Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 1 of 12

Plant area: TURBO GENERATOR

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

Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 2 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST
SL.NO
1.0
1.1

STATUS
PLANT DETAILS
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.

Signatures
NTPC

BHEL

Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 3 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST
SL.NO

STATUS

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.
Technical Specification of Generator are given below.
Generator Type
THDF 115/59

1.5

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

Signatures
NTPC

BHEL

Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 4 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST
SL.NO
2.0

STATUS
OBJECTIVE
The objective of the test is to ensure.

2.1

Gas tightness of gas pipe lines in assembled condition including

valves 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
NTPC

BHEL

Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 5 of 12

Plant area: TURBO GENERATOR

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.

Signatures
NTPC

BHEL

Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 6 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST
SL.NO

STATUS

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.

7.0

STATE OF THE PLANT

7.1

Assembly of generator and fixing of end shields and manhole

covers 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.

Signatures
NTPC

BHEL

Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 7 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST
SL.NO

STATUS

7.7

Instrument air supply connected before valve MKG25 AA 501. Air

for filling should be free from moisture, oil and any mechanical
impurity.

7.8

Precision pressure gauge of class 0.6 for pressure measurement

fixed 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 pressuirsed 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.

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.

Signatures
NTPC

BHEL

Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 8 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST
SL.NO

STATUS

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.
8.2
Disconnect pipe lines at isolating flange Nos. 94 and 95. Blank
one end 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.

Signatures
NTPC

BHEL

Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 9 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST
SL.NO
8.3

STATUS
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.

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

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.

Signatures
NTPC

BHEL

Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 10 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST
SL.NO

STATUS
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.
If any leakage is observed the generator should be depressurised
and same should be attended and test should be repeated.

Ii

Record half hourly reading on the mercury manometer provided

in H2 unit for this test. Record ambient and generator temperature
as measured from RTDs.

Signatures
NTPC

BHEL

Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 11 of 12

Plant area: TURBO GENERATOR

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
P2

= Gauge Pressure within the system at beginning of

leakage test, in m bar.
= Gauge Pressure within the system at the end of
leakage test, in m bar.

Signatures
NTPC

BHEL

Station: NTPCRAMAGUNDAM

BHEL Ref No.PS-DC-202-500-0018

NTPC Ref no RGM1/TS/2/007

Sheet 12 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR AIR TIGHTNESS TEST
SL.NO

9.0

STATUS
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 0C.

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
NTPC

BHEL

PROCEDURE FOR GENERATOR AIR

TIGHTNESS TEST

PROJECT

M/S RAMAGUNDAM 500 MW

PROCEDURE

GENERATOR AIR TIGHTNESS TEST

PURPOSE OF
DOCUMET

FOR EXECUTION / INFORMATION

DOCUMENT

PS:TSX:183:00:03

Copy No:
Issued to :

00

KJ

MKS

KPTM

17.09.2003

Rev.No.

Prepared by

Reviewed by

Approved by

Date

BHARAT HEAVY ELECTRICALS LIMITED

PSSR/TECHNICAL SERVICES
474, Anna Salai, Nandanam,
Chennai 600 035.