PLANT AREA: TG
PS-WR
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
8.0
METHOD
9.0
COMPLETION CRITERIA
COMMISSIONING PROTOCOL
4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR,
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG
PS-WR
STATUS
PLANT DETAILS
250 MW Generator consists of the following components.
a. STATOR
Stator Frame
End Shields
Stator Core and winding assembly
Baffle and labyrinth rings
Terminal bushings
Hydrogen coolers
b. ROTOR
Rotor Shaft
Rotor windings
Rotor Retaining Rings
Field Connections
Sliprings and brush gear
c. BEARINGS
d. SHAFT SEALS
1.2
The two pole generator is designed with direct hydrogen cooling of the
rotor. The heat losses arising in the generator are dissipated to the
secondary coolant (DMCW) through hydrogen.
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4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR,
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG
PS-WR
The Generator is provided with the following auxiliaries which are essential
for generator operation.
1.4
They are
Bearing oil supply system
Seal oil systems
Gas Systems
Excitation System
Respective Testing Schedules / O & M manuals are to be referred for
commissioning, operation and maintenance of these systems.
1.5
ELP 50/29-30/16
294.1 MVA
250 MW
Current
10.291 KA
Voltage
16.5 KV + 825KV
Speed
3000 RPM
Freqency
50HZ
Power Factor
0.85 (Lag)
Hydrogen Pressure
300 V
2497 A
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JPL
BHEL
STATUS
COMMISSIONING PROTOCOL
4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR,
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG
PS-WR
OBJECTIVE
STATUS
2.2
2.3
3.0
PROPOSAL
The objective will be achieved through the following proposals.
3.1
3.2
3.3
3.4
Leakage Test of Generator along with Gas System using air at 4.0 bar
for 72 Hrs
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BHEL
COMMISSIONING PROTOCOL
4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR,
RAIGARH
PS-WR
SERVICES REQUIRED
4.1
4.2
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
4.5
Availability of lighting/communication
4.6
5.0
SAFETY PRECAUTIONS
5.1
5.2
5.3
5.4
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BHEL
COMMISSIONING PROTOCOL
4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR,
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG
PS-WR
STATUS
6.0
6.1
6.2
7.0
7.1
7.2
Seal oil system commissioned and put into operation for continuous
running.
Assembly of gas system piping is completed.
7.3
Generator terminal bushings are connected.
7.4
H2 gas coolers not be charged with water.
7.5
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 NOT
APPLICABLE TO JPL
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PS-WR
7.8
7.9
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
at MKG25 CP001.
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
7.11
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
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.
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PS-WR
Values MKG69 AA 504 and MKG69 AA 501 are opened to take dryers
in service.
7.17
8.0
METHOD
8.1
8.2
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4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR,
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PS-WR
8.4
8.4.1
8.4.2
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, H 2 coolers etc.
Gas piping welding joints and flanged joints.
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COMMISSIONING PROTOCOL
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RAIGARH
PS-WR
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PS-WR
IV
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.
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.
Calculation of Leakage Rate
8.4.3
273+T1
273 + T2
VG
= Generator volume, m3
P1
P2
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COMMISSIONING PROTOCOL
4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR,
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG
PS-WR
COMPLETION CRITERIA
9.0
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
STATUS
COMMISSIONING PROTOCOL
4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR,
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG
PS-WR
PROJECT
PROCEDURE
COMMISSIONING PROTOCOL
4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR,
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG
PS-WR
Signature:
BHEL
JPL
BHARAT HEAVY ELECTRICALS LTD., POWER SECTOR WESTERN REGION