NTPC/RhSTPP OPERATION DEPARTMENT UNIT -

AREA- Turbine Generator air tightness test REV: 0

STAGE# 2&3 Date:09.12.2019

Procedure for Generator Air Tightness Test:

Criteria for acceptance of the test:
1) The test pressure drop in the system should be monitored for a period of 24 hours. No break is
allowed.
2) The gas system can be considered sufficiently tight when the pressure drop during a 24hours test
with compressed air loss of air is below 1.5m³/24 hrs (s.t.p).
3) If air loss is higher than 2.4m³ (s.t.p) / 24 hrs, a search for leakages must be made.
4) The test pressure should correspond to the rated gas pressure of the generator (i.e. 3.5 bar)
5) The loss of air is determined as follows:

V= [(0.2694×24)/z] X Vа {[(P1+ Pb1)/ (273+ t1)] - [(P2+ Pb2) / (273+

t2)]}
0.2694 = (273ºK / 1013.25mbar).
Where
V= loss of air in m³ (s.t.p) / 24 hrs periods Z = duration of leakage test in hrs.
P1= gauge pressure within the system at beginning of the leakage test in mbar.
P2= gauge pressure within the system at end of the leakage test in mbar.
Pb1 = Barometer reading at beginning of the leakage test in mbar.
Pb2 = Barometer reading at end of the leakage test in mb.
t1 = temperature of the gaseous atmosphere at beginning of leakage test in ºC.
t2 = temperature of the gaseous atmosphere at end of leakage test in ºC.
6) If the test is not successful then the reason of higher pressure drop is to be ascertained & the test is
to be reconducted.

PRE TEST CONDITION OF THE SYSTEM: -

1) Unit is under shutdown.
2) Clearance is available from C&I , TMD , EMD for conducting the air tightness test.

PREPARATION FOR THE TEST:

1) Check the line up for the test. All LLDs drains are closed, H2 drier status etc.
2) Ensure the seal oil system is in operation. Ensure DC SOP is available.
3) Ensure that the H2 coolers are filled with / without water but important is no circulation of water takes
Place through the cooler. Both inlet & outlet valve of all 4 hydrogen coolers are closed.
4) Internal primary water circuit should also be included in the leakage test of H2 gas system.
5) Ensure the availability of Cold gas temperature points in OWS for temperature measurements.
5) Close the main gas and measuring gas pipes at the generator
6) Ensure the availability of instrument air and bleed the instrument air sufficiently to ensure the air is
free of moisture.

Page 1 of 4
 NTPC/RhSTPP OPERATION DEPARTMENT UNIT -

AREA- Turbine Generator air tightness test REV: 0

STAGE# 2&3 Date:09.12.2019

TEST PROCEDURE: -
1) Air Filling valve is to be opened for flushing of line & removal of moisture in atmosphere.
2) Chemistry is to take sample for dew point measurement. After chemistry clearance, Filling process
has to be continued.
3) Close the waste gas (vent) valves.
4) Connect flexible air hose with the gas plant through the coupling and ensure no air leakage is there.
5) The filling is to be done by opening the valves in the normal H2 filling line where as the valve from
H2 rack side will remain closed.
6) Once the air filling is commenced the test record data sheet as per annexure –1 is to be filled.
7) The air valve is to be opened full.
8) While pressurizing, LLD status / Seal oil parameters are to be recorded as per the enclosed sheet.
9) The generator casing is to be pressurized with instrument air up to pressure of 3.5 ksc.
10) If any problem is experienced in maintaining the DP or DPR is haunting then EMD is to be informed.
11) Record the time when the pressure has reached at 3.5 ksc.
12) During the filling procedure, the valves at the gas valve rack (except for the waste gas valves)
should be open continuously to ensure that the air components are included in the leakage test.
13) Stop the air filling and shut off the valve when the test pressure has been reached (3.5bar) and then
disconnect the air hose from the system to avoid further pressurization of the system.

Commencement of the test:

1) Once the rated pressure has been attained, the test can be commenced.
2) Once the test is commenced the test record data sheet as per annexure –2 is to be filled at
hourly basis for continuous 24 hrs.
3) During test ensure the LLD‘s are not getting oil.
4) Monitor the pressure drop in the system for a period of 24hours.
5) If a pressure increase was observed in the primary water tank, a leak of the primary water
system within the generator would be expected and must be located and attended.
6) If an air loss higher than 2.4m³ (s.t.p) / 24 hrs, a search for leakages must be made.
7) Leakages must be attended and then test must be repeated until satisfactory results are
obtained.

Normalisation of the system:

1) After the test is declared complete, the air is to be depressurised and the system is to be
normalised.
2) If immediate filling of H2 is not programmed, depressurise the system by opening waste gas line
valve up to 2.0 bar.
3) Normalise the primary water system.
4) Normalise the all-4 hydrogen coolers.
5) Open the main gas and measuring gas pipes at the generator.
6) Then the generator may be filled with CO2 and subsequently with H2 as per normal procedure
after recording clearance from concerned departments.

Page 2 of 4
 NTPC/RhSTPP OPERATION DEPARTMENT UNIT -

AREA- Turbine Generator air tightness test REV: 0

STAGE# 2&3 Date:09.12.2019

ANNEXURE-1
DATA SHEET FOR AIR PRESSURISATION TO 3.5 BAR

1. Filling Start Time

2. Filling End Time
3. Total Duration

Time Casing Seal Oil Pressure Seal Oil DP Seal Oil Pump In service
Pressure
In KSC TE EE
AS SOP H2S SOP
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5

Page 3 of 4
 NTPC/RhSTPP OPERATION DEPARTMENT UNIT -

AREA- Turbine Generator air tightness test REV: 0

STAGE# 2&3 Date:09.12.2019

ANNEXURE-2
LOG SHEET FOR GENERATOR AIR LEAKAGE TEST AT 3.5 bar

Casing Air temperature Barometer

S.no Date Time Pressure reading
In ksc 1 2 3 4 AVERAGE AMBIENT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Prepared By Reviewed By Approved By

Name Omesh Kumar R K Maurya A K Patra

Designation Manager(O) DGM (O) AGM (O)

Page 4 of 4
 HAZARD IDENTIFICATION & RISK ASSESSMENT (HIRA)
S. NO. POTENTIAL HAZARDS Y/N PREVENTIVE MEASURES Y/N
Wear safety shoes, helmet, nose
1 Use of proper PPE. mask and ear muff/plug before
entering to plant premises.
Wear safety shoes and walk
2 Accident due to fall during walking on floor
carefully
Instruct everyone to walk/work
Accident/injury due to fall of material from top
3 carefully on platform, so nothing
side plate form
falls down. Wear safety Helmet.
Arrange for proper illumination in
4 Accident/injury by fall due to low illumination
working area
Care to be taken while walking on
Accident/injury due to floor opening/loose
5 gratings. Floor opening to be
gratings
barricaded.
Care to be taken while walking or
6 Accident/Injury/Fall due to oil/water spillage
operating system.
Wear goggles. Work safely keeping
7 Injury to eyes due to dust/ash
safe distance from co-worker.
Provide fans for ventilation & cool
8 Fainting of worker due to high heat exposure air. Rotate workers during long
working hours
Keep space for movement of
Accident/injury from moving tractor trolley or
9 vehicles. Check horn & back-horn
skid loader
regularly.
Keep safe escape routes in working
10 Stampede during escape in case of emergency
area.
During opening of water valve,
Accident/Injury due to mishandling of water hose & lance should be hold
11
lances/hose pipes properly. Water jet should be
focused on right place.
Care to be taken while isolating /
12 Accident due to electrical burn/shock working / checking on motor or
electrical panel
Ensure complete mechanical
13 Accidents while working on pressurized system isolation/locking and draining of
the system before start of work
Do not touch any insulated/bare
14 Accidents due to burn
pipes, equipment.