Jindal Power Limited

O.P.J.S.T.P.P, Tamnar, Raigarh

Commissioning Department

Project OPJSTPP (4X600 MW), Tamnar

Procedure Generator Air Tightness Test
Purpose of Document For Execution/Information
Document No. JPL Reference No: Turbine/Comm./027

Prepared By - Reviewed By -
Rev No. 00
Dtd: Commissioning Commissioning Project

Name

Sign

Approved By :
HEAD – Steering Committee

Copy No:

Issued To:
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./027
Plant Area: Turbine

COMMISSIONING PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL. NO LIST OF CONTENTS

1.0 PLANT DETAILS

2.0 OBJECTIVE

3.0 PROPOSAL

4.0 SERVICES REQUIRED

5.0 SAFETY PERECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 COMPLETION CRITERIA

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./027
Plant Area: Turbine

COMMISSIONING PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO
STATUS

1.0 PLANT DETAILS

1.1 500 MW Generator consists of the following components.

a. STATOR

 Stator Frame
 End Shields
 Stator Core
 Stator winding
 Hydrogen coolers

b. ROTOR

 Rotor Shaft
 Rotor windings
 Rotor Retaining Rings
 Field Connections

c. BEARINGS

d. SHAFT SEALS

1.2 The two pole generator is designed with direct water cooling for the
stator winding, phase connectors and bushings and direct Hydrogen
cooling for rotor winding. Generator losses, such as iron losses,
windage losses and stray losses are also dissipated through hydrogen.
The generator frame is pressure – resistant, gastight and equipped with
major components mentioned above. The hydrogen coolers are
arranged vertically inside the turbine end stator end field.

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

1.4 They are

 Seal oil systems

 Gas Systems
 Primary Water System
 Excitation System

Respective Testing Schedules / O & M manuals are to be referred for

commissioning, operation and maintenance of these systems.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./027
Plant Area: Turbine

COMMISSIONING PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO
STATUS
1.5 Technical Specification of Generator are given below.
Generator Type THDF 115/59
Main Excitor Type ELR 70/90 – 30/6-20
Pilot Excitor Type ELP 50/42-30/16
Generator Apparent Power 588 MVA
Generator Active Power 500 MW
Current 16.166 KA
Voltage 21KV + 1.05KV
Speed 3000 RPM
Freqency 50HZ
Power Factor 0.85 (Lag)
Hydrogen Pressure 3.5 bar
Rated Field Voltage 340 V
Rated Field Current 4040 A

2.0 OBJECTIVE

The objective of the test is to ensure.

Gas tightness of gas pipe lines in assembled condition including valves

2.1
and instrumentation.

2.2 Gas tightness of various joints on generator stator, terminal bushings,

primary water system, hydrogen coolers etc.

2.3 Effectiveness of the seal oil system at operating pressure.

3.0 PROPOSAL

The objective will be achieved through the following proposals.

3.1
Testing of pipe between CO2 Bottle Rack and Hydrogen Unit at a
pressure of 4.8 bar of Nitrogen gas for 2 Hrs.

3.2 Testing of pipe between Hydrogen Bottle rack and Hydrogen Unit at a
pressure of 4.8 bar of Nitrogen gas for 2 Hrs.

3.3 Testing of Pipe between Nitrogen Bottle rack and P.W. Tank at a
pressure of 5.0 bar of Nitrogen gas for 2 Hrs.

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

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./027
Plant Area: Turbine

COMMISSIONING PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO STATUS

4.0 SERVICES REQUIRED

4.1 Availability of Instrument air

4.2 Availability of Nitrogen gas

4.3 Availability 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

4.4 Availability of man power with required tools

4.5 Availability of lighting/communication

4.6 Availability of Soap Solution for test.

5.0 SAFETY PRECAUTIONS

5.1 Debris in the test area cleared.

5.2 Approach/Stair Case/Platforms wherever required are made available.

5.3 Display of board “No cutting/welding” at all floors made

5.4 Portable fire extinguishers are available in the test area.

6.0 EMERGENCY PROCEDURES

6.1 The test team should be well aware of procedures to be adopted in

case of any abnormality in the activity.

6.2 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.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./027
Plant Area: Turbine

COMMISSIONING PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO
STATUS
7.0 STATE OF THE PLANT

Assembly of generator and fixing of end shields and manhole covers

7.1
completed.

7.2 Seal oil system commissioned and put into operation for continuous
running.

7.3 Assembly of gas system piping is completed.

7.4 Generator terminal bushings are connected.

7.5 H2 gas coolers not be charged with water.

7.6 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.

7.7 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

7.8
at MKG25 CP001.

7.9 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.

7.10 Soap solution kept ready to check the leakages during test.

7.11 All the instruments in gas system are mounted as per scheme.

7.12 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.

7.13 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.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./027
Plant Area: Turbine

COMMISSIONING PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO
STATUS
7.14 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.

7.15 Valves provided in gas impulse line for valve A1, A2 in seal Oil system
are opened.

7.16 Values MKG69 AA 504 and MKG69 AA 501 are opened to take dryers
in service.

7.17 Air leakage test done in stands still condition of generator.

8.0 METHOD

Testing of Pipe between CO2 Bottle Rack and H2 Unit

8.1 Disconnect pipe lines 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. Pressurise the pipe line by N2 gas to a Pr. Of 4.8 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 pipe lines 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
8.2
of this pipe line by a temporary flange. Pressurise this pipe by N2 gas
to a pressure of 4.8 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.

8.3 Testing of Pipe Between N2 Bottle Rack and P.W. Tank

Disconnect 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.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./027
Plant Area: Turbine

COMMISSIONING PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO
STATUS
8.4 Leakage Test of Generator along with Gas System using Air.

8.4.1 Air Filling in Generator Casing

Open valve MKG25 AA 501 and fill air in generator and gas piping upto
pressure of 4 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 4 bar.

8.4.2 Checks during Air Leakage Test

I 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.

 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.

II 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 RTD’s.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./027
Plant Area: Turbine

COMMISSIONING PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

SL.NO
STATUS
III 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.
IV 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.

8.4.3 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.

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
0
C.
9.0 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.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./027
Plant Area: Turbine

COMMISSIONING PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST

COMMISSIONING PROCEDURE FOR

GENERATOR AIR TIGHTNESS TEST
4X600MW, JPL, TAMNAR

Signatures

JPL BHEL