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PS-DC-202-500-0019
RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018 Sheet 1 of 14
M
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF
P.W. SYSTEM FOR GENERATOR
SLNO
1.0
PLANT DETAILS
2.0
OBJECTIVE
3.0
PROPOSAL
4.0
SERVICES REQUIRED
5.0
SAFETY PERECAUTIONS
6.0
EMERGENCY PROCEDURE
7.0
8.0
METHOD
9.0
COMPLETION CRITERIA
10.0
APPENDICES
a) DRAWING
b) LOG SHEETS
PLANT DETAILS:
The Primary Water System (Stator water System) consists of the
following
1.1
1.2
2 Nos of filters.
1.3
1.4
1.5
Polishing Unit
1.6
1.7
1.8
Plant Item completion list for Mechanical, Electrical and C & I are
to be prepared at site.
1.9
Signatures
NTPC
BHEL
Sheet 3 of 14
STATUS
2.0
OBJECTIVES:
2.1
3.0
PROPOSAL:
3.1
4.0
SERVICES REQUIRED:
4.1
4.2
4.3
4.4
4.5
4.6
Signatures
NTPC
BHEL
4.8
5.0
SAFETY PRECAUTIONS:
5.1
5.2
5.3
6.0
EMERGENCY PROCEDURE:
6.1
6.2
6.3
Signatures
NTPC
BHEL
7.1
7.2
7.3
Power supply system for the pumps are commissioned and for
operation available.
7.4
7.5
7.6
7.7
7.8
7.9
Inlet and out let pipes from generator winding are disconnected
and generator winding by passed by temporary loop.
7.10
Inlet and outlet water pipe connections from terminal bushing are
disconnected and inter connected with temporary loop.
7.11
A fine wire mesh provided in the inlet flange joint of P.W. Tank.
Signatures
NTPC
BHEL
Sheet 6 of 14
STATUS
Orifice MKF 80 BP501 removed for flushing and to be restored
back after the completion of activity.
7.13
8.0
METHOD:
8.1.0
RINSING
The purpose of rinsing is to avoid the entry of any mechanical
impurity in the P.W. tank, because the primary water tank does
not have manhole and its mechanical cleaning is not possible.
8.1.1
PREPARATION
In the P.W. pump rack, the spool piece between the valve MKF
12AA501 and pump MKF12AP001 to be removed and valve
MKF12AA502 to be connected to drain. Similarly, the spool piece
after valve MKF80AA503 to be removed and the valve to be
connected to drain.
Make a check list of the items being removed indicating name of
the item, date of removal by whom removed. This list will be used
at the time of restoration. While restoring date of restoration will
be indicated against the item and will be signed by the restorer.
During the initial filling of DM water in P.W. tank, the following
valves to be kept closed.
MKF 82 AA 501
MKF 80 AA 503
MKF 12 AA 501
MKF 22 AA 501
MKF 83 AA 502
MKF 83 AA 501
MKF 80 AA 504
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BHEL
PROCESS
The rinsing is carried out in the following steps:
8.1.3
STEP I
After filling the tank, the valve MKF 12 AA 501 should be opened
and water is drained for the cleaning of the pump suction pipe
from the P.W. tank. This is repeated 2-3 times and then valve
MKF12AA501 should be closed.
8.1.4
STEP II
After filling the tank, the valve MKF83AA502, MKF83AA501,
MKF80AA504, MKF80AA503 should be opened so that the
recirculation line as well as the bushing supply lines are cleaned.
This step should be repeated 2-3 times and then the valves
MKF83AA502, MKF83AA501, MKF80AA504, MKF80AA503
should be closed.
8.1.5
STEP III
For cleaning the P.W. supply to generator P.W. inlet header, a
temporary connection is to be made between the P.W. supply line
and the P.W tank (ref. Fig.1). The P.W. tank is filled with D.M.
water and the valves MKF82AA501 and MKF80AA503 should be
opened for the cleaning of P.W. supply line. This step is repeated
2-3 times and the valves MKF82AA501 and MKF80AA503 should
be closed.
Signatures
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BHEL
8.2.1
PREPARATION
After the rinsing is over, the spool pieces after the valves
MKF12AA501 and MKF80 AA503 which were removed for rinsing
should be connected as per the schematic drawing.
8.2.2
PROCESS:
The process is carried out in the following stages.
8.2.3
8.2.4
Signatures
NTPC
BHEL
The fine wire mesh provided in the inlet line of P.W. tank at flange
joints is to be removed after 4 hours of pump running.
8.2.6
8.2.7
8.2.8
8.2.9
STAGE III
During this stage, all impulse lines for instruments and P.W. tank
are flushed.
8.2.10
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BHEL
8.3.0
8.3.1
Signatures
NTPC
BHEL
Pre-requisite
Before performing the pressure test of primary water system, the
completion of following works should be ensured:
i)
ii)
iii)
iv)
v)
8.3.3
ii)
P.W collers
iii)
Signatures
NTPC
BHEL
Sheet 12 of 14
STATUS
iv)
Filters.
v)
8.3.4
ii)
Signatures
NTPC
Station: NTPCBHEL Ref No.PS-DC-202-500-0019
RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018
M
Plant area: TURBINE
BHEL
Sheet 13 of 14
8.3.5
STATUS
2
iii)
iv)
v)
vi)
Normalisation of System
On completion of pressure test the system is normalized as
follows:
i)
ii)
iii)
iv)
v)
vi)
Signatures
NTPC
BHEL
9.0
vii)
viii)
ix)
COMPLETION CRITERIA:
Flushing of P.W. system for Generator declared completed when
the filter remains in clean condition after 8 hours of operation.
Half hourly P.W. outlet sample conductivity is almost steady for at
least three consecutive readings.
Signatures
NTPC
BHEL
LOG SHEET
P.W PUMP NO. 1 / 2
Oil temperature
Sl.No
Date/Time
Pump Dis.Pr.
Bef.
Cooler
After
Cooler
Thermal
Shock
Remarks
Signatures
NTPC
BHEL
PROJECT
PROCEDURE
PURPOSE OF
DOCUMET
DOCUMENT
PS:TSX:181:00:03
Copy No:
Issued to :
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KJ
MKS
KB
08.09.2003
Rev.No.
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Reviewed by
Approved by
Date