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.
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.
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