Station: NTPCBHEL Ref No.

PS-DC-202-500-0019
RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018 Sheet 1 of 14
M
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF
P.W. SYSTEM FOR GENERATOR
SLNO
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

10.0

APPENDICES
a) DRAWING
b) LOG SHEETS

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018 Sheet 2 of 14
M
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF
P.W. SYSTEM FOR GENERATOR
STATUS
SLNO
1.0

PLANT DETAILS:
The Primary Water System (Stator water System) consists of the
following

1.1

2 Nos of Primary water pumps

1.2

2 Nos of filters.

1.3

P.W. cooler unit consisting of 3 Nos of coolers.

1.4

Measuring instrument rack.

1.5

Polishing Unit

1.6

Inter connecting pipe lines, including DM make up line and ACW

lines.

1.7

Primary water tank with level Indicator and Nitrogen pressurized

connecting lines.

1.8

Plant Item completion list for Mechanical, Electrical and C & I are
to be prepared at site.

1.9

The schematic of Primary Water system is enclosed in

Section 10.0
(Drg.No. 4:PS:TSX:0065:00)
Note: While flushing & HT, original drawing (No:0-153-00-01048,
0-149-00-01131) may be referred.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018
M
Plant area: TURBINE

Sheet 3 of 14

PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF

P.W. SYSTEM FOR GENERATOR
SLNO

STATUS

2.0

OBJECTIVES:

2.1

The flushing of PW system is to remove any dust, dirt or foreign

particles from the pipings erected at site and to ensure the
cleanliness of the complete system before admitting the water
into generator stator winding.

3.0

PROPOSAL:

3.1

The cleaning of PW system in carried out in two stages.

a. Rinsing of the pipe lines and tank.
b. Flushing of the system with the primary water pumps.
In both the above, Stator winding and Generator bushing are
isolated.

4.0

SERVICES REQUIRED:

4.1

Availability of Manpower with required tools for attending any leak

& cleaning of filters.

4.2

Availability of Operating personnel to co-ordinate the activities.

4.3

Availability of Lighting arrangements in the operating floors.

4.4

Availability of Portable fire fighting equipments in all the floors.

4.5

Availability of sufficient quantity of DM Water.

4.6

Availability of L.T Power Supply

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018 Sheet 4 of 14
M
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF
P.W. SYSTEM FOR GENERATOR
STATUS
SLNO
4.7

Availability of Nitrogen for the activity

4.8

Availability of Cooling Water.

5.0

SAFETY PRECAUTIONS:

5.1

Display of Board No cutting / welding at all floors.

5.2

Debris in all floors shall be removed.

5.3

Approach / Stair case / platform where ever required are made

available.

6.0

EMERGENCY PROCEDURE:

6.1

First Aid kit shall be made available.

6.2

The test team should know well about the procedure to be

adopted in case of damage to machinery or injury to any
personnel connected to the activity.

6.3

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

in case of any abnormality in the activity.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018 Sheet 5 of 14
M
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF
P.W. SYSTEM FOR GENERATOR
STATUS
SLNO
7.0

STATE OF THE PLANT:

7.1

P.W pumps and its associated system are erected as per

recommended drawing.

7.2

P.W Tank cleaned and DM Water is filled in the tank to the

required level. The pipelines should be separately cleaned by
wire brush to remove site welding slag and foreign material like
electrode etc.

7.3

Power supply system for the pumps are commissioned and for
operation available.

7.4

Trial run of motors / pumps are completed.

7.5

Required local / Remote I & C inputs are made available. (List to

be mutually prepared at site)

7.6

Cooling Water connections are completed.

7.7

Filters are cleaned / checked and placed in position.

7.8

D.M. water with conductivity 0.5 to 1.0 micro mho/cm and PH

value between 6.8 to 7.2 should be available.

7.9

Inlet and out let pipes from generator winding are disconnected
and generator winding by passed by temporary loop.

7.10

Inlet and outlet water pipe connections from terminal bushing are
disconnected and inter connected with temporary loop.

7.11

A fine wire mesh provided in the inlet flange joint of P.W. Tank.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018
M
Plant area: TURBINE

Sheet 6 of 14

PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF

P.W. SYSTEM FOR GENERATOR
SLNO
7.12

STATUS
Orifice MKF 80 BP501 removed for flushing and to be restored
back after the completion of activity.

7.13

Temporary arrangement for heating Primary Water is made by

wrapping suitable Ni-Chrome wire on discharge line of P.W
pumps or any one of the cooler body.

8.0

METHOD:

8.1.0

RINSING
The purpose of rinsing is to avoid the entry of any mechanical
impurity in the P.W. tank, because the primary water tank does
not have manhole and its mechanical cleaning is not possible.

8.1.1

PREPARATION
In the P.W. pump rack, the spool piece between the valve MKF
12AA501 and pump MKF12AP001 to be removed and valve
MKF12AA502 to be connected to drain. Similarly, the spool piece
after valve MKF80AA503 to be removed and the valve to be
connected to drain.
Make a check list of the items being removed indicating name of
the item, date of removal by whom removed. This list will be used
at the time of restoration. While restoring date of restoration will
be indicated against the item and will be signed by the restorer.
During the initial filling of DM water in P.W. tank, the following
valves to be kept closed.
MKF 82 AA 501
MKF 80 AA 503
MKF 12 AA 501
MKF 22 AA 501
MKF 83 AA 502
MKF 83 AA 501
MKF 80 AA 504

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018 Sheet 7 of 14
M
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF
P.W. SYSTEM FOR GENERATOR
STATUS
SLNO
8.1.2

PROCESS
The rinsing is carried out in the following steps:

8.1.3

STEP I
After filling the tank, the valve MKF 12 AA 501 should be opened
and water is drained for the cleaning of the pump suction pipe
from the P.W. tank. This is repeated 2-3 times and then valve
MKF12AA501 should be closed.

8.1.4

STEP II
After filling the tank, the valve MKF83AA502, MKF83AA501,
MKF80AA504, MKF80AA503 should be opened so that the
recirculation line as well as the bushing supply lines are cleaned.
This step should be repeated 2-3 times and then the valves
MKF83AA502, MKF83AA501, MKF80AA504, MKF80AA503
should be closed.

8.1.5

STEP III
For cleaning the P.W. supply to generator P.W. inlet header, a
temporary connection is to be made between the P.W. supply line
and the P.W tank (ref. Fig.1). The P.W. tank is filled with D.M.
water and the valves MKF82AA501 and MKF80AA503 should be
opened for the cleaning of P.W. supply line. This step is repeated
2-3 times and the valves MKF82AA501 and MKF80AA503 should
be closed.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018 Sheet 8 of 14
M
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF
P.W. SYSTEM FOR GENERATOR
STATUS
SLNO
8.2.0

FLUSHING OF THE P.W.SYSTEM

8.2.1

PREPARATION
After the rinsing is over, the spool pieces after the valves
MKF12AA501 and MKF80 AA503 which were removed for rinsing
should be connected as per the schematic drawing.

8.2.2

PROCESS:
The process is carried out in the following stages.

8.2.3

STAGE I (Flushing of Generator Inlet Header)

8.2.4

The connection as per above sketch should be completed. The

primary water should be filled with the DM water keeping the
valvesMKF12AA501,MKF22AA501,MKF80AA503&MKF82AA501
open and the system should be checked for leakage, if any. The
vent valves should be operated to vent the system. In the first
step, the flushing of the P.W. line for the generator inlet header is
to be carried out. After filling the system, run either of primary
water pumps MKF12AP001 or MKF11AP001 for flushing keeping
valves MKF80AA504 & MKF83AA501 closed. While the water is
in circulation, heat the DM water up to 75 0 C with the heating
arrangement provided and initially throughout the flushing. The
filter should be changed over for few times after every 3-4 hours
and standby filters should be taken into service.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018 Sheet 9 of 14
M
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF
P.W. SYSTEM FOR GENERATOR
STATUS
SLNO
8.2.5

The fine wire mesh provided in the inlet line of P.W. tank at flange
joints is to be removed after 4 hours of pump running.

8.2.6

When the filter elements are observed clean after keeping in

operation for 8 hours, the other cooler should be taken into
service one by one and the cooler already in service should be
isolated.

8.2.7

The flushing should be declared completed when the filter

remains in clean condition after 8 hours of operation. The system
should be drained completely.

8.2.8

STAGE II (Flushing of Generator Bushing PW lines)

The P.W. system should be normalized as per the original
scheme while retaining temporary looping for the inlet and outlet
of bushing P.W. connection. After filling the system, either of the
pumps should be run, keeping the valve MKF82AA501 closed.
The flushing should be completed as per the criteria described in
8.10.4.

8.2.9

STAGE III
During this stage, all impulse lines for instruments and P.W. tank
are flushed.

8.2.10

Flushing of impulse lines

Open the root valve provided in impulse line one by one and flush
the D.M. water to atmosphere till clear water flows out. During
this step, fresh D.M. water make up valve MKF60AA520 may be
operated to maintain water level in P.W. tank.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018 Sheet 10 of 14
M
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF
P.W. SYSTEM FOR GENERATOR
STATUS
SLNO
8.2.11

Flushing of P.W. tank / Waste gas line

To flush the tank, stop P.W. pumps and close valve MKF91AA502
provided in Nitrogen feed line to P.W. tank. Open valve no.
MKF91AA513 and MKF91AA505 and close valve No.
MKF91AA506 Provided in waste gas line. Open DM water filling
line inlet valve No.MKF60AA520 and increase the water level in
P.W. tank. DM water will flow to atmosphere through waste gas
line after P.W tank is filled. Continue flushing of P.W. tank till clean
water comes out from the waste gas line. Close the filling line
valve no. MKF60AA520.

8.3.0

Pressure Test of Primary Water System

8.3.1

Pressure test of P.W system is performed to check the tightness

of all components joints in the system including the stator
winding. This test is done after the charging of stator winding and
terminal bushing with primary water. This test is to be carried out
before boxing up generator casing. This test is carried out in two
stages:
Stage 1 :
For external pipe connections.
Stage 2 :
For primary water tank with expansion joints Teflon hoses and
winding including terminal bushings.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018 Sheet 11 of 14
M
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF
P.W. SYSTEM FOR GENERATOR
STATUS
SLNO
8.3.2

Pre-requisite
Before performing the pressure test of primary water system, the
completion of following works should be ensured:
i)

That stator winding and terminal bushings have been

filled with De- oxygenated primary water of required
quality.

ii)

N2 gas cylinders are connected at N2 cylinder rack and

sufficient numbers of N2 cylinders are available for
raising the pressure.

iii)

Replace pressure gauge provided in waste gas line

MKF91 CP 501 with the range of 0-6 Kg/cm 2 and least
count of 0.01 kg/cm2 .

iv)

Close valve MKG91 AA 506 in waste gas line.

v)

Ensure PW tank is filled with DM water up to of level

gauge glass.

8.3.3

Pressure Test of External Piping & System Components

The following system components and pipings are pressure
tested at 10 Kg/cm2 for 30 Hrs.
i)

Pipe from pump discharge to P.W cooler unit.

ii)

P.W collers

iii)

Pipe between PW cooler unit and filters.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018
M
Plant area: TURBINE

Sheet 12 of 14

PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF

P.W. SYSTEM FOR GENERATOR
SLNO

STATUS
iv)

Filters.

v)

Water Inlet Pipe upto isolating valves MKF82 AA 501

and MKF83 AA 501.

Pressurisation of the system is done by running one of PW

pumps as follows:

8.3.4

Close valves MKF82 AA 501, MKF83 AA 501, MKF80

AA 504 and MKF60 AA 502.

Start PW pump MKF22 AP 001 and raise discharge Pr.

Up to normal operating pressure of the pump in Pr.
Gauge MKF22 CP 501 by slowly opening pump
discharge valve. Now raise the pressure further to 10
kg/cm2 by external pressurizing pump / hand pump.

Check for any visible leakage.

After test is completed, system should be normalized.

Pressure Test of Stator Winding
The primary water tank is pressurized to 6 bar with the help of N2
gas for checking the tightness of PW system. The same is carried
out as following.
i)

Stop P.W. Pumps

ii)

Open Valve MKG31 AA 502, MKG31 AA 503, MKG35

AA 501 and MKF91 AA 502 in N 2 gas feed line to P.W.
tank.

Signatures
NTPC
Station: NTPCBHEL Ref No.PS-DC-202-500-0019
RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018
M
Plant area: TURBINE

BHEL
Sheet 13 of 14

PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF

P.W. SYSTEM FOR GENERATOR
SLNO

8.3.5

STATUS
2

iii)

Adjust N2 gas Pr. Regulator NKG31 AA 001 to 6 Kg/cm .

iv)

Open the N2 gas cylinder regulating valve and fill N2 gas in

primary water tank. Observe the pressure in PW tank by
pressure gauge provided in water gas line.

v)

Stop filling N2 gas as soon as 6 Kg.cm 2 N2 Pr. is achieved

in P.W tank and close valve MKG31 AA 502.

vi)

Check for visual inspection for any water leakage / seepage

from the various joints of primary water system and stator
winding portion. The test should be performed for 48 Hrs. to
check pressure drop of system.

Normalisation of System
On completion of pressure test the system is normalized as
follows:
i)

Open valve MKG91 AA 506 to release the N2 gas PW

tank and maintain pressure about 0.2 Kg/cm 2 in PW
tank with the help of pressure relief valve MKF91 AA
003.

ii)

Replace Pr. gauge provided at MKF91 CP 501 with the

required pressure range.

iii)

Put back the Orifice MKF 80 BP501

iv)

The generator casing man holes covers can be closed

for air tightness of generator casing.

v)

Remove temporary heating arrangement.

vi)

Clean both the filters and re-assemble.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0019

RAMAGUNDA NTPC Ref no OS-COMM-RGM-Commg-PRO-018 Sheet 14 of 14
M
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF
P.W. SYSTEM FOR GENERATOR
STATUS
SLNO

9.0

vii)

Mount all the instrument provided in the system after its

proper calibration.

viii)

Remove temporary by-pass line provided in inlet /

outlet water header of generator winding terminal
bushing and connect the header to respective flange
connection.

ix)

Start P.W. Pump for circulation of primary water.

COMPLETION CRITERIA:
Flushing of P.W. system for Generator declared completed when
the filter remains in clean condition after 8 hours of operation.
Half hourly P.W. outlet sample conductivity is almost steady for at
least three consecutive readings.

Signatures
NTPC

BHEL

LOG SHEET
P.W PUMP NO. 1 / 2

Oil temperature
Sl.No

Date/Time

Pump Dis.Pr.

Bef.
Cooler

After
Cooler

Thermal
Shock

Remarks

Signatures
NTPC

BHEL

PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF

P.W. SYSTEM FOR GENERATOR

SCHEME FOR STATOR WATER

FLUSHING (P.W)
DRG.NO.4:PS:TSX:0152:00
Drawn Checked Apprd Date
KJ
MKS
KB
08.09.03

PROJECT

M/S RAMAGUNDAM 500 MW

PROCEDURE

HYDRAULIC TEST AND OIL FLUSHING OF PW SYSTEM

PURPOSE OF
DOCUMET

FOR EXECUTION / INFORMATION

DOCUMENT

PS:TSX:181:00:03

Copy No:
Issued to :

00

KJ

MKS

KB

08.09.2003

Rev.No.

Prepared by

Reviewed by

Approved by

Date

BHARAT HEAVY ELECTRICALS LIMITED

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