Gen Seal Oil Sys

Station: NTPC Simhadri
BHEL Ref No. PS-DC-186-500-0006

NTPC Ref No. SIM/1/TS/2/005
Sheet 1 of 20
Plant area : TURBINE

PROCEDURE FOR HYDRAULIC TEST AND OIL FLUSHING OF GENERATOR
SEAL OIL SYSTEM
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
Sheet 2 of 20

SEAL OIL SYSTEM
Sl. No.
STATUS
1.0
PLANT DETAILS
1.1
Generators cooled by H2 are provided with seal

oil system for preventing the leakage of H 2 to
atmosphere for the formation of explosive
mixture and to reduce the consumption of H2.
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
Sheet 3 of 20

SEAL OIL SYSTEM
Sl. No.
STATUS
2.0
OBJECTIVE
The objective of this oil flushing is to ensure the

cleanliness of seal oil piping before connecting it
to the various racks of seal oil system.
Signatures
NTPC
BHEL
Sheet 4 of 20

SEAL OIL SYSTEM
Sl. No.
STATUS
3.0
TESTING PROPOSAL
The oil flushing of Seal Oil System is proposed

to be carried out in two stages.
3.1
Stage I Oil Flushing of Seal Oil Piping (Seal Oil

rack excluded)
The oil flushing is carried out by taking the lub oil
from lub oil supplu line near bearing No.4 as
shown in enclosed circuit.
The oil flushing is carried out in two parts.
PART I : includes seal oil air side supply pipe
line and ring relief supply pipe lines.
PART II : includes the seal oil H2 side supply
pipe line.
Stage II Oil Flushing of Seal Oil System
including the various components of Seal Oil
rack and the system piping.
3.2
During flushing thermal shocks on seal oil is

given Refer Procedure for Hydraulic test and
flushing of Turbine lub-oil and Jacking Oil
System. BHEL Ref.No.PS-DC-186-500-0004
(NTPC.Ref.No. SIM/1/TS/2/001)
All weld joints should be hammered to
remove any loose weld slag.
Signatures
NTPC
BHEL
Sheet 5 of 20

SEAL OIL SYSTEM
Sl. No.
STATUS
4.0
SERVICES REQUIRED
4.1
Availability of Electrical heating arrangement for heating the

CW to turbine oil cooler for thermal shock operation during
oil flushing.
4.2
Availability of laboratory facility for analysis of oil sample.
4.3
Availability of service air and thinner/petrol for filter

cleaning.
4.4
Availability of sufficient skilled manpower for supervision /

execution of the process.
4.5
Availability of required quantity of Turbine oil
4.6
Availability of portable fire extinguishen at oil flushing area.
4.7
Availability of proper lighting and communication facility.
Signatures
NTPC
BHEL
Sheet 6 of 20

SEAL OIL SYSTEM
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
Sheet 7 of 20

SEAL OIL SYSTEM
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.
They shall be aware of how to act in case of any
personal injuries.
6.3
They shall know to stop the pumps quickly in

case of any leakage and then inform the
concerned higher official.
6.4
They shall be aware of re-establishing the

operation in case of system stoppage due to
failure of power supply.
6.5
Signatures
NTPC
BHEL
Sheet 8 of 20

SEAL OIL SYSTEM
Sl. No.
STATUS
7.0
STATE OF THE PLANT
7.1
Before starting the flushing, the completion of

following jobs should be ensured.
7.1.1
Erection of interconnected piping is completed.
7.1.2
Provide temporary connection wherever required

as per enclosed circuit.
7.1.3
The temporary pipes should be acid cleaned and

neutralised before installation.
7.1.4
Ensure that flange joints are tightened with

gasket in position.
7.1.5
The pressure regulating valve MKW 73 AA 011

and MKW 73 AA 021 have been removed and
spool pieces have been placed.
Signatures
NTPC
BHEL
Sheet 9 of 20

SEAL OIL SYSTEM
Sl. No.
STATUS
7.1.6
Erection of seal oil pump unit, seal oil unit, seal

oil valve rack, measuring instrument rack, seal
oil storage tank and interconnected pipings is
completed.
7.1.7
Physical cleaning of seal oil storage tank and

seal oil tank.
7.1.8
Availability of power and control supply for

motors and starting panels.
7.1.9
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.
H2 side seal oil pump motor (AC)
1 no.
c.
7.1.10
Disconnect air side seal oil inlet pipes at the seal

body on both sides of generator and connect it to
bearing drains by a temporary piping.
Signatures
NTPC
BHEL
Sheet 10 of 20

SEAL OIL SYSTEM
Sl. No.
STATUS
7.1.12
Disconnect H2 side seal oil inlet and outlet pipes

at seal body on both sides of generator and
interconnect it by a temporary piping.
7.1.13
Disconnect ring relief oil inlet pipe at seal body

on both sides of generator and interconnect by a
temporary piping into air side seal oil drain pipes.
7.1.14
Take out both float valves from seal oil tank.

MKW 03BB001.
7.1.15
Keep the springs of regulating valves A1, A2 and

C at completely released condition.
7.1.16
Make necessary arrangement for heating seal oil

upto 65 70oC during oil flushing process.
7.1.17
Fire fighting system of TG Lub-oil and generator Seal

oil system made available before commencement of
flushing.
7.1.18
Acid cleaning of pipe line normally not envisaged.

However, if traces of pitting observed in any of the
pipe line, acid cleaning of the pipe line to be carried
out
(Refer
Procedure
No.PS-DC-186-5000013B/NTPC Ref.No.SIM/1/TS/2/001 for acid
cleaning)
Signatures
NTPC
BHEL
Sheet 11 of 20
SEAL OIL SYSTEM
Sl. No.
STATUS
8.0
METHOD
Seal oil system is filled with oil by taking the oil
supply from seal oil storage tank. To ensure oil
level in seal oil storage tank, lub oil pump should
be kept running during this process or oil should
be filled manually in this tank. Seal oil system is
filled up in two stages as follows (ensure that all
shut off and gate valves are closed).
Signatures
NTPC
BHEL
Sheet 12 of 20

SEAL OIL SYSTEM
Sl. No.
8.1
8.1.1
STATUS
FILLING OF AIR SIDE SEAL OIL CIRCUIT

Open following shut off and gate valves in air
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
Sheet 13 of 20

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
Sheet 14 of 20

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
Sheet 15 of 20

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
Sheet 16 of 20

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.
ii.
iii.
8.4.1
Flushing of air side circuit

Flushing of H2 side circuit
Flushing of oil impulse lines
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
Sheet 17 of 20

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 65-70 0C.
8.4.6
Give thermal stocks as done in Turbine lub oil

system flushing. (Refer Procedure PS-DC_186500-0004/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

Sheet 18 of 20

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
Sheet 19 of 20

SEAL OIL SYSTEM
Sl. No.
STATUS
9.0
COMPLETION CRITERIA
Oil flushing for each stage may be declared
completed on the following basis.
No foreign particle and material present at

thefiltering elements after 24 hours of
flushing.
Moisture content in return oil should be less

than 0.01% (100 ppm) and mech. Impurities
should be less than 0.01% (100 ppm). For
lab analysis of oil samples for mechanical
impurities, filter of size 0.45 micron shall be
used.
Signatures
NTPC
BHEL
Sheet 20 of 20
SEAL OIL PUMP NO. 1 / 2
Oil temperature
Sl.No
Date/Time
Pump Dis.Pr.
Bef.
Cooler
After
Cooler
Thermal
Shock
Signatures
NTPC
BHEL
Remarks
PROCEDURE FOR HYDRAULIC TEST AND OIL

FLUSHING OF GENERATOR SEAL OIL SYSTEM

Gen Seal Oil Sys

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Station: NTPC Simhadri

BHEL Ref No. PS-DC-186-500-0006

Plant area : TURBINE

STATE OF THE PLANT

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-500-0006

NTPC Ref No. SIM/1/TS/2/005

Generators cooled by H2 are provided with seal

This system consists of tank, pumps, (Both

DC pump is meant to supply oil to the seals

For Technical Specifications, the respective O & M

The drawings enclosed at section 10.0 are

Schematic for oil flushing of Seal Oil Piping.

Control Value rack of Seal Oil System.

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-500-0006

NTPC Ref No. SIM/1/TS/2/005

The objective of this oil flushing is to ensure the

Station: NTPC Simhadri

BHEL Ref No. PS-DC-186-500-0006

NTPC Ref No. SIM/1/TS/2/005

The oil flushing of Seal Oil System is proposed

Stage I Oil Flushing of Seal Oil Piping (Seal Oil

During flushing thermal shocks on seal oil is

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-500-0006

NTPC Ref No. SIM/1/TS/2/005

Availability of Electrical heating arrangement for heating the

Availability of laboratory facility for analysis of oil sample.

Availability of service air and thinner/petrol for filter

Availability of sufficient skilled manpower for supervision /

Availability of required quantity of Turbine oil

Availability of portable fire extinguishen at oil flushing area.

Availability of proper lighting and communication facility.

Station: NTPC Simhadri

BHEL Ref No. PS-DC-186-500-0006

NTPC Ref No. SIM/1/TS/2/005

Readiness of stair cases, platforms, hand rails for Seal Oil

Safety and protection equipments like hand gloves, helmet etc

Precautions taken to avoid spillage of oil and contamination of

Service water source available near the activity area.

Buckels containing sand are available at process area.

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

Provision for emergency stopping of oil pumps from local/UCB

Cordoning of lub-oil flushing area wherever required.

Display of caution sign boards, danger tags are provided at

Round the clock monitoring of oil flushing activity.

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-500-0006

NTPC Ref No. SIM/1/TS/2/005

The teams for this operation shall be aware of

They shall be aware of operation of fire

They shall know to stop the pumps quickly in

They shall be aware of re-establishing the

Station: NTPC - Simhadri

BHEL Ref No. PS-DC-186-500-0006

NTPC Ref No. SIM/1/TS/2/005

STATE OF THE PLANT

Before starting the flushing, the completion of

Erection of interconnected piping is completed.

Provide temporary connection wherever required

The temporary pipes should be acid cleaned and

Ensure that flange joints are tightened with