Gen Air Test

COMMISSIONING PROTOCOL
4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR,

RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG
Station: JPL - RAIGARH

OPJSTPP (4X250MW)
PS-WR
PROCESS: GENERATOR AIR TIGHTNESS TEST
BHEL Ref No. _____________________

Sheet 1 of 12
JPL Ref no ________________________
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
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG

OPJSTPP (4X250MW)
PS-WR
BHEL Ref No. _____________________

Sheet 2 of 12
JPL Ref no ________________________

SL.NO
1.0
1.1
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.
Signatures
JPL
BHEL
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG

OPJSTPP (4X250MW)
PS-WR
BHEL Ref No. _____________________

Sheet 3 of 12
JPL Ref no ________________________

1.3
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
Technical Specification of Generator are given below.

Generator Type
THRI 108/44 TOTALLY IMPREGNATED
Main Excitor Type
ELR 70/62 30/6-10
Pilot Excitor Type
ELP 50/29-30/16
Generator Apparent Power
294.1 MVA
Generator Active Power
250 MW
Current
10.291 KA
Voltage
16.5 KV + 825KV
Speed
3000 RPM
Freqency
50HZ
Power Factor
0.85 (Lag)
Hydrogen Pressure
4.0 kg/cm2 (g)
Rated Field Voltage
300 V
Rated Field Current
2497 A
Signatures
JPL
BHEL
STATUS
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG

OPJSTPP (4X250MW)
PS-WR
BHEL Ref No. _____________________

Sheet 4 of 12
JPL Ref no ________________________

2.0
OBJECTIVE
STATUS
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 Air for 2 Hrs.
3.2
Testing of pipe between Hydrogen Bottle rack and Hydrogen Unit at a

pressure of 4.8 bar of Air 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.-NOT APPILICABLE TO
JPL
3.4
Leakage Test of Generator along with Gas System using air at 4.0 bar
for 72 Hrs
Signatures
JPL
BHEL
RAIGARH
PS-WR
UNIT UNIT NO. 1

PLANT AREA: TG
BHEL Ref No. _____________________
OPJSTPP (4X250MW)
Sheet 5 of 12
JPL Ref no ________________________
STATUS
4.0
SERVICES REQUIRED
4.1
Availability of Instrument air
4.2
Availability of Nitrogen gas- NOT APPILICABLE TO JPL
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
5.4
Display of board No cutting/welding at all floors made

Portable fire extinguishers are available in the test area.
Signatures
JPL
BHEL
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG

OPJSTPP (4X250MW)
PS-WR
BHEL Ref No. _____________________

Sheet 6 of 12
JPL Ref no ________________________

EMERGENCY PROCEDURES
STATUS
6.0
6.1
6.2
The test team should be well aware of procedures to be adopted in

case of any abnormality in the activity.
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.
STATE OF THE PLANT
7.0
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.
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
Signatures
JPL
BHEL
RAIGARH
PS-WR
UNIT UNIT NO. 1

PLANT AREA: TG
BHEL Ref No. _____________________
OPJSTPP (4X250MW)
Sheet 7 of 12
JPL Ref no ________________________
7.7
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
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.
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
JPL
BHEL
RAIGARH
PS-WR
UNIT UNIT NO. 1

PLANT AREA: TG
BHEL Ref No. _____________________
OPJSTPP (4X250MW)
Sheet 8 of 12
JPL Ref no ________________________
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
8.1
Testing of Pipe between CO2 Bottle Rack and H2 Unit

Disconnect pipelines 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. Pressurize the pipeline by Air to a Pr. Of _______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 pipelines on system after successful completion of
test.
8.2
Testing of Pipe between H2 Bottle Rack and H2 Unit.

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 _____ 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
JPL
BHEL
STATUS
RAIGARH
PS-WR
UNIT UNIT NO. 1

PLANT AREA: TG
BHEL Ref No. _____________________
OPJSTPP (4X250MW)
Sheet 9 of 12
JPL Ref no ________________________
8.3
Testing of Pipe Between N2 Bottle Rack and P.W. Tank-NOT STATUS

APPILICABLE TO JPL
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
8.4.1
Leakage Test of Generator along with Gas System using Air.

Air Filling in Generator Casing
Open valve MKG25 AA 501 and fill air in generator and gas piping upto
pressure of ____ Bar. During filling observe the performance of
pressure regulating valve of seal oil system and maintain the H 2 and air
side seal oil Pressure as recommended. Close valve MKG25 AA 501 as
soon as pressure in the casing reaches ____ bar.
Checks during Air Leakage Test
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.
Signatures
JPL
BHEL
RAIGARH
PS-WR
UNIT UNIT NO. 1

PLANT AREA: TG
BHEL Ref No. _____________________
OPJSTPP (4X250MW)
Sheet 10 of 12
JPL Ref no ________________________
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 H 2

unit for this test. Record ambient and generator temperature as
measured from RTDs.
Signatures
JPL
BHEL
STATUS
RAIGARH
PS-WR
UNIT UNIT NO. 1

PLANT AREA: TG
BHEL Ref No. _____________________
OPJSTPP (4X250MW)
Sheet 11 of 12
JPL Ref no ________________________
Iii
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
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
= 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
JPL
BHEL
STATUS
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG

OPJSTPP (4X250MW)
PS-WR
BHEL Ref No. _____________________

Sheet 12 of 12
JPL Ref no ________________________

Pb1
Pb2
T1
T2
= Barometer reading at beginning of leakage test, in m bar.

= Barometer reading at the end of leakage test m bar.
=
Temperature of the gaseous atmosphere at beginning of

leakage test 0C.
= Temp. of the gaseous atmosphere at end of leakage Test 0C.
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
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG
PS-WR
PROJECT
M/S JINDAL POWER LIMITED (4 * 250 MW)
PROCEDURE
GENERATOR AIR TIGHTNESS TEST
RAIGARH
UNIT UNIT NO. 1
PLANT AREA: TG
PS-WR
PROTOCOL ON THE GENERATOR AIR TIGHTNESS TEST

The generator air tightness test of 250 MW TG, Unit no # 1 at O.P.Jindal Super Thermal
Power Station, Tamnar, Raigarh was carried out between ___________ and
______________. The Chronological log of activities of the operations, quantity of
chemicals added and test results obtained during the process are given in the annexure I.
The pressure at the start of activities was ________ kg/cm2 and the pressure at the end of
activity was ________ kg/cm2. The loss in air (leakage rate) during this period was
observed as ____________ m3, which is less than normal __________ m3 as desired.
The readings at different intervals are attached as separate sheet.
The generator air tightness test was satisfactorily completed on ____________.
Signature:
BHEL
JPL
BHARAT HEAVY ELECTRICALS LTD., POWER SECTOR WESTERN REGION

Gen Air Test

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COMMISSIONING PROTOCOL

4x 250 MW BHEL SITE , Jindal Power Limited , TAMNAR,

Station: JPL - RAIGARH

PROCESS: GENERATOR AIR TIGHTNESS TEST

BHEL Ref No. _____________________

Plant area: TURBO GENERATOR

STATE OF THE PLANT

Station: JPL - RAIGARH

PROCESS: GENERATOR AIR TIGHTNESS TEST

BHEL Ref No. _____________________

Plant area: TURBO GENERATOR

Station: JPL - RAIGARH

PROCESS: GENERATOR AIR TIGHTNESS TEST

BHEL Ref No. _____________________

Plant area: TURBO GENERATOR

Technical Specification of Generator are given below.

ELR 70/62 30/6-10

Pilot Excitor Type

Generator Apparent Power

Generator Active Power

4.0 kg/cm2 (g)

Rated Field Voltage

Rated Field Current

Station: JPL - RAIGARH

PROCESS: GENERATOR AIR TIGHTNESS TEST

BHEL Ref No. _____________________

Plant area: TURBO GENERATOR

The objective of the test is to ensure.

Gas tightness of gas pipe lines in assembled condition including valves

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

Effectiveness of the seal oil system at operating pressure.

Testing of pipe between CO2 Bottle Rack and Hydrogen Unit at a

Testing of pipe between Hydrogen Bottle rack and Hydrogen Unit at a

Testing of Pipe between Nitrogen Bottle rack and P.W. Tank at a

UNIT UNIT NO. 1

Availability of Instrument air

Availability of Nitrogen gas- NOT APPILICABLE TO JPL

Availability of man power with required tools

Availability of Soap Solution for test.

Debris in the test area cleared.

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

Display of board No cutting/welding at all floors made

Station: JPL - RAIGARH

PROCESS: GENERATOR AIR TIGHTNESS TEST

BHEL Ref No. _____________________

Plant area: TURBO GENERATOR

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

Assembly of generator and fixing of end shields and manhole covers

UNIT UNIT NO. 1

Soap solution kept ready to check the leakages during test.

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

Valves provided in Generator oil drain lines are opened as follows:

UNIT UNIT NO. 1

Air leakage test done in stands still condition of generator.

Testing of Pipe between CO2 Bottle Rack and H2 Unit

Testing of Pipe between H2 Bottle Rack and H2 Unit.

UNIT UNIT NO. 1

Testing of Pipe Between N2 Bottle Rack and P.W. Tank-NOT STATUS

Leakage Test of Generator along with Gas System using Air.

UNIT UNIT NO. 1

Record half hourly reading on the mercury manometer provided in H 2

UNIT UNIT NO. 1

Loss of air is determined as follows:

Where V = Loss of air in M3 at N.T.P./ 24 Hrs.