Beruflich Dokumente
Kultur Dokumente
REVISION LOG
Prepared by
Issue Rev. Page Concurred by
Details Date Checked by
No. No. No. Approved by
Reviewed by
V.K.Kuhikar, Dy.Mgr
01 NA First Issue NOV. ‘03 NA R.M, Bagul. Engr., QA
J. Mathew, Incharge-TG
CONTENTS
COVER SHEET 1
REVISION LOG 3
CONTENTS 5
1. PURPOSE 6
2. PRE-REQUISITES 6
2.1 STATUS OF OTHER SYSTEMS
SYSTEM REQUIREMENTS
MANPOWER REQUIREMENTS
2.4 REQUIREMENT OF SPECIAL EQUIPMENTS
REQUIREMENT OF OUTSIDE AGENCIES
2.6 HAZARDS & PRECAUTIONS
8. GENERAL METHOD 10
9. DESIGN INTENTS 31
10. EXPECTED PROCESS PARAMETERS 31
11. WORK PLAN 32
12. TEST REPORT FORMAT 33
13. REFERENCE 49
14. VERIFICATION PROCESS 49
FLOW CHARACTERISTICS OF OIL THROTTLE
15.
Nb25, Nb50, Nb65, Nb80 & Nb100 (5 PAGES)
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 6 of 52
1.0 Purpose:
To flush the complete lube oil and control oil system to remove mechanical
impurities, dirt, welding slag etc. by simulating conditions similar to operating
conditions of plant by adopting thermal shock process, for effective oil flushing oil
system is flushed in loops as:
a. Lube oil system flushing
b. Jacking oil system flushing
c. Control oil system flushing and purification system
d. Seal oil system
To circulate the Lube oil and Jack Oil in the systems after the completion of oil
system flushing and adjusting the pressure and flow in the Circuits.
To carry out the logic checks and operational performance of various active
components in the system i.e. various pumps.
2.0 Pre-requisites:
a. All erection activities in lube oil, control oil, jacking oil, oil purification circuit
should be completed.
b. Temporary supports should be removed.
c. AOPs (Auxiliary Oil Pump) and control fluid pumps are available for running.
d. Oil Purification (BHEL Temporary Centrifuge) System should be available for
operation.
e. Service air should be available near filters for cleaning of filters.
f. Cooling water at oil cooler should be available.
g. Seal oil system: Ensure following:
1. Erection of seal oil pump unit, seal oil unit, seal oil valve rack, measuring
instrument rack, and seal oil storage tank and interconnected piping.
2. Physical cleaning of seal oil storage tank.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 7 of 52
o. The team for this operation shall be aware of this procedure for oil flushing
and shall act at the time of any emergency.
p. The team should be aware of first aid to be followed in case of accident
involving injury to personnel.
q. The team should be aware of operating procedures of fire extinguisher to be
used for quenching minor oil fires.
r. The team should be aware of restarting the operation in case of system
stoppage due to failure of power supply.
n. Oil coolers inspected through oil line connection and, if required, the same
shall be cleaned before starting of flushing.
o. Temperature indicators before and after oil cooler are made available for Oil
as well as cooling water.
p. Before filling the oil in Main oil tank (MOT)/SOST (seal oil storage tank), both
tanks are cleaned carefully.
q. All C&I installation and calibration of Oil tank level indicators, level switches
etc. completed before Oil filling.
r. Vapour extraction system with vapour extraction fan is available for operation.
s. All the filter elements in the system, other than the tank filters are removed
before initial flushing.
t. The necessary by pass work as per scheme (1-131480-99001 & 0-13149-
99001& 2.1-7111-7404/3)) enclosed is carried out and the correctness of
looping checked.
u. Insulation of Turbine & piping shall be completed (or otherwise no insulation
work shall be permitted during oil flushing) and TG floor, Oil Tank & flushing
area completely cleaned.
v. Availability of Hydraulic pumps 5 to 300 bars as backup for hydraulic test.
a. The hydraulic systems of governing system are equipped with oil storing
accumulators. Loosening or tightening of any mechanical item should be done
after depressurization & draining of the system.
b. While testing and adjusting the LP Bypass & governing systems no insulation
work shall be allowed.
c. Debris in and around oil systems and MOT (Main Oil Tank) floor to be
removed.
d. Approach / Stair Case / Platform wherever required are made available.
e. Sign boards to be displayed at strategic location to indicate that Oil System is
charged and oil pumps are ‘ON’.
f. Welding / cutting shall not be carried out in flushing area.
g. Load on pumps shall not exceed full load current of the motor.
h. An operator to be posted near the pump area and instructed that he should
trip the pumps in the event of emergency being notified to him by the team /
observers.
a. Oil throttle internals in oil supply line to bearings are to be removed and are
provided dummy plates on top of the throttle body. These dummy plates are
provided with oil flushing material.
b. Duplex filter elements provided in the supply line to thrust bearing are to be
removed. These elements are to be put back in position during the final stage
of flushing.
c. The regular adaptors in the bearing pedestals for supply are replaced with
flushing device so that oil is deflected to bearing-to-bearing pedestal instead
of going to the bearings.
d. MOP (Main Oil Pump) is to be completely removed and a flushing device is to
be placed in position.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 11 of 52
p. The Governing Rack & LP (Low Pressure) bypass racks are to be excluded
from flushing. The stop valves servomotors of ESV (Emergency Stop Valve) &
LPBP (Low Pressure Bypass) and water injection valve to be bypassed.
q. Suitable piping connections to be provided as per drawing for bearing
pedestal, over speed trip device, thrust bearing trip device etc. as per flushing
loops.
r. By pass connections as per drawing (flushing loops given in this write-up) for
all extraction NRV’s (Non Return Valve). The solenoid valves must be
replaced with suitable adopters.
s. Ensure the temporary pipe work is completed in seal oil system as per the
enclosed sketch.
3.1 Precautions:
For thermal shock during oil flushing the two oil coolers will be used. One will be
used as hot water cooler and other as cold water cooler. Before starting thermal
shock activity ensure the following inputs.
1. Ensure that both the coolers are charged in oil and watersides and venting is
done properly.
2. The hot water cooler inlet and out let ACW (Auxiliary Cooling Water) valves are to
be kept closed once it is filled up with water.
3. Ensure that the oil and water temperature gauges are provided in the cooler inlet
and outlet line for both oil and water sides.
4. Ensure that flushing of all the loops is completed bypassing the cooler and MOT
filters are sufficiently clean.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 16 of 52
5. Ensure oil is getting heated as per requirement using centrifuge & churning effect
6. The oil temperature will increase. Allow increase in temperature > 60 deg. C but
keep < 80 Deg. C by adjusting the water in the cooler.
7. Ensure the cold water cooler is charged form ACW side and ACW system is in
operation
8. Change over the oil flow to the cold water cooler with the change over valve.
9. The oil temperature will start reducing. Continue cooling process till the inlet oil
(to cooler) temperature reduced to 45 deg .C.
10. While cooling process is on slowly tap the oil lines (with wooden hammer)
through which oil is flowing for descaling the dirt.
11. After completion of heating process repeat cooling process as above.
a. The jacking oil system flushing can be started after initial dirt / muck of Lub oil
system is cleared.
b. Oil flushing is done by using the temporary connection from AOP discharge
header.
c. Initially the jacking oil header is to be flushed by using the connection from
JOP header dead end to drain header with temporary pipe.
d. After using above circuit for about 1-2 day the above connection is to be
closed and then the lines to the individual bearing are to be flushed, say 2 or
3 lines at a time for effective flushing.
e. Final flushing of the jacking oil lines will be done at high pressure (>30 kg/cm 2 )
by running the jacking oil pump.
a. After ensuring flushing circuit as per scheme in section 3.11. Keep all the
valves of control oil circuit close, and open only such small lines, which are at
end of system and will act as vent lines.
b. Open the interconnecting valves from AOP and fill up the 8-bar and 32 –bar
system. Ensure that there is no leakage (if any attend to it).
c. Start one COP and pressurized the system with minimum flow. Ensure that
there is no leakages at high pressure ( 8-bar and 32-bar).
d. To achieve maximum velocity through pipeline the circuit of control oil lines
should be divided into 4 to 5 groups and circulation of oil should be rotated in
these groups.
e. For details of loop please refer scheme of loops given in this procedure.
f. Both COP will be run during oil flushing of the control oil flushing. The loading
of the pumps will be kept within the rated load
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 18 of 52
a. The oil analysis of sample drawn from oil purifier inlet should not have any
mechanical impurities and moisture.
b. Main oil tank filter (provided inside MOT) should be in clean condition over a
period of 24 hours.
c. Duplex filter element should be free from impurities such that no chocking of
filter should be experienced in duration of 24 hours.
d. Bearing Line filters are to be installed and flushing carried out for 24 hours
and no accumulation of dirt should be observed.
e. All criteria to be met for declaring the oil flushing completion.
b. When the oil is drained into the drain tanks provided, the drain tank, which
accepts oil, must be clean. The oil contained in the system, main oil tank and
oil coolers are to be completely drained using purifier & MOT drain lines.
c. The MOT (Main Oil Tank) / SOST are carefully cleaned and inspected as
done earlier before flushing. Jacking oil lines are to be normalized.
d. The cooler tube nest should be withdrawn for inspection and cleaning of the
coolers should be done with compressed air. Taking care so that O-rings are
protected. It is done to remove entrapped dirt particles in tube nest during
flushing operation.
e. All bearing pedestals are to be cleaned thoroughly before boxing up the
pedestals.
f. All temporary arrangements must be removed / normalized.
g. All bearing pedestal connections should be normalized. Turbine bearings
should be normalized.
a. Put plugs in the relief holes of oil throttles and put the throttles in full close
position.
b. Provide dummies ( as per enclosed list ) at the last flange joint available in
the permanent piping, before it is connected to the drain in the oil canal.
c. Make a connection from jacking oil header supply line to the Lube oil circuit
as marked in the drawing given in this procedure.
d. Close the valves wherever the valves are located at the end of pipeline.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 20 of 52
** The hydraulic test pressure & duration will be verified with the latest
recommendations of the designers before conducting the same.
After hydraulic test drain the system & normalize system. On filling the Fresh oil start
system commissioning.
3.11 Commissioning:
Lub oil and jacking oil system
1. Start main oil tank vapor fans from control system and record observations as per
STG LO-06.
2. Commission Oil purifier and record observations as per STG LO-07.
3. Before starting the Auxiliary Oil Pump, place persons in strategic locations for
observing leaks.
4. Start Auxiliary Oil Pump from control room and establish header pressure.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 21 of 52
5. Adjust lube oil throttles in the oil inlet lines as per design flow requirements of
individual bearing as per O&M instructions supplied by designer.
6. Check for oil flow through the sight glass at all consumption points
7. Stop AOP
8. Start AC EOP from control system and establish header pressure Record
observations.
9. Check status of pressure switches.
10. Stop EOP and start AOP
11. Check Auto Start of EOP with interlock of pressure switches
12. Check feedback of thermocouples
13. Lube oil system ready and functional with AOP available for operation.
14. Control & signal cable loop checks completion done
15. Release JOP discharge header pressure relief valve completely
16. Run AC Jacking Oil Pump from control room
17. Adjust relief valve to establish Jacking Oil Pressure at 150 kg/cm2
18. Check status of pressure switches
19. Stop AC Jacking oil pump
20. Start second Jacking Oil Pump from control room.
21. Run the pump for 10 Minutes and record observations
22. During the first charging of oil system oil spill may happen due to improperly
tightened pipe joints, uncovered openings or flooding of pedestal.
23. Before starting the oil pump, the system shall be checked for flange tightness and
correct valves line up.
24. Place persons in strategic locations for observing oil leakage before starting the
pump.
25. Funnels connected with hosepipes, empty buckets and empty drums shall be
used for collecting any drip.
26. Spraying fine sand over the spill and removing the sand after oil absorption will
clean oil drip on the floor.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 22 of 52
Scheme No. 1
TO DRAIN
HEADER
TOMOT
JOP JOP
1 2
MOT
Scheme No. 2
SIGNAL SIGNAL
OIL OIL
OIL FROM
PUMP DISCH
C.F.PUMP DISCIT
SOL
VALVE
RACK VAC
W.I
VAL
DRAIN BREAKER
VE
Scheme No. 3
SEC.OIL
HP
CONTR
OL
TRIPOIL VALVE
ABOVE 1/2
ESV PISTON
1/2 32 BAR SUPPLY UNIT
UNFILTERED
32 BAR
TRIPOIL FILTERED
BELOW
PISTON
HPCV1/2 DRAIN TO
S.M.DRAIN S.M. ESV1/2
DRAIN
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 25 of 52
Scheme No. 4
RACK
PRI.OIL DRAIN
AUX.
TRIP
SEC.OIL TO OIL TO TEST OIL TO O/S
HPCV 1/2 SOL. GOVERNOR
VALVE
Scheme No. 5
C.F.PUMP
DISCH.
SOL
VALVE DRAIN
LPBP
VALVE
TO ACCUMULATOR
DRAIN
FROM AOP
TO SYST.
TO 32-BAR
JO JO
P P
I II TO 8-BAR
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
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Scheme No. 6
MOP
BYPASS
THROTTLE
FROM JOP
DUPLEX FILTER
TO SEAL SOIL
AOP
AOP1 2
COOLER BYPASS
MOT EOP
DIRTY
SIDE MOT CLEAN SIDE
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
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Page 28 of 52
TO MOT
DIRTY OIL
TANK
CLEAN OIL DIRTY OIL
COMP. COMP.
TEMPORARY
TANK
CAP 2.5 M3
WIRE MESH
AND CLOTH Nb 80MM
TO MOT
TEMPORARY
CENTRIFUGE
Oil of viscosity class ISOVG 46 shall be used. For the topping of the oil system it
is preferable if the oil used is of the same brand & quality as that already in
system. The oil should comply with the requirements given in the table on sheet
no. 5.1-0130-02 of O & M manual.
a. The oil analysis of sample drawn from oil purifier inlet should not have any
mechanical impurities and moisture.
b. Main oil tank filter should be in clean condition over a period of 24 hours.
c. Duplex filter element should be free from impurities such that no chocking of
filter should be experienced in duration of 24 hours.
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
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COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 30 of 52
d. Line filters are to be installed and flushing carried out for 24 hours and no
accumulation of dirt should be observed.
e. All criteria to be met for declaring the oil flushing completion.
Other plans:
1. Oil draining arrangement as per schedule.
2. Proper team distribution & availability
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
COMMISSIONING PROCEDURE FOR
TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 32 of 52
Schedule of Check Lists for Lube Oil System and jacking oil system
INSTALLATION OF ORIFICES
BHARAT HEAVY ELECTRICALS LIMITED
PROCEDURE NO: TAPP3&4-41300-CP-1
PS: WR NAGPUR
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Page 33 of 52
Date:
Checklist STG-LO-02
INSTALLATION OF DEVICES
Date:
Refer for Tag no, set points & other details :INSTRUMENT LIST, DRG.NO. 4
13300 98 001, REV02 NPC DOC. TAPP
Checklist STG-LO-03
Date:
Sl. Device Tag no Range / Set Checked
no. Point OK / NOT
OK
1. MOT level indicator
2. MOT level high switch
3. MOT level low switch
4. AOP discharge pressure
indicators
5. EOP discharge pressure
indicator
6. Lube oil inlet to cooler local
temperature indicator.
7. Lube oil inlet to cooler local
temperature indicator.
8. Lube oil outlet from cooler local
temperature indicator.
9. Lube oil outlet from cooler local
temperature indicator.
10. Lube oil temperature after
cooler - temperature element
11. Differential pressure indicator
for lube oil filters
12. Differential pressure switch for
lube oil filters
13. Lube oil header pressure
indicator
14. Lube oil header pressure
transmitter
15. Lube oil header pressure low –
switch
16. Lube oil header pressure low-
low – switch
17. Lube oil header pressure low-
low switch
18. Lube oil header pressure low-
low – switch
19. Lube oil header pressure low-
low switch
20. Lube oil header pressure low-
low – switch
21. MOP discharge header
pressure low – switch
22. MOP discharge header
pressure indicator
BHARAT HEAVY ELECTRICALS LIMITED
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PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
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TG OIL SYSTEM DATE OF ISSUE: NOV. 2003
Page 36 of 52
Refer for Tag no, set points & other details :INSTRUMENT LIST, DRG.NO. 4 13300
98 001, REV02 NPC DOC. TAPP
BHARAT HEAVY ELECTRICALS LIMITED
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Page 37 of 52
Checklist STG-LO-04
MAIN OIL TANK READINESS
Checklist STG-LO-05
Size of sample:
Tested at:
Checklist STG-LO-06
TIME
DATA UNIT
Motor Amps
Current
Vibration at Microns /
Motor CE mm/sec
Vibration at Microns /
Motor FE mm/sec
Vibration at Microns /
fan body mm/sec
Checklist STG-LO-07
Checklist STG-LO-08
AUXILIARY OIL PUMPs COMMISSIONING
Equipment tag number …………………………….
System Description………………………….
P&ID Number ……………………………….
Manufacturer’s Name ……………………………….
Name Plate details ……………………………………
Date
No Description Remarks
TIME
DATA UNIT
Motor Amps
Current
Pump Kg/cm2
discharge
pressure
Vibration at Microns /
Motor CE mm/sec
Vibration at Microns /
Motor FE mm/sec
Legend: CE – Coupling End, FE- Free End
Checklist STG-LO-09
Checklist STG-LO-10
Date:
Ref: BHEL SOE List :
Checklist STG-LO-11
Date:
8 OK / NOT OK
Auto start of EOP
9 OK / NOT OK
10 OK / NOT OK
Checklist STG-LO-12
Checklist STG-LO-13
SL Activity Remarks
NO
1 Valve operation OK / NOT OK
2 Temperature control 45 degC
setting
Checklist STG-JO-01
INSTALLATION OF DEVICES
Date:
Checklist STG-JO-02
Date:
Sl Tag no Device Range / Calibrated
no set point yes/no
1 JOP discharge header
transmitter
2 JOP discharge header pressure
low
3 JOP Discharge header to
Turning gear interlock
Refer for Tag no , set points & other details :INSTRUMENT LIST, DRG.NO. 4 13300
98 001, REV02 NPC DOC. TAPP
Checklist STG-JO-03
TIME
DATA UNIT
Motor Amps
Current
Vibration at Microns /
Motor CE mm/sec
Vibration at Microns /
Motor FE mm/sec
Checklist STG-JO-04
No Description Remarks
Pump set is ready for trial run.. Set Jacking Oil Header Pressure at 150 kg/cm2.
Refer for Tag no , set points & other details :INSTRUMENT LIST, DRG.NO. 4
13300 98 001, REV02 NPC DOC. TAPP
Checklist STG-CO-01
CONTROL OIL PUMPs COMMISSIONING
Equipment tag number …………………………….
System Description………………………….
P&ID Number ……………………………….
Manufacturer’s Name ……………………………….
Name Plate details ……………………………………
Date
No Description Remarks
TIME
DATA UNIT
Motor Amps
Current
Pump Kg/cm2
discharge
pressure
Vibration at Microns /
Motor CE mm/sec
Vibration at Microns /
Motor FE mm/sec
BHARAT HEAVY ELECTRICALS LIMITED
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PS: WR NAGPUR
ISSUE NO:01 REV NO: ZERO
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Page 49 of 52
8.0 Reference
APPENDIX-1
VERIFICATION TABLE
TO AIR
SIDE
DRAIN
RING RELIEF
AIR & H2
SIDE SEAL
OIL AIR & H2
BYPASS SIDE SEAL
OIL
BYPASS
H2 SIDE
SOST DRP
BYPASS
FROM L.O.
HRADER