Seal Oil System Commissioning

Vikram Singh
Dy. Manager(TG)
Power Sector – Technical Services
NOIDA
 Why Seal Oil System
• To prevent H2 escape from Generator body
by maintaining a continuous oil film
between Generator body and Rotor shaft at
both the ends.
H2 Seals
 Seal Oil System
• Types of Seal Oil System
– Thrust Type
– Ring Type
• Single Flow (210/250MW)
• Double Flow(500MW)
 System Components
Air Side Seal Oil Circuit
• Seal Oil Storage Tank
• Seal Oil Pumps ( 3X100%)2 AC & 1 DC
• Seal Oil Coolers (2x100%)
• Filters
• Diff. Pressure Regulators ‘A1’ & ‘A2’
 System Components
H2 Side Seal Oil Circuit
• Seal Oil Tank
• Seal Oil Pump (1x100%)
• Seal Oil Coolers (2x100%)
• Filters
• Differential Pressure Valve ‘C’
• Pressure Equalising Valves TE & EE
 Simplified Diagram
Hydrogen
Air H2
Seal Oil

Ring Relief Oil

 Simplified Diagram
Hydrogen
Air H2
Seal Oil

Ring Relief Oil

 Generator Casing How DPRV Works ?
Pressure Signal

From SOST Seal Oil Supply

Differential Pressure Regulator
• Gas pressure and the impulse oil
pressure act in opposite directions
• Valve stem moves UP or DOWN
whenever there is unbalance.
• Valve cone arrangement is such that
it closes further for a down
movement of the valve stem
• DP to be maintained is set by pre-
loading of the main bellows. The pre-
loading is adjusted with a
Compression spring linked to the
valve stem by means of an adjusting
nut.
Differential Pressure Regulator ‘C’
 Pressure Equalizing Valve

• Separate pressure equalizing valves

for TE & EE Seals, to control
constant differential pressure
between the Air side and the H2
side oil
• Air side and H2 side Seal oil act in
opposite directions, the valve stem
moves or when these
pressures are unbalanced.
• Valve opens further with a down
movement of the valve stem.
• Setting of desired DP is done by
corrosponding pre-loading of
control piston.
 Seal Oil Pump

• Seal Oil pumps are Screw Type pumps with provision of relief
valve.
Seal Oil Coolers
Seal Oil Coolers
Seal Oil Filters
Seal Oil Unit
Seal Oil Unit
 Oil Flushing of Seal Oil Piping
• Prerequisite
o Erection of interconnected piping is complete as per
scheme.
o Proper slope (min. 40mm/m) on all Seal Oil drain pipes as
per drawing.
o Temporary connections provided as per schematic.
o Flow Meters removed and temporary spool pieces
provided.
o Stem of adjustable orifice removed.
o Equalizing valves removed and temporary spool pieces
provided.
 Oil Flushing of Seal Oil Piping
• Procedure
o Oil Flushing of Seal Oil Piping is carried out by taking lube
oil from lube oil supply line near bearing no. 4.
o It is carried out in two paths:
o PATH – I : Includes Air Side S.O Supply pipeline and Ring Relief line
o PATH – II : Includes H2 Side S.O. Supply pipeline
o All weld joints should be tapped to remove any loose weld
slag
 Oil Flushing of Seal Oil Piping
• Normalisation
o On completion of Oil flushing, system should be
normalised as follows:
o Drain Oil from Seal Oil Piping and Seal Oil Storage Tank (SOST)
o Remove all temporary connections and normalise Seal Oil system
as per scheme.
o Clean SOST physically.
o Prepare scheme for Flushing of Seal Oil System.

• Completion Criteria
o Completion of Turbine Lube Oil Flushing
 Oil Flushing of Seal Oil System
• Prerequisite
o Erection of Seal Oil Pump Unit, Skid, Valve Rack,
Interconnected piping etc.
o Physical Cleaning of SOST & SOT
o Oil Flushing of Seal Oil pipelines
o Trial Run of Motors completed
o Float Valves in SOT Removed
o Regulating Valves ‘A1’, ‘A2’ & ‘C’ removed & temporary
spool piece provided.
o Arrangement for Heating of Seal Oil up to 70oC
 Oil Flushing of Seal Oil System
• Filling in Seal Oil System
o Seal Oil taken from SOST
o To maintain level in SOST, lube oil pump to be kept running
or oil should be filled manually in this tank.
 Oil Flushing of Seal Oil System
• Filling & Flushing of Air Side Seal Oil Circuit
o Open shut off valves in circuit given in procedure.
o Charge Air Side Seal Oil Coolers with oil, one at a time.
o Keep one cooler in service
o Momentarily Start & Stop Seal Oil pump 1 to bleed air
from piping until Pr gauges indicate constant pressure.
o Set 3-way valves in rack, such that no oil flows through
flow indicators
o Carry out flushing of Air Side circuit.
 Oil Flushing of Seal Oil System
• Flushing of Air Side Seal Oil Circuit
o During this process, oil flow is maintained as below:

SKID TO RACK
FILTER ORIFICE
PIPELINE

COOLER INLET SEAL

OIL LINES
SPOOL PIECE
A1, A2

SO SEAL OIL BEARING

PUMP STORAGE TANK DRAIN
 Oil Flushing of Seal Oil System
• Filling & Flushing of H2 Side Seal Oil Circuit
o Open shut off valves in circuit given in procedure.
o Fill oil from Air side circuit by opening SOT makeup supply
valve. Open plug provided on prechamber and fill oil till it
reaches prechamber level.
o Charge H2 Side Seal Oil Coolers with oil, one at a time.
o Keep one cooler in service
o Start & Stop Seal Oil pump 1 to bleed air from piping until
H2 side gauges in eq. rack indicate constant pressure.
o Set 3-way valves in rack, such that no oil flows through
flow indicators
o Carry out flushing of H2 Side circuit.
 Oil Flushing of Seal Oil System
• Flushing of Oil Impulse Lines
o Impulse lines for various gauges, pressure regulators to be
cleaned by opening their root valves.
o Oil should be collected in a container / bucket.
o Impulse line for equalising valves should be cleaned by air
blowing .
 Oil Flushing of Seal Oil System
• Flushing of H2 Side Seal Oil Circuit
o During this process, oil flow is maintained as below:

SKID TO RACK EQ. VALVE

FILTER
PIPELINE SPOOL

INLET SEAL
COOLER
OIL LINES
SPOOL PIECE
‘C’

SO H2 SIDE
SEAL OIL TANK PRECHAM
PUMP DRAIN
BERS
LOOP
 Oil Flushing of Seal Oil System
• Precautions
o Ensure No leakages are there at flange joints, tapping joints etc.
o Maintain Seal Oil Temperature around 60-70oC.
o Provide thermal shocks, by suddenly reducing oil temperature
to 35-40oC. During this tap pipelines, specially over bends &
welded joints with a small hammer.
o DP across the filters should be observed, and changeover to be
done if it exceeds 0.8kg/cm2.
o Changeover filter after every 2 hr during flushing.
o Open filter and clean mesh element using clean cloth & blower.
o Frequency of filter changeover to be decided depending upon
quantum & type of debris collected.
o Take a sample of return oil and analyse it for the presence of
moisture and mechanical impurities.
 Oil Flushing of Seal Oil System
• Completion Criteria
o Oil flushing process can be declared completed on
following basis:
o No foreign particle / material present at filter elements
o Moisture content in return oil is NIL and impurities not more than
0.05%.
 Oil Flushing of Seal Oil System
• Restoration of Seal Oil System
o Remove temporary piping and restore original
connections.
o Remove blanks provided, if any.
o Connect back impulse lines.
o Reassemble valves A, A2, C, Orifice, Equalising valves.
o Clean both filters and reassemble.
 Commissioning of Seal Oil System
• Prerequisite
o Restoration & Normalisation after completion.
o Verfication of logic & control scheme of Seal Oil Pumps as
per SLC.
o Mounting & connection of all instrumentation as per
scheme.
o Check functioning of low level detectors in SOT & SOST
before oil filling.
o Filling of fresh oil in SOST.
o Ensure full open condition of regulating valves A1, A2 & C
by Loosening of Springs.
 Commissioning of Seal Oil System
• Filling & Operation of Air Side Circuit
o Fill Air Side oil circuit, charge coolers & filters with oil.
o Charge coolers with Cooling water on both sides.
o Keep one vapour exhauster in service and second on
standby.
o Start Pump-1
o With Pump running, perform venting of:
o Pressure Signal lines to measuring devices
o Main Bellows of DPRV A1 & A2
 Commissioning of Seal Oil System
• Filling & Operation of H2 Side Circuit
o During filling of Air Side, SOT gets simultaneously filled via
float valve.
o Fill H2 Side oil circuit, charge coolers & filters with oil.
o Charge coolers with Cooling water on both sides.
o Start H2 side Pump & stop to bleed air.
o With Pump running, perform venting of Pressure gauges,
Reg. valve C and Equalising valves.
 Commissioning of Seal Oil System
• Setting of Seal Oil Pressures
o This is carried out in two stages:
o Without Air filling
o With Air Filling at rated pressure(3.5/4kg/cm2)
o Static head of instrument and respective unit
should be taken into account.
 Commissioning of Seal Oil System
• Setting of DPRV A1
o Adjust nut of A1 valve so that
Seal Oil pressure is
1.5kg/cm2 at Seals.
o Fill Air and adjust nut again
to maintain 1.5kg/cm2 above
air pressure till rated casing
pressure value.
 Commissioning of Seal Oil System
• Setting of Orifice MKW71
BP501
o This orifice is adjusted to
keep Ring Relief oil pressure
above seal oil pressure.
o Adjust such that, ring relief
oil pressure is approx
1kg/cm2 higher than seal oil
pressure.
 Commissioning of Seal Oil System
• Setting of DPRV ‘C’
o Adjust ‘C’ valve nut, such
that H2 side Seal Oil pump
discharge pr higher than air
side discharge pr by 1kg/cm2
is achieved.
 Commissioning of Seal Oil System
• Setting of Pressure Equalising
Valve
o Remove lower cap and loosen
lock nut.
o Pressure diff between Air side
& H2 side oils is indicated by
differential gauges.
o Adjust H2 side seal oil pr < Air
side seal oil pr by ~10mBar.
o Pressure is decreased by
turning clockwise & vice versa.
o Ensure that position of upper
threaded stem is not disturbed.
 Commissioning of Seal Oil System
• Setting of DPRV A2
o This is adjusted after Setting
completion of valve A1 & C.
o Purge out air and record Seal
Oil pressure value with A1
valve.
o Stop the pump.
o Take A2 in service and isolate
A1 valve.
o Start pump, adjust A2 nut to
achieve A1 values.
o Normalise A1 valve.
 Commissioning of Seal Oil System
• NOTE:
o All adjustment should be rechecked, after
pressurisation and rolling of TG set.
o If required, fine adjustments can be done at rated
casing pressure and machine running at 3000rpm.