Station: NTPC- BHEL Ref No.

PS-DC-202-500-0016
Sheet 1 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
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

Station: NTPC- BHEL Ref No.PS-DC-202-500-0016
Sheet 2 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
SLNO STATUS

1.0 PLANT DETAILS:

1.1 The plant consists of condenser, Hotwell, 2 Nos, of vacuum

Pumps and drains and vents from different specified systems to
condenser. Vacuum system is mainly to condense steam exiting
the LP Turbine at subatmospheric pressure so that the over all
efficiency of the cycle is improved. Also the condensed steam is
re-cycled with out wastage. Functions of the main equipment
system are as given below.

1.2 Condenser : -

It is mainly to condense the steam coming out of LP turbine last

stage by admitting cooling water in the tubes. The steam loose its
enthalpy to cooling water while condensing.

1.3 Hot well : -

This is to store the condensate arising out of cooling of steam

and give the suction head to condensate pumps.

1.4 Vacuum Pump :-

This is to evacuate the air-vapour mixture from the condenser

and create a negative pressure to improve the cycle efficiency.

1.5 Plant item completion list for mechanical, Electrical and C & I to
be prepared at site.

1.6 Signed copy of SRCC to be enclosed.

Signatures

NTPC BHEL
Station: NTPC- BHEL Ref No.PS-DC-202-500-0016
Sheet 3 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
SLNO STATUS

2.0 OBJECTIVE:

The objective of the procedure is to check the system for air

ingress points and to achieve the desired rated vacuum.

Signatures

NTPC BHEL
Station: NTPC- BHEL Ref No.PS-DC-202-500-0016
Sheet 4 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
SLNO STATUS

3.0 TESTING PROPOSAL:

The objective is achieved by carrying out the following test

proposals.

3.1 STAGE I Water Fill Test

The tightness of the system shall be established by water fill test.

Under this all the equipments and systems coming in contact with
condenser are filled with DM water and leaks are noticed. Then
the leakage points are arrested to prevent the air ingress while
vacuum is raised.

3.2 STAGE II Vacuum Pulling

Vacuum is raised to check the tightness of the system which were

not included in the water fill test. During this test, the parts which
were not subjected to water fill test are examined for any air
ingress and the same will be arrested after identification. By this,
the entire system is tested thoroughly to obtain the desired rated
Vacuum for better performance of the steam cycle.

Signatures

NTPC BHEL
Station: NTPC- BHEL Ref No.PS-DC-202-500-0016
Sheet 5 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
SLNO STATUS

4.0 SERVICES REQUIRED:

4.1 Availability of DM water for water fill test.

4.2 Availability of proper illumination around the equipments in the

test area.

4.3 Availability of Condenser cooling water system.

4.4 Availability of H.T/L.T Power supply (for operating CEP, Vaccum

Pumps)

4.5 Availability of communication facility at test area.

4.6 Availability of Man Power and T & P for leak detection and
attending.

4.7 Availability of Portable fire extinguisher at test area.

4.8 Availability of dewatering pump near test area and a pit for
dewatering.

4.9 Availability of flexible polythere tube for level monitoring in

condenser steam space.

Signatures

NTPC BHEL
Station: NTPC- BHEL Ref No.PS-DC-202-500-0016
Sheet 6 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
SLNO STATUS

5.0 SAFETY PRECAUTIONS :

5.1 Ensure the availability of first Aid Box near the test area

5.2 Ensure that the personnel deployed to check the system leakage
are provided with required safety gears, such as helmets, safety
belts etc.

5.3 Ensure proper temporary scaffolding is provided to reach

condenser neck portion and other unapproachable areas
wherever required.

5.4 Ensure the test area is clean and devoid of obstruction and the
required flooring completed.

Signatures

NTPC BHEL
Station: NTPC- BHEL Ref No.PS-DC-202-500-0016
Sheet 7 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
SLNO STATUS

6.0 EMERGENCY PROCEDURE:

6.1 The personnel for this operation shall be well aware of the layout
of this system.

6.2 They shall be in a position to use the safety devices while

searching for leaks during testing.

6.3 Test Team should be aware of emergency steps to be taken on

the event of any accidents occurring to men and material while
conducting the test.

6.4 During the test, all precautions to be taken at local and remote to
observe the running CEP, Vacuum pump and any tend in
increase in bearing temperature or vibration should be
communicated to control room for appropriate follow up action.

6.5 Test team should be aware of operation of portable fire

extinguishers.

Signatures

NTPC BHEL
Station: NTPC- BHEL Ref No.PS-DC-202-500-0016
Sheet 8 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
SLNO STATUS

7.0 STATE OF THE PLANT:

7.1 For water fill test; The following are completed.

7.1.1 Erection of condenser and connected piping of vacuum system

as per recommended drawing.

7.1.2 The erection work in LP casing exhaust.

7.1.3 Removal of temporary platform, if any erected in LP casing

exhaust.

7.1.4 The permanent hangers and supports for connected piping.

7.1.5 Removal of temporary supports.

7.1.6 Make up water line to condenser for filling the condenser steam
space.

7.1.7 Installation of flexible polythene tube for monitoring the water

level in condenser steam space.

7.1.8 Locking of the jack bolts of condenser springs before starting

water fill test so as to arrest the spring action.

7.1.9 Locking of all the hangers of drain flash tanks and connected pipe
Lines in vaccum system.

7.1.10 Installation of level gauge glass of hot well, LP heaters and HP

heaters.

7.1.11 Cleaning of hot well.

Signatures

NTPC BHEL
Station: NTPC- BHEL Ref No.PS-DC-202-500-0016
Sheet 9 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
SLNO STATUS

7.1.12 Installation of level switches and level transmitters for hotwell

level & LP Heaters & HP heaters.

7.1.13 The piping & tanks under vacuum system are not to be insulated
including at welding joints and flange joints, manholes, root
valves, stubs etc.

7.2 For actual vacuum pulling: The following are completed

7.2.1 Vacuum pumps are ready for operation.

7.2.2 Gland seal steam exhauster fans trial run completed.

7.2.3 CEP trial run completed with required interlock and protections.
(The list of minimum interlocks and protections to be mutually
prepared at site).

7.2.4 Gland steam control valves commissioning.

7.2.5 Availability of mercury manometer/calibrated gauge.

7.2.6 Charging of cooling water to condenser water boxes.

7.2.7 Vacuum breaker valve commissioning.

7.2.8 Barring gear with interlocks & protections should be ready.

7.2.9 Gland sealing water lines for valves coming under vacuum
system are completed.

Signatures

NTPC BHEL
Station: NTPC- BHEL Ref No.PS-DC-202-500-0016
Sheet 10 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
SLNO STATUS

8.0 METHOD:

8.1 Water fill test

8.1.1 Start filling water in system gradually. Release the air of LP

Heaters, HP Heater, Drain cooler and Gland steam condenser by
opening their vent valves during filling.

8.1.2 Check for leakages in the system after every 1 M rise in water
level.

8.1.3 Drain and attend leakage wherever leaks are noted.

8.1.4 Check the leakages upto 1 M above tube nest and maintain this
level during this test.

8.1.5 Drain the system and attend all leakages.

8.1.6 After the completion of leak test, clean hot well and release the
jack bolts of condenser springs.

8.1.7 Fill Hot wall up to normal level.

8.2 Vacuum Pulling

8.2.1 Run one CEP on recirculation.

8.2.2 Put machine on barring gear.

8.2.3 Line up seal steam supply and gland steam cooler.

8.2.4 Start one seal steam exhauster fan and both vacuum pumps.

8.2.5 After achieving about 0.2 kg/cm2 vacuum, charge seal steam to
turbine glands. Downstream parameters to be maintained are:
Pressure : 0.01 KSC and temp > 160oC

Signatures

NTPC BHEL
Station: NTPC- BHEL Ref No.PS-DC-202-500-0016
Sheet 11 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
SLNO STATUS

8.2.6 Check system for air ingress points if proper vacuum is not
achieved and same shall be rectified.

8.2.7 Stop one vacuum pump when desired vacuum is achieved and
stabilised. However, if with one vacuum pump, vacuum is not
holding then check for air ingress and attend the leakages.

Signatures

NTPC BHEL
Station: NTPC- BHEL Ref No.PS-DC-202-500-0016
Sheet 12 of 12
Ramagundam NTPC Ref no RGM /1/TS/2/004
Plant area: TURBINE
PROCEDURE FOR CONDENSER FLOOD TEST AND VACUUM TIGHTNESS TEST
SLNO STATUS

9.0 COMPLETION CRITERIA:

9.1 Condenser Flood Test and Vacuum tightness test is completed

with following completion criteria.

9.2 Condenser Flood Test is completed after satisfactorily attending

all the identified leakages.

9.3 After achieving the required vacuum, stop both vacuum pumps
and record the rate of fall of vacuum for 10 minutes. The rate of
fall of vacuum should be 2 to 3 mm of Hg per minute.

9.4 After attending all the leakages, total hogging time taken for
achieving full vacuum shall be noted down by running each
vacuum pump separately one by one and by running both the
vacuum pumps together.

Signatures

NTPC BHEL
PROCEDURE FOR CONDENSER FLOOD TEST
AND VACUUM TIGHTNESS TEST
PROJECT RAMAGUNDAM 500 MW, UNIT - 7

PROCEDURE CONDENSER FLOOD TEST AND VACUUM TIGHTNESS

TEST

PURPOSE OF FOR EXECUTION / INFORMATION

DOCUMENT

DOCUMENT NO. PS:TSX:185:00:03

COPY NO:

ISSUED TO :

00 KJ MKS KB 22.09.2003

Rev. Prepared by: Reviewed by: Approved by: Date

BHARAT HEAVY ELECTRICALS LIMITED

PSSR / TECHNICAL SERVICES
474, ANNA SALAI, NANDANAM,
CHENNAI 600 035