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TAPP-3&4 COMMISSIONINGPROCEDURE

PROCEDURE NO: 3&4-

COMMISSIONING PROCEDURE FORGLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1

NUCLEAR POWER CORPORATION OF INDIA LIMITED(A Govt.of India Enterprise)

TARAPUR ATOMIC POWER PROJECT-3&4

Concurred BY

Name & design.

NPC Design Group

PREPAREDBY

CHECKED BY REVIEWEDBY

APPROVEDBY

ISSUED BY

COMMISSIONING PROCEDURE FORGLAND SEALING STEAM SYSTEMTAPP-3&4-41150-CP-1


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REVISION LOG

Revision Details Preparation Details

Issue No. Rev.No. Details DatePageNo.

Prepared byChecked byReviewed by

Concurred byApproved by


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CONTENTS

SL

NO.TITLE CLAUSE PAGE NO.

Cover sheet 1

Revision log3

Contents5

1.Purpose

6

2.

Pre-requisites

2.1 Status of other systems2.2 System Requirements2.3 Manpower requirements2.4 Requirement of special Equipments2.5 Requirement of outside agencies

2.6 Hazards & precautions

6

3.General method

7

4.Design intents

11

5.Expected process parameters

11

6.Work plan

11

7.Test report format

12

8.Reference

14

9.Verification process

14

10.List of annexure----Verification requirements

14


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1.0 Purpose:

The purpose of this procedure is to provide guidelines forcommissioning of the gland sealing steam system.

2.0 Pre-requisites:

2.1 Status of other systems:

a All erection activities should be completed.b Steam blowing/chemical cleaning of lines for auxiliary steam

and sealing steam supply up to gland steam supply valveshould be completed.

c Pipes should be normalized.d Temporary supports should be removed.e Steam supply from steam generators/another source is

available.

f Area telephone & communication system inside TB, controlroom & switchgear is available.g First Aid provision for skin burns due to hot pipes shall be

available.h Placards /signboards for alerting the personnel against hot

pipe contact & area cordoning is required during steamblowing of the system piping.

i Fire fighting system / portable fire extinguishers/fire tendersare available

2.2 System Requirements

Clearance to Commission following auxiliaries:

1. Turbine Sealing Steam Supply (MAW 10AA001)2. Leak off valve (MAW 50AA001)3. Gland steam supply control by pass valve (MAW 15AA001)4. Gland steam Leak-off control by pass valve (MAW 50AA005)5. Clearance to Commission Gland Steam Exhauster fans (MAW

80 AN001 & MAW 80 AN002)6. Drain downstream of Gland steam supply control valve MAL81

AA 0017. MAW 80 AA015-Steam air mixture line valve to GSC


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8. MAW 80 AA016-Steam air mixture line valve to GS fans9. Suction valves of GS Fans MAW 80 AA 031, MAW 80 AA 03210. GSC drip to FT (MAW 80 AA 005)11. RV (GSC RELIEF VALVE)- (MAW80 AA 011) commissioning

aspect i.e. it should be calibrated to its set pressure & calibration reportwith QA certification shall be available. (Setting to be checked at site forcalibration as per the standard check list of safety valve)

Ensure the persons working have valid certificate for working

on electrical equipment.

2.3 Manpower requirements:

Commissioning team (mechanical engineer -1, electrical engineer -1& C&I engineer -1 & supporting manpower from contractor onefitter, one electrician two helpers) should be available.

2.4 Requirement of special Equipments:

a. Oil fill for supply & leak off valves (HLP/ grade asspecified)

B. 1000V MEGGERc. Digital Multimeter d. Clamp-on meter e. Milli-ampere sourcef. N2 charging arrangement for N2 accumulator.g. Vibration meter.h. Direct reading contact type thermometer /non-contact type

infrared thermometer.

2.5 Requirement of outside agencies

a. NPCIL TG commissioning group for co-ordination.b. M/s BHEL commissioning group for execution & supervision of

commissioning activities

2.6 Hazards& precautions

The hydraulic units of gland steam supply & leak-off valves areequipped with positive displacement pumps. Loosening or

tightening of any mechanical item should be done afterdepressurization of the system.


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Gland steam condenser drain to be put to steam drain for initial period

3.0 General method

a Check the completion of erection as per thedesign flow sheets and drawings. Check the completion ofequipments and supports in gland supply steam lines & returnlines. Support checking shall be certified by support checkingcommittee of NPCIL

b Check for the proper identification, tagging of valves & equipment. Colour coding of painting on thepipelines shall conform the NPCIL norm T- 3&4 N-02

c Check for the flow direction marking and pipenumbers for system piping. Check that the valves areinstalled in the appropriate flow direction by comparing withthe flow direction marked in the valves. This is specificallyrequired for supply , return valves & & check valves.

d Check that isolation of equipments is possible formaintenance purpose.e Check electrically operated valves for electrical

and manual operation. The gearbox of the valves are to befilled with oil/ grease as per manufacturers guidelines.

f Check the proper working/stroking of controlvalves as per control output /Manual signal.

g Check that the alarm windows are of the requiredcolour.

h Check the proper wording in the alarm at theannunciation windows.

i Fill up the tanks through filter with the requiredgrade of oil (HLP 46) up to normal level for valves (MAW10AA001) &(MAW 50 AA 001). For this a funnel is to be used.

j Start the respective pump of individual actuators& see that pressure developed & maintained by relief valves ismore than 35 kg/cm2. Otherwise, set the pressure byadjustment of relief valve.

k Check the N2 pressure in the accumulator.Makeup N2 if required.


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l Commissioning Checklist for Unidirectional ElectricalDrives. (Applicable for Gland Steam Exhauster fans (MAW 80AN001 & MAW 80 AN002)

NO. ACTIVITY REMARKS

1. Check the correctness of installation as per approved drawing.2. Obtain commissioning clearance in writing from competentagency

3. Check that the equipment has been properly earthed.

4. Check and record the insulation resistance by a meggar.

5. Check and record the winding resistance (WR & Inductance)and nameplate details of the device.

6. Check for the test report of the Electrical MCC

7. Check for the correctness of overload relay setting

8. Perform functional check of the MCC by removing the outgoingcable connections and connect back after the functional check.

9. Issue start command from local and check for proper feedback.10. Check for the correctness of direction of rotation.

11. Record the starting current of each phase

12. Stop the device and select in remote mode.

13. Check the interlock and protection of the device as per logic

14. Operate the device from remote. After operating the devicefrom remote in no load condition, keep it operating for 2-3 hrs.& note down stabilized parameters such as windingtemperatures bearing temperatures current vibration

15. If everything is all right, then load the device to full load and

note down down the winding temperatures, bearingtemperatures, current & vibration.

16. Run the device for four /eight hours as per requirement andrecord the current in each phase at an interval of half an hour.

17. Prepare an interim report jointly.


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m Commissioning Checklist for Electrical Actuators: Applicable for

Gland steam supply control by pass valve (MAW 15AA001)Gland steam Leak-off control by pass valve (MAW 50AA005)Drain downstream of Gland steam supply control valve MAL81AA 001Steam air mixture line valve to GSC MAW 80 AA015 Steamair mixture line valve to GS fans MAW 80 AA016Suction valves of GS Fans MAW 80 AA 031, MAW 80 AA 032GSC drip to FT MAW 80 AA 005


Check the correctness of installation as per approveddrawing.

Obtain commissioning clearance in writing from competentagency

Check that the equipment has been properly earthed.

Check and record the insulation resistance by a meggar.

Check and record the winding resistance & inductance and

nameplate details of the device.Check for the test report of the Electrical MCC Necessary/relevant

document from EMUShould be available

Check for the correctness of overload relay setting Necessary/relevantdocument from EMUShould be available

Perform functional check of the MCC by removing theoutgoing cable connections and connect back after thefunctional checks.

Necessary/relevantdocument from EMUShould be available

Set the close and open limit switches by manuallyoperating the actuators.

10. Record the setting of the close and open torque switches

11. Keep the actuator in middle position

12. Issue open and close command from local and check forcorrectness of open and close direction. Since 3C-1 & 3C-2relays are inside MCC local operation of the valves are tobe dine by suitable jumpering from field JB. For thisnecessary jumpering details are to be worked out by C& Iengineers. After the checks the jumpering is to benormalised and verified.

13. Operate the valve for full open and full close position.Record the open and close timings.


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14. Calibrate the position transmitter if available and check forthe indication in the control room.

15. Operate the actuator from remote.

16. Prepare an interim report jointly.

n Commissioning Checklist for Hydraulic Actuators. Applicable for:Turbine Sealing Steam Supply Valve (MAW 10AA001), Leak off

valve (MAW 50AA001)


1. Check the correctness of installation as per approved drawing.

2. Obtain commissioning clearance in writing from competentagency

3. Check for the correct hydraulic pressure developed by the

pump. Check for any oil leakage and rectify if any4. Feed 4-20 milli amperes from local and check for valve

opening from full close condition to full open.

5. Calibrate the valve in steps of 0%, 25%, 50%, 75% and 100%in both open and close direction. Check for any oil leakage andrectify if any

6. Calibrate the position transmitter.

7. Give full close to full open command from remote in steps of10% and record the position feed back.

8. Prepare a joint protocol.

o System Commissioning:

1st stage commissioning

Stage ISteam blowing of the gland steam system downstream of G.S. supplyvalve

Ensure that the temporary piping has been as per the steam-

blowing scheme.


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Keep the gland steam supply-isolating valve (V-2401) near PRDSheader closed.

Install a spool piece in place of the gland steam supply valve.

Ensure that isolating valve of gland steam supply valve (MAW 10 AA511& 512) are open.

Ensure that bypass isolating valve of gland steam supply valve(MAW 10 AA 001) is open

Ensure that isolating valve of gland steam leak off valve (MAW 50AA 515 & 516) are closed.

The bypass valve of G.S. leak off valve (MAW 50 AA 005) is alsoclosed.

All drain lines of the gland steam system should not be connected tocondenser. They are to be left to atmosphere till completion ofblowing. Ensure the drain valve are open.

Ensure that proper diversion of steam blowing temporary pipeshas been done. Ensure that the exhaust ends of the temporarypipes are laid to a safe location

Ensure that the pressure and temperature points in the pipe systemis completed and the pressure points are closed and temperature

points are plugged with suitable plugs. Ensure that insulation of the pipe is completed.

Ensure that all temporary supports are removed and permanentssupports are erected.

After charging the main steam line at pressure of 20 kg/cm2 slowlyopen the isolating valve V 4201 and warm up of the line up to theoutlet of the gland steam pipes near turbine seals for 10 min tillwater stops coming out through the drains

Increase the valve (V-2401) opening and continue blowing of linesfor 15 minutes at 20-kg/cm2 pressures.


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HP

TURBINE

TURBINE

LP

LP

TURBINE

T O C O N D E N S E R

F R O M P R D S S Y S T E M

T E M P O R A R Y P I P I N G S F O R S T E A M B L O W I N G . T O B E R O U T E D T O S A F E L O C A T I O N

2nd stage commissioning


1. Complete the settings in the Procontrol panel meant for GlandSteam controller as per C&I O&M manual

2. After ensuring draining of water in the pipeline and its warmadmit steam. Check for any leaks and if any get it attended.Ensure the following readiness

One GS blower is in service

GSC condensate valve are opened and properly vented.

Condenser is ready for accepting leak off steam

Fire fighting staff and facility is availableCharge the pressure transmitters and ensure correct indicationof gland steam pressure in control room.

3. Operate the gland seal supply valve manually and check forchange in gland steam pressure variation.

4. Operate the leak steam valve manually and check for changein gland steam pressure variation. Note down maximum

pressure and gland steam supply valve opening when steamstarts coming out of turbine glands.


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5. Put the gland steam pressure controller on auto and observethe behavior of the controller.

6. Stabilize the controller by tuning the control parameters likeProportional Gain, Integral Gain etc.

7. Check for the change over from Gland seal supply valve toleak steam control valve during loading of the machine andvice versa.

8. Check for the operation of Drain before Seal steam supplyvalve as per logic. Repeat step 7 if required for optimizing theG.S controller with TG on load

9. Check for related alarms and annunciations in the control room

10. Prepare an interim report jointly

4.0 Design intents

a Overlap between valves (MAW 10AA001) &(MAW50 AA 001) should not be less than 5%.

b Breathing of control valves should be within + 2%of stroke.

c Dp high across filters of (MAW 10AA001) &(MAW50 AA 001) should appear in control room.

5.0 Expected process parameters

The gland steam pressure in the header should be maintained

within 0.03 + 0.005 Kg/cm2 under stabilised conditions of self-

sealing or external supply steam conditions.

6.0 Work plan:

a Commissioning of electrical actuatorsb Commissioning of Hydraulic actuatorsc Commissioning of system in dynamic conditions.d COMMISSIONING NETWORK :

COMMISSIONING NETWORK OF GLAND STEAM SYSTEM

1 2 3 4 5 6


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NORMALISATION OF GLAND STEAM PIPINGSAFTER STEAM BLOWING

COMPLETION OF COMMISSIONING OFELECTRICAL ACTUATORS IN MS , HRH ,CONDENSATE SYSTEM

COMPLETION OF COMMISSIONING OFHYDRAULIC ACTUATORS IN MS, HRH LINES

INSTALLATION OF PRESSURE ANDTEMPERATURE INSTRUMENTS

COMPLETION OF FIELD CHECKS OF ALLPRESSURE AND TEMPERATURE INSTRUMENTSUP TO CONTROL ROOM

READINESS OF BARRING GEAR SYSETM

READINESS OF CONDENSATE SYSTEM

READINESS OF CW SYSTEM

STEAM GENERATOR READINESS FOR VACUUMPULLING OPERATION

READINESS OF CONTROL FLUID SYSTEM

VACUUM PULLING WITH GLAND STEAM ANDTUNING OF GLAND STEAM CONTROLLER FORMANUAL & AUTO OPERATION

7.0 Test report format

(A) PRE-COMMISSIONING CHECKLIST FOR FANS

Equipment tag number: MAW 80 AN001

System Description: Gland steam exhauster fan

P&ID No:TAPP-4/41150/5001/FS/REV NO R1

Manufacturers Name.

Name Plate details


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Date

SlNo

Activity Description Remarks

1. Bearing lubricated as recommended

2. Rotor free in its bearings

3. Motor checked and rotation proved

4. Instrumentation & protection devices

checked5. Holding-down bolts and dowels fitted

securely

Fan is ready for commissioning

DATA SHEET FOR FANS

Start Time: Stop Time:

TIMEDATA UNITS

Motor Cur-rent

Amps

Vibration atMotor CE

Microns/mm/sec

Vibration atMotor FE

Microns/mm/sec

Temperatureat Motor CE

Deg C

Temperatureat Motor FE

Deg C

Legend: CE Coupling End, FE- Free End

Equipment tag number: MAW 80 AN002

System Description: Gland steam exhauster fan

P&ID No:TAPP-4/41150/5001/FS/REV NO R1

Manufacturers Name. Name Plate details


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Date

SlNo

Activity Description Remarks

1. Bearing lubricated as recommended

2. Rotor free in its bearings

3. Motor checked and rotation proved

4. Instrumentation & protection devices

checked5. Holding-down bolts and dowels fitted

securely

Fan is ready for commissioning

DATA SHEET FOR FANS

Start Time: Stop Time:

TIMEDATA UNITS

Motor Cur-rent

Amps

Vibration atMotor CE

Microns/mm/sec

Vibration atMotor FE

Microns/mm/sec

Temperatureat Motor CE

Deg C

Temperatureat Motor FE

Deg C

Legend: CE Coupling End, FE- Free End

SEALING STEAM SYSTEM COMMISSIONING

Sl

No

Description Checked

OK/NOT OK

Remarks

1 Gland steam system pressure


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control from remote.

2 Aux PRDS Pressure controlfrom remote.

3 PRDS Temperature controlfrom remote.

4 Change-over from MAW 80AA015 to MAW 80 AA016 onGSC level high

5 Opening/closing of MAL81 AA

001 on temperature interlock6 Tripping of MAW 10AA001 on

temperature protection

8.0 Referencea. Turbine O&M manualb. Drawing no. TAPP-4/41150/5001/FSc. FCD For gland steam supply system


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9.0 Verification process

Verification process is to be carried out as per the followingverification table.

Activity Acceptance criteria Verification agency

Steam blowing As the provision no targetplate can be provided, so the

guideline will be blowingsteam pressure (20kg/cm2),temperature (220-240 deg)& duration (20 minutes) oncontinuous blowing mode.

Engineer from TGcommissioning group

& as per practice ofNPCIL.

Gland steamblower (fan)commissioning

Acceptance criteria would beas per MI/ED/FCD/SFD

Commissioning ofelectrically

operated valves

Acceptance criteria would beas per MI/ED/FCD/SFD

Commissioning ofgland steamsupply and leaksteam valves

AS per MIs of these valves &as per the design documentsof GS pressure control

10.0 List of annexure

a Verification requirements


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APPENDIX 2

VERIFICATION TABLE

COMMISSIONING PROCEDURE FOR (Title)__________________COMMISSIONING PROCEDURE NO._________________________________

SL.

NO

ACTIVITY

VERIFIED

ACCEPTANCE

CRITERIA

VERIFYING

AGENCY

CERTIFICATION BY VERIFYING AGENCY

PROCEDUREVERIFICATION

INSPECTIONWITNESS

FUNCTION-AL TEST

RESULTVERIFICA-TION

GENERALREMARKS

1 Pl refer4.0

Pl refer 4.0


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ANNEXURE

NUCLEAR POWER CORPORATION OF INDIA LIMITED(A Govt. of India Enterprise)

TARAPUR ATOMIC POWER PROJECT3&4

COMMISSIONING PROCEDURE ACCEPTANCE NOTE

Contractor commissioning procedure number ___________________________ forthe commissioning of GLAND SEALING STEAM SYSTEM submitted by BHEL underthe contract number ______________ is received and found conforming to therequirement of NPCIL specifications & Norms & hence accepted.

Commissioning procedure number:

Commissioning procedure title:

_____________________________________

GLAND SEALING STEAM SYSTEM

NAME & DESIGNATION SIGNATURE

Reviewed by:Concerned Commg. Engs./Sr.Commg. Engs/SMEs

Concurredby:

ConcernedENCs/Suptds.

NPC DesignGroup

Approved by:

GS construction

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