proper lighting and communication facility.

Sl. No. STATUS

5.0 SAFETY PRECAUTIONS:

5.3 Precautions taken to avoid spillage of oil and contamination of

5.4 Service water source available near the activity area.

5.6 Buckels containing sand are available at process area.

5.7 Welding/cutting shall not be carried out in lub-oil flushing

5.9 Provision for emergency stopping of oil pumps from local/UCB

5.10 Cordoning of lub-oil flushing area wherever required.

5.11 Display of caution sign boards, danger tags are provided at

5.12 Round the clock monitoring of oil flushing activity.

Sl. No. STATUS

6.0 EMERGENCY PROCEDURES:

6.1 The teams for this operation shall be aware of

6.2 They shall be aware of operation of fire

6.3 They shall be aware of how to act in case of any

6.4 They shall know to stop the pumps quickly in

6.5 They shall be aware of re-establishing the

Sl. No. STATUS

7.0 STATE OF THE PLANT

7.1 Restoration of oil piping and normalization after oil

7.1.1 Verification of logic and control scheme of seal oil

7.1.3 Availability of sufficient skilled manpower for

7.1.4 Ensure the cleanliness of both filters provided in air

Sl. No. STATUS

7.1.6 Physical cleaning of seal oil storage tank and

7.1.7 Availability of power and control supply for

7.1.8 Trial run of following motors and coupled with

a. Air side seal oil pump motor (AC) 2 nos.

b. Emergency air side seal

c. H2 side seal oil pump motor (AC) 1 no.

Sl. No. STATUS

Sl. No. STATUS

8.1 FILLING AND OPERATION OF AIR SIDE SEAL OIL

Sl. No. STATUS

8.1 FILLING OF AIR SIDE SEAL OIL CIRCUIT

MKW 01 AA 503 At seal oil storage tank

Sl. No. STATUS