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TAPP-3&4 COMMISSIONINGPROCEDURE
PROCEDURE NO: 3&4-
COMMISSIONING PROCEDURE FORGLAND SEALING STEAM SYSTEM
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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
NO. ACTIVITY REMARKS
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)
NO. ACTIVITY REMARKS
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
NO. ACTIVITY REMARKS
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: