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NTPC

VINDHYACHAL

TESTING SCHEDULE FOR INSTRUMENT AIR COMPRESSOR

COMMISSIONING GROUP (2x500MW) STAGE-III/OFF SITE

Station: NTPC- VINDHYACHAL BHEL Ref No. Sheet 1 of 20 Stage III (2X 500 MW) NTPC Ref No. Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT TEST METHOD PROGRAMME RESULTS REINSTATEMENT AND PRESERVATION STAFFING RESPONSIBILITIES COMMUNICATION SPECIFICATIONS

LIST OF CONTENTS

Station: NTPC- VINDHYACHAL BHEL Ref No. Sheet 2 of 20 Stage III (2 X 500 MW) NTPC Ref No Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO REMARK PLANT DESCRIPTION 1.0 1.1 Compressed air requirement of 2x500 MW units of stage III of VSTPS will be met by proposed compressor installation which consist of three (3) nos of Instrument air compressors and two (2) nos of plant air compressors of capacity 48.96M3/min each. The normal working pressure & temperature of these systems is 7.5 KSC & 50 degree c. Each Inst Air Comp shall be complete with drive motor, intake air filter ,silencer, inter cooler& drier.. 1.2 Compressor description: Compressors are enclosed in a sound insulated body work & include mainly Air filter Low pressure compressor element Inter cooler High pressure compressor element After cooler Oil pump Electric motor Drive coupling Gear casing Electronic control system Safety valve Air drawn through filters is compressed in low-pressure compressor element and discharged to intercooler. The cooled air is further compressed in high-pressure compressor element & discharged through silencer and after cooler towards the air net. A check valve is provided down stream the after cooler. The cooling water flows through oil cooler, the cooling jackets of high pressure compressor element, low pressure compressor element, around the outlet pipe of compressor element as well as through inter cooler & after cooler. Signatures NTPC BHEL

Station: NTPC- VINDHYACHAL BHEL Ref No. Sheet 3 of 20 Stage III (2 X 500 MW) NTPC Ref No. Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO

PLANT DESCRIPTION
Oil is circulated by pump from the sump of gear casing through cooler & filter towards the bearing & timing gears. Oil circuit bypass valve opens if the oil pressure should rise above a given value. Three moisture trap are installed: one downstream of the intercooler to prevent condensate from entering compressor element, one downstream of the after cooler to prevent condensate from entering the air outlet pipe & one fitted in the blow off pipe to prevent moisture trap from blowing through silencers during transition from loaded to unloaded operation. The moisture traps are connected to condensate drain receiver. Each drain receiver is provided with a float valve to automatically drain condensate and manual drain valve.

REMARK

2.0 2.1 2.2 2.3 2.4 2.5

TESTING OBJECTIVE
To test the compressors suitability for continuous running without any abnormality. To set intercooler safety valve. To set after cooler safety valve. To set air receiver tank safety valve. To test the loading and unloading of the compressor.

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Station: NTPC- VINDHYACHAL BHEL Ref No. Sheet 4 of 20 Stage III (2 X 500 MW) NTPC Ref No. Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 3.0 3.1

TESTING PROPOSAL
Test run the compressor at no load for 10 minutes and observed the following;1) motor starting current 2) motor end bearing temperature & plumber block temperature. 3) Motor bearing & pedestal bearing vibration. 4) Any knocking sound from crank case or cylinder. 5) Any leakage of water 6) Oil pressure & temperature. Test run the compressor for 8 hrs at load and observe the following;1) motor starting current 2) motor end bearing temperature & plumber temperature. 3) Motor bearing & pedestal bearing vibration. 4) Any knocking sound from crank case or cylinder. 5) Any leakage of water 6) Oil pressure & temperature. 7) 1st stage air pressure. 8) 2nd stage air pressure. 9) Air temp at inlet & outlet of intercooler. block

REMARK

3.2

3.3 3.4 3.5 3.6

Set the pressure of intercooler safety valve at 2.136KSC(G) Set the pressure of aftercooler safety valve at 8.80 KSC(G) Set the pressure of receiver safety valve at 8.80 KSC(G) Set the pressure switches on unloading header at recommended pressure and check the unloading & loading operation of the compressor

Signatures NTPC BHEL

Station: NTPC- VINDHYACHAL BHEL Ref No. Sheet 5 of 20 Stage III (2 X 500 MW) NTPC Ref No. Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 4.0 4.1 4.2 4.3 4.4 5.0 5.1

SERVICES REQUIRED
Availability of compressors Availability of cooling water Availability of Electric supply (3.3 KV AC, 220V AC & 415V AC) Availability of recommended grade of lubricating oil. SAFETY PROPOSAL All the members of the test team and all other persons involved in this commissioning schedule must be made familiar with the contents of the commissioning schedule. Safe access to and adequate escape routes from confined areas must be maintained. The test area will be effectively defined. Access to the test area will be restricted where necessary by use of barriers and / or warning notices. The test area will be clear of obstructions. Permanent lighting supplemented by temporary lighting where necessary, must be available to give the adequate lighting for all times. All handrails, access stair, ladders, guards and trench cover must be permanently fitted unless specifically exempted by the test method. All check list and other pre commissioning activities will have been completed.

REMARK

5.2 5.3 5.4 5.5 5.6

5.7

5.8

Signatures NTPC BHEL

Station: NTPC VINDHYACHAL Stage III (2 X 500 MW)

Plant area:
ITEM NO 5.9 5.10 5.12 5.13

BHEL Ref No. Sheet 6 of 20 NTPC Ref No INSTRUMENT AIR SYSTEM (IAC # ------) REMARK

Safety rules & clearance certificate will be in force. The operation department must be informed on a daily basis of the programmed being carried out. Safety clearance notification certificate will be in force. The test method must be strictly adhered to all times except in the following circumstances : 1) In an emergency situation. 2) By agreement with the working party. 3) On instruction from the test team Leader. Emergency push button should be manned at the time of 1st starting of the compressor.

5.14

6.0 6.1

EMERGENCY PROCEDURE All the member of the test team should be aware of the procedure to be adopted in the event of major / minor accident / incident which requires emergency services. Fire extinguishers should be available to prevent the fire.

6.2

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Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 7 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 STATE OF THE PLANT The erection of the compressor and its associated air pipe work completed. Suction and discharge pipe work pressure tested and proven. Cooling water pipe work pressure tested and proven. Oil pipe work pressure tested & proven. All pressure parts are tested and proven. Test certificate available. Receiver outlet is disconnected (after the receiver outlet valve) from the system and open to atmosphere. Lubricant quality report must be available, duly signed by the chemist. All the service mentioned in section 4 is available. Safety clearance certificate will be in force. Safety notification certificate will be in force. Mechanical plant item completion list is completed & available. Electrical plant item completion list is completed & available. Instrumentation plant item completion list is completed & available. Manufacturers test certificate is available. All erection FQPS (signed) handed over to commissioning. REMARK

Signatures NTPC BHEL

Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 8 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 8.0 8.1 8.1.1 8.1.2

TEST METHOD
Trial run of compressor: Check that the compressor drive unit is properly aligned. Carry out physical inspection to check complete installation including all the pipe work and the alignment of the compressor with its driving unit. Ensure that no permit are outstanding and that the plant is safe. Before carry out the following activities, ensure that the 3.3 KV motor breaker is racked out & isolated. Open the inspection door of crankcase and check:1) Cleanliness of inside of crankcase. 2) The bigger end bearing & main bearing fasteners are tightened to the correct torque setting. 3) Fly wheel key is installed. Fill up the crankcase with recommended grade & specified quantity of lubricating oil. Observe the level in the indicator. Prime the oil pump as follows;Loosen the connection to oil pressure gauge to remove air locking. Rotate the AOP motor in correct direction.

REMARK

8.1.3 8.1.4 8.1.4.0

8.1.5.1 8.1.5.2 8.1.6 8.1.6.1 8.1.6.2

Signatures NTPC BHEL

Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 9 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 8.0 8.1.6.3

TEST METHOD
Check for oil discharging through the impulse pipe of all the oil pressure gauge. Then tighten the connection to the oil pressure gauge. Open the main isolating valve in cooling water inlet & outlet header. Establish the cooling water flow in the cooling water circuits. Open the drains provided in the cooling water pipes and observe that water is coming out of this. Then close the drains. Ensure that there are no leakages in the cooling water pipes. Rotate the coupling in proper direction by hand & check the freeness. Fully open the following valves:1) Inter cooler drain. 2) After cooler drain 3) Air receiver drain 4) Air release valve 5) After cooler outlet valve 6) Discharge damper drain 7) Air receiver outlet valve Check all the start permissive, alarms & protections Put the circuit breaker in TEST position & check the operation of emergency push button. Open the isolation valves in all impulse lines. Put the circuit breaker in service position

REMARK

8.1.7.1 8.1.7.2 8.1.7.3 8.1.7.4 8.1.8 8.1.9

8.1.10 8.1.11 8.1.12 8.1.13 Signatures

NTPC

BHEL

Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 10 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 8.0 8.1.14 Start the compressor from control panel and allow it to run up to full speed, then stop it and check the following:1) starting current 2) Coasting down time. 3) Any abnormal noise during starting and coasting down of the compressor. 8.1.15 If every thing is normal then start the compressor from control panel Run the compressor for 10 minutes at no load and check the following:1) 2) 3) 4) 5) 6) 7) 8.1.17 Motor current and voltage Motor body temperature Pedestal bearing vibration. Plumber blocks temperature. Lu oil pressure and temperature. Motor end bearing vibration. Cylinder & crank case vibration.

of 20

REMARK

8.1.16

Upon satisfactory completion of the 10 min run period, fully closed all the drain valves mentioned in 8.1.9 and air release valve. Commission the condensate traps on the inter cooler, after cooler and receiver drain. Commence loading the M/C by controlling (throttling) the air outlet valve, fitted on the air receiver outlet.

8.1.18 8.1.19 Signatures

NTPC

BHEL

Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 11 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 8.0 8.1.20 Throttle the air receiver out let valve so that 2nd stage air pressure reaches 2.0KSC. Run the machine continuously for 1 hr. and check the following,: 1) 2) 3) 4) 5) 6) 7) Motor current and voltage Motor body temperature Pedestal bearing vibration. Plumber blocks temperature. Lu oil pressure and temperature. Motor end bearing vibration. Cylinder & crank case vibration. REMARK

Reading to be taken at 15 min interval, until the temperature stabilized. 8.1.21 Also check the 1st stage air pressure, 2nd stage air pressure, air temp at inter cooler and after cooler, inlet and outlets, cooling water inlet header temp., cooling water out let temp Further increase the 2nd stage air pressure, by 1.00KSC step by step, by throttling the air receiver outlet valve and run the m/c for 1hr. Continue the above procedure at increased pressure steps of 1.00KSC up to max of 7.00 KSC Finally rise the 2nd stage air press to 7.00 KSC. Run the compressor for 2hrs. Maintain the 2nd stage air pressure at 8.00 KSC Take readings as specified on the log sheet at one(1) hr intervals, spaced 15 min after each step change ion load. If there is any abnormality during this trial run, immediately stop the m/c and attend the abnormality. After the defects have been attended, again run the m/c as per above procedure for 8 hrs.

8.1.22

8.1.23

8.1.24 8.1. 25

Signatures NTPC BHEL

Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 12 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 8.0 8.1.26 8.1.27 8.1.28 8.2 8.3 8.4 8.5 8.5.1 8.5.2 8.5.3 8.5.4 Open the air receiver outlet valve fully. Stop the compressor by pushing the emergency push button. Open after cooler, air receiver, inter cooler drains. Set the intercooler safety valve at 2.2 KSC. Set the after cooler safety valve at 8.8 KSC. Set the air receiver safety valve at 8.8 KSC To check the unloading and loading of compressor:Start the compressor as described in section 8.1. Gradually raise the 2nd stage pressure to 8.0 KSC by throttling the air receiver outlet valve Set the pressure switches at the recommended set values. Observed the unloading & loading operation take place at the set values. Observe the motor current during the unloading and loading sequence. Run the compressor for 2 hrs and take reading as per log sheet. REMARK

8.5..5

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Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 13 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 9.0 9.1

PROGRAMME
When all checks list have been completed and the defects and omission complied and the area brought under safety clearance certificate then testing can commence. The test programme can take place at any time when all the concerned parties are assembled. Once the general conditions as mentioned in section 7 of this testing schedule have been met, the testing method can be carried out at any time thereafter.

REMARK

9.2 9.3

10.0 10.1 10.2 10.3

RESULT
Result will be tabulated in the log sheet as shown in appendix Conclusion will be recorded upon completion of the test run. A test report will be produced upon successful completion of this programme

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Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 14 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 11.0 11.1 11.2 11.3 11.4 REINSTATEMENT AND PRESERVATION Isolate 3.3 KV supply Switch off 220 V AC supply Switch off 415 V AC supply. Close the inlet cooling water valve after the compressor has cooled to near ambient temperature. Drain the cooling water pipes. After complete draining of inter cooler, after cooler, air receiver. Close all the drain cocks. REMARK

11.5

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Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 15 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 12.0 12.0

STAFFING
The test team, which has been approved by the Boiler / Turbine/Off site commissioning panel, will consist of :1. Test Team Leader 2. Erection Mechanical 3. Erection Electrical 4. Erection C&I 5. O&M Mechanical 6. O&M Electrical 7. O&M C&I 8. O&M Chemist 9. Civil construction 10. Contractor Mechanical 11.Contractor Electrical 12.Contractor Comm..Mech 13.Contractor Comm..Elect 14.Contractor Comm..advisor 15.Contractor C&I Erection 16.Contractor C&I Commissioning

REMARK

Signatures NTPC BHEL

Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 16 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO 13.0 13.1 13.2

RESPONSIBILITIES
Team leaders responsibilities are : To ensure that all the items within the testing schedule are compiled with. He has the authority to delegate formally some of the function and checking contained within the schedule. To ensure that an effective communications skill has been set up between the test areas and other affected pertaining plant. All test team members have the responsibility of carrying out the test method in a manner that will safeguard both plant and personnel.

REMARK

13.3

13.4

14.0 14.1

COMMUNICATION
A reliable communications system must be established between the team members, control panels and local stations.

Signatures NTPC BHEL

Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 17 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO

SPECIFICATIONS

REMARK

Air compressor Instrument air Manufacturer Atlas copco (India Ltd.) Model no ZR355-10 Type of compressor Oil free screw Total no offered 2W+1S Capacity of each compressor 37.4 Nm3/min or 50.88 m3/min Discharge pr at HP outlet 7.8 Ksc Discharge pr of instrument air at 7.5 Ksc ADP outlet Capacity considering ambient 48.96 m3/min condition (450C & 75% RH) Outlet temp after high pr stage of 1900C compressor Outlet air temp after cooler for 400C plant air system Outlet air temp after ADP for 400C plant air system Sound level 71 DB Intake filter & silencer Type Dry paper filter Pressure drop .02 bar Filtering medium Spherical paper Air receiver Design code IS 2825 Class II Design pr 10 Ksc Inter cooler, after cooler & heat exchanger Intercooler After cooler Heat exchanger Quantity One One One Air inlet temp 160 165 Signatures NTPC BHEL

Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 18 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO

SPECIFICATIONS

REMARK

Cooling water outlet temp 43 43 Cooling water outlet temp 43 43 Cooling water consumption at 4.8 lps or 17.28 m3/hr temp rise of 15 C Inlet pr to coolers 74.5 MWC Moisture separator provided Yes Yes Yes Oil capacity 85 litre Compressor Motor Make Crompton Greaves Rating 340 KW Speed 1480 rpm 3 No of permissible starts when motor is in cold condition No of permissible starts when 2 motor is in hot condition Max permissible temp of rotor 4500C Air dryer Manufacturer Atlas Copco air power, Belgium Model no MD 1000W Total no offered 3 Type of operation Continuous Location Indoor Rated flow 1000 lps (60 cub m) Dew point meter at air dryer -400C outlet Air pressure drop .25 bar Max electrical power input 120 W Cooling water consumption 3 lps or 10.8 m3/hr corresponding to water temp rise of 5 degree & inlet temp 38 degree Temp of dried compressed air 410C Signatures NTPC BHEL

Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 19 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------)

LOG SHEET
Plant Air Compressor # _____started at________hrs
S. no

Date: _________ hrs ______ hrs

Tag no

Description Motor current Motor DE brg temperature Motor NDE brg temperature Motor winding temperature Cooling water flow/in /out pr

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 PT-29 PDT-02 PT-18 PT-49 TT-11 TT-18 TT-21 TT-44 TT-29 TT-51 TT-58 TT-59

Current discharge air pressure Delta P filter Intercooler pressure Lub oil pressure LP air outlet temperature HP air inlet temperature HP air outlet temperature Lub oil temperature Air discharge temperature Cooling water inlet temperature Cooling water LP outlet temperature Cooling water pack outlet temp

The Air compressor # _____ stopped at ________Hrs. Signatures NTPC BHEL

Station: NTPC VINDHYACHAL BHEL Ref No. Sheet 20 of 20 Stage III (2 X 500 MW) NTPC Ref No. / Plant area: INSTRUMENT AIR SYSTEM (IAC # ------) ITEM NO REMARK

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