A. B. Hopkins Generating Station
OPERATING PROCEDURE
Seal Oil And Hydrogen System
HOPKINS REPOWERING PROJECT
UNIT HP2A
A.B. Hopkins Generating Station
August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HP2A
TABLE OF CONTENTS
Section
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
Draft
Page
Introduction .....................................................................................................................................................1
1.1 Purpose and Scope .............................................................................................................................1
1.2 System Identification and Scope Definition .......................................................................................1
SYSTEM STARTUP ............................................................................................................................................1
2.1 Preoperational Procedures ................................................................................................................1
2.1.1 Prerequisites .......................................................................................................................1
2.1.2 Prestart Requirements .......................................................................................................1
2.2 Precautions and Limitations ...............................................................................................................2
2.3 Seal Oil and Hydrogen System Block Flow Diagrams .........................................................................2
2.3.1 Electric Generator Auxiliary Systems .................................................................................2
2.3.2 Seal Oil and Hydrogen System Diagrams ...........................................................................4
2.4 Replacing Generator Air with Carbon Dioxide ...................................................................................7
2.5 Replacing Generator Carbon Dioxide with Hydrogen ........................................................................7
2.6 Placing the Generator Seal Oil System in Service ..............................................................................8
SYSTEM NORMAL OPERATION ........................................................................................................................9
3.1 System Routine Checks ......................................................................................................................9
SYSTEM ABNORMAL OPERATION ..................................................................................................................10
4.1 Gas Dryer Reactivation .....................................................................................................................10
SYSTEM SHUTDOWN .....................................................................................................................................11
5.1 Removing Seal Oil System from Service ...........................................................................................11
5.2 Purging Generator Hydrogen with Carbon Dioxide .........................................................................12
5.3 Replacing Generator Carbon Dioxide with Air .................................................................................12
5.4 System Post-Shutdown Checklist .....................................................................................................13
5.4.1 Short Term ........................................................................................................................13
5.4.2 Long Term .........................................................................................................................13
ALARM RESPONSES .......................................................................................................................................13
6.1 Summary of Alarms ..........................................................................................................................13
CHECKLISTS AND TABLES ...............................................................................................................................28
Table 1 - Power Supply Checklist ...............................................................................................................28
Table 2 - Prestart Valve Lineup Checklist ...................................................................................................28
Table 3 - Local Indicating Instruments .......................................................................................................30
Table 4 - Control Room Indicating Instruments.........................................................................................31
REFERENCES ...................................................................................................................................................31
8.1 P&ID ..................................................................................................................................................31
8.2 Electrical One Line Diagrams ............................................................................................................31
8.3 Control Diagrams ..............................................................................................................................31
8.4 Instrument Loop Diagrams ...............................................................................................................32
8.5 Instruction Manuals ..........................................................................................................................32
8.6 Miscellaneous ...................................................................................................................................32
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A.B. Hopkins Generating Station
August 1 2014
1.0
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
INTRODUCTION
1.1 Purpose and Scope
The purpose of this operating procedure is to provide the operator with specific procedures for
operating the Seal Oil and Hydrogen System and Associated Systems. The operating procedures include those
detailed procedures required to start up, operate, and shut down the Seal Oil and Hydrogen System in a logical,
efficient, and safe manner. The seal oil and hydrogen system cools the hydrogen-cooled generators. The
operating procedure includes the following sections:






Section 2.0 - System Startup
Section 3.0 - Normal Operations
Section 4.0 - System Abnormal Operations
Section 5.0 - System Shutdown
Section 6.0 - Alarm responses
Section 7.0 - Checklists and Tables
1.2 System Identification and Scope Definition
The Seal Oil and Hydrogen System supports the hydrogen-cooled electric generators. The hydrogen
cools the generator and the seal oil prevents the hydrogen from mixing with the atmosphere outside of the
generator. The system contains the following subsystems and major components:
a. Seal Oil System
b. Gas System
2.0
SYSTEM STARTUP
2.1 Preoperational Procedures
2.1.1
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
Prerequisites
The 125 VDC electrical distribution system is in service.
The 480 VAC electrical distribution system is in service.
The compressed air system is in service.
The circulating water system is in service.
The steam turbine and auxiliary system are ready for service.
The fire protection system is in service.
The main steam system is in service.
The steam generation system is in service.
The condensate cooling system is in service.
The condensate and feedwater systems are in service.
2.1.2
Prestart Requirements
a. All clearances are released and the equipment is in safe operating condition.
b. The power supply lineup is correct per Table 1
c. The prestart valve lineup is correct per Table 2.
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Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
d. All system instrumentation is available per Tables 3 and 4.
e. There are sufficient quantities of hydrogen and carbon dioxide on hand for filling the generator.
2.2 Precautions and Limitations
THE FOLLOWING PRECAUTIONS ARE SYSTEM SPECIFIC OPERATIONAL CONSIDERATIONS THAT MUST
BE CLOSELY FOLLOWED. FAILURE TO FOLLOW THESE PRECAUTIONS MAY RESULT IN PERSONNEL INJURY OR
EQUIPMENT DAMAGE.
a.
b.
c.
d.
All pumps and heat exchangers must be filled and vented to ensure proper and efficient operation.
The discharge valve on a positive displacement pump must be open prior to starting the pump.
Absolutely no smoking or open flames are allowed in any areas of the hydrogen system.
Immediately report any suspected hydrogen leaks. Leaks in the gas piping should be corrected
immediately. A mixture of hydrogen in air is explosive from 4 to 74 percent by volume.
e. Carbon dioxide must always be used as the scavenging medium to remove air or hydrogen from
the generator. NEVER add air to hydrogen or hydrogen to air.
f. Carbon dioxide is odorless, colorless, and tasteless. It is non-toxic but can cause asphyxiation
because it displaces oxygen in confined spaces. Do not allow anyone to enter the generator until it
is verified that the generator atmosphere is suitable for breathing.
g. The gland seals must be supplied with oil whenever the shaft is rotating.
h. The gland seals must be supplied with oil whenever there is hydrogen in the generator.
2.3 Seal Oil and Hydrogen System Block Flow Diagrams
2.3.1
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Electric Generator Auxiliary Systems
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Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
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2.3.2
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Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Seal Oil and Hydrogen System Diagrams
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Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
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August 1 2014
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Operating Procedure Unit 2 HPA
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Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
2.4 Replacing Generator Air with Carbon Dioxide
ACTION
LOC
VERIFICATION
NOTE: The LOC column in this procedure specifies where the associated ACTION step is taken. A "C"
step is performed in the Control Room, an "L" step is performed locally, and an "L/P" step is
performed at a local panel. A "C/L" or "L/C" step indicates a combination of Control Room and
local activities.
NOTE: For valve numbers referenced, see Section 2.3.2 Seal Oil and Hydrogen Diagrams.
1. VERIFY all gas system valves are aligned
L
per Table 2.
2. DISCONNECT the hydrogen supply line
L
removable link.
3. PLACE blanks on link flanges.
L
4. CLOSE valves 1, 3, 8, and 50.
L
Valves are closed
5. OPEN valves 2, 4, 5, and 7.
L
Valves are open.
6. OPEN CO2 bottle supply valves.
L
Valves are open.
7. OPEN valve 60.
L
Valve is open.
8. VERIFY carbon dioxide pressure on bottle
L
header gauge.
9. VERIFY the purity meter on the Hydrogen
L
Hydrogen Control Panel purity meter.
Control Panel goes to 95% or greater CO2.
10. CLOSE CO2 bottle supply valves.
L
Valves are open.
11. CLOSE valve 60.
L
Valve is closed.
12. CLOSE valves 2, 4, 5, and 7.
L
Valves are closed.
13. OPEN valves 1 and 3.
L
Valves are open.
2.5 Replacing Generator Carbon Dioxide with Hydrogen
ACTION
LOC
VERIFICATION
NOTE: The LOC column in this procedure specifies where the associated ACTION step is taken. A "C"
step is performed in the Control Room, an "L" step is performed locally, and an "L/P" step is
performed at a local panel. A "C/L" or "L/C" step indicates a combination of Control Room and
local activities.
NOTE: For valve numbers referenced, see Section 2.3.2 Seal Oil and Hydrogen Diagrams.
1. REMOVE the hydrogen line removable link
L
blanks.
2. REPLACE the hydrogen removable link.
L
3. OPEN valves 6, 8 and 53.
L
Valves are open.
4. OPEN valve 50.
L
Valve is open.
NOTE: In an emergency filling situation, valve 52 can be used to fill the generator faster.
5. ADJUST hydrogen pressure regulator to
L
supply 60 psig hydrogen.
6. VERIFY the purity meter value reads 95%
L
Hydrogen control panel purity meter.
or greater hydrogen.
7. CLOSE valve 6.
L
Valve is closed.
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8. OPEN valve 24 for 2 minutes and then
CLOSE valve.
9. ADJUST the hydrogen regulator as
required to maintain the proper hydrogen
pressure.
10. VERIFY the generator gas system
maintains the proper hydrogen
pressure and purity in the generator.
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
L
L
L/C
Hydrogen Control Panel or indicators in
control room.
2.6 Placing the Generator Seal Oil System in Service
ACTION
LOC
VERIFICATION
NOTE: The LOC column in this procedure specifies where the associated ACTION step is taken. A "C"
step is performed in the Control Room, an "L" step is performed locally, and an "L/P" step is
performed at a local panel. A "C/L" or "L/C" step indicates a combination of Control Room and
local activities.
NOTE: For valve numbers referenced, see Section 2.3.2 Seal Oil and Hydrogen Diagrams.
1. VERIFY electrical lineup per Table 1.
L
2. VERIFY the seal oil system valves are
L
aligned per Table 2.
3. CLOSE turbine lube oil backup supply
L
Valves closed.
valves, 263 and 265.
4. START the air side seal oil pump.
L
RED indicating light illuminates.
Pressure increases on local pressure indicator.
5. VERIFY hydrogen side drain regulator level
L
Local level gauge.
increases.
6. VERIFY hydrogen side drain regulator level
L
Local level gauge.
is maintained by drain (231) and fill (232)
valves.
7. CLOSE air side seal oil outlet valve (254).
L
Valve is closed.
8. ADJUST the air side seal oil pump relief
L
Local pressure indicator.
valve (258) until the pressure indicator
reads 100 psig.
9. OPEN air side seal oil outlet valve (254).
L
Valve is open.
10. ADJUST the differential pressure regulator
L
Air side seal oil pressure indicator.
(256) to bring air side seal oil pressure to
12 psig above gas pressure.
11. START the hydrogen side seal oil pump.
L
RED indicating light illuminates.
Pressure increases on local pressure indicator.
12. CLOSE hydrogen side seal oil valves 211
L
Valves are closed.
and 218.
13. CLOSE hydrogen side seal oil recirc valve
L
Valve is closed.
242.
14. ADJUST the hydrogen side seal oil pump
L
Local pressure indicator.
relief valve (243) until the pressure
indicator reads 100 psig.
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Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
15. OPEN hydrogen side seal oil valves 211,
218, and 242.
16. ADJUST regulating valves 210 and 217 until
the associated pressure gauges read ± 2"
H2O.
17. ADJUST the backup main oil pressure
regulating valve (291) to a 125 psig outlet.
18. OPEN turbine oil backup supply valves 263
and 265.
19. STOP the air side seal oil pump.
L
Valves are open.
L
Local pressure gauges.
L
Local pressure indicator
L
Valves are open.
L
20. ADJUST the backup supply regulator (264)
to maintain the seal oil supply at 8 psig
above hydrogen pressure.
21. RESTART the air side seal oil pump.
L
Green indicating light illuminates.
Pressure decreases on local pressure
indicator.
AIR SIDE SEAL OIL PUMP OFF alarm
annunciates at the Hydrogen Control Panel.
Local pressure indicators.
22. OPEN pressure switch PS-8 test valve
(274).
23. When pressure on associate indicator
reaches 5 psi, VERIFY the air side seal oil
backup pump starts.
L
24. CLOSE pressure switch PS-8 test valve
(274).
25. STOP the air side seal oil backup pump.
26. STOP the hydrogen side seal oil pump.
L
27. VERIFY the HYDROGEN SIDE SEAL OIL
PUMP OFF alarm at the Hydrogen Control
Panel.
28. RESTART the hydrogen side seal oil pump.
L
3.0
L
L
L
L
L
RED indicating light is illuminated.
Pressure increases on local pressure indicator.
RED indicating light illuminates.
BACKUP SEAL OIL PUMP RUNNING alarm is
annunciated at the Hydrogen Control Panel.
GREEN indicating light illuminates.
GREEN indicating light is illuminated.
Pressure decreases on local pressure
indicator.
Alarm annunciates.
RED indicating light illuminates.
Pressure increases on local pressure indicator.
SYSTEM NORMAL OPERATION
3.1 System Routine Checks
ACTION
Draft
LOC
VERIFICATION
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Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
NOTE: The LOC column in this procedure specifies where the associated ACTION step is taken. A "C"
step is performed in the Control Room, an "L" step is performed locally, and an "L/P" step is
performed at a local panel. A "C/L" or "L/C" step indicates a combination of Control Room and
local activities.
NOTE: Proper operation of plant equipment will lead to increased availability, sustained performance,
and extended life of the equipment, while reducing the chance of failure. Proper operations
include close adherence to operating procedures when starting the equipment, proper
monitoring and inspections when the equipment is in normal operation, and following proper
operating procedures when shutting down.
1. CHECK all indication listed in Tables 3 and
C/L
Verify each is within the normal operating
4, Local and Control Room Indicating
range.
Instruments.
2. CHECK the generator for unusual noises or
L
No unusual noises or vibrations.
vibrations.
3. VERIFY hydrogen side seal oil pump
L
 Check the bearings.
operation.
 Check for signs of leaks.
 Check motor/pump coupling.
 Check for abnormal noises or vibration.
4. VERIFY air side seal oil pump operation.
L
 Check the bearings.
 Check for signs of leaks.
 Check motor/pump coupling.
 Check for abnormal noises or vibration.
5. VERIFY generator seal oil vapor extractor
L
 Check the bearings.
operation.
 Check motor/extractor coupling.
 Check for abnormal noises or vibration.
6. VERIFY hydrogen side seal oil drain
L
 Check the level.
regulator operation.
 Check for signs of leaks.
 Check for valve/float malfunction.
7. VERIFY seal oil coolers operation.
L
Temperature between 80 and 120 F.
8. ADJUST the seal oil regulating valves as
L
 Valve 256 maintains 12 psi difference.
require to maintain the proper seal
 Valves 210 and 217 maintain ± 2" H2O.
pressure.
9. Once per shift, ROTATE the seal oil knife
L
filter handles.
10. VERIFY gas dryer operation and if required
L
 Check the two-way valves.
REACTIVATE per section 4.1 of this
 Check for depleted (gray) desiccant.
procedure.
 Check for gas leakage.
11. VERIFY the hydrogen control panel
operation.
4.0
L
 Check purity blower operation.
 Test the annunciators.
SYSTEM ABNORMAL OPERATION
4.1 Gas Dryer Reactivation
ACTION
Draft
LOC
VERIFICATION
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August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
NOTE: The LOC column in this procedure specifies where the associated ACTION step is taken. A "C"
step is performed in the Control Room, an "L" step is performed locally, and an "L/P" step is
performed at a local panel. A "C/L" or "L/C" step indicates a combination of Control Room and
local activities.
NOTE: The gas dryer should be reactivated when the crystals turn gray and have become saturated.
NOTE: For valve numbers referenced, see Section 2.3.2 Seal Oil and Hydrogen Diagrams.
1. PLACE the gas dryer inlet and outlet twoL
Lever in upper position.
way valves (20 and 21) lever in the
reactivating, or upper, position.
2. START reactivation blower.
L
Blower switch in ON position.
3. START reactivation heater.
L
Heater switch in ON position.
4. REACTIVATE gas dryer for 4 hours, or until
L
Observation port indicates crystal color.
the crystals turn blue.
5. STOP reactivation heater.
L
Heater switch in OFF position.
6. STOP reactivation blower.
L
Blower Switch in OFF position.
7. PLACE the gas dryer inlet and outlet twoL
Lever in lower position.
way valves (20 and 21) lever in the
operating, or lower, position.
5.0
SYSTEM SHUTDOWN
5.1 Removing Seal Oil System from Service
ACTION
LOC
VERIFICATION
NOTE: The LOC column in this procedure specifies where the associated ACTION step is taken. A "C"
step is performed in the Control Room, an "L" step is performed locally, and an "L/P" step is
performed at a local panel. A "C/L" or "L/C" step indicates a combination of Control Room and
local activities.
NOTE: For valve numbers referenced, see Section 2.3.2 Seal Oil and Hydrogen Diagrams.
1. VERIFY the generator seal oil system is no
L/C
longer required for service.
2. STOP the hydrogen side seal oil pump.
L
GREEN indicating light is illuminated.
Pressure decreases on local pressure indicator.
HYDROGEN SIDE SEAL OIL PUMP OFF alarm
annunciates at the Hydrogen Control Panel.
3. STOP the air side seal oil pump.
L
GREEN indicating light illuminates.
Pressure decreases on local pressure indicator.
AIR SIDE SEAL OIL PUMP OFF alarm
annunciates at the Hydrogen Control Panel.
4. When pressure on associate indicator
L
RED indicating light illuminates.
reaches 5 psi, VERIFY the air side seal oil
BACKUP SEAL OIL PUMP RUNNING alarm is
backup pump starts.
annunciated at the Hydrogen Control Panel.
5. STOP the air side seal oil backup pump.
L
GREEN indicating light illuminates.
Pressure decreases on local pressure indicator.
6. CLOSE turbine seal oil backup supply
L
Valves close.
valves 263 and 265.
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7. VERIFY the seal oil pressure decrease to 0.
8. CLOSE condensate cooling water valves to
and from seal oil coolers.
9. STOP the generator seal oil vapor
extractor.
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
L
L
L/C
Local pressure indicators.
Valves are closed.
GREEN indicating lights illuminated at local
and remote switches.
5.2 Purging Generator Hydrogen with Carbon Dioxide
ACTION
LOC
VERIFICATION
NOTE: The LOC column in this procedure specifies where the associated ACTION step is taken. A "C"
step is performed in the Control Room, an "L" step is performed locally, and an "L/P" step is
performed at a local panel. A "C/L" or "L/C" step indicates a combination of Control Room and
local activities.
NOTE: This procedure will be performed with the generator unit at standstill or while on the turning
gear.
NOTE: For valve numbers referenced, see Section 2.3.2 Seal Oil and Hydrogen Diagrams.
1. OPEN meter sampling valves 2 and 4.
L
Valves are open.
2. CLOSE meter sampling valves 1 and 3.
L
Valves are closed.
3. CLOSE hydrogen feed valves 8 and 50.
L
Valves are closed.
4. DISCONNECT the hydrogen supply line
L
removable link.
5. PLACE blanks on link flanges.
L
6. OPEN hydrogen vent valve 7.
L
Valve is open.
7. OPEN carbon dioxide bottle supply valves
L
Valve is open.
(63 - 66) and block valve (60).
8. OPEN carbon dioxide generator block
L
Valve is open.
valve (5).
9. VERIFY gas pressure does not exceed 3 - 5
L
Gas pressure indicator.
psig during carbon dioxide admission.
10. When the purity meter reads 95% CO2, or
L
Valves are closed.
greater, CLOSE the carbon dioxide bottle
supply valves (63-66) and supply block
valves (60 and 5)
5.3 Replacing Generator Carbon Dioxide with Air
ACTION
LOC
VERIFICATION
NOTE: The LOC column in this procedure specifies where the associated ACTION step is taken. A "C"
step is performed in the Control Room, an "L" step is performed locally, and an "L/P" step is
performed at a local panel. A "C/L" or "L/C" step indicates a combination of Control Room and
local activities.
NOTE: This procedure will be performed when the generator is at standstill prior to opening the
generator for inspection/maintenance.
NOTE: For valve numbers referenced, see Section 2.3.2 Seal Oil and Hydrogen Diagrams.
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1. VERIFY the seal oil system is removed
from service per section 5.2 of this
procedure.
2. REMOVE the manhole cover at each end
of the generator.
3. TAKE a gas sample from the generator
with a portable gas analyzer.
4. After a one hour ventilation period, PLACE
a non-sparking fan at one of the
manholes.
5. OPEN all water detector drain valves.
6. VENTILATE for several hours.
7. TAKE a gas sample from the generator
with a portable gas analyzer and VERIFY
generator is within human limits.
8. ENTER generator as required.
9. REINSTALL manhole cover.
10. CLOSE water detector drain valves.
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
L/C
L
L
Observe gas properties.
L
L
L
L
Analyzer scale.
L
L
L
5.4 System Post-Shutdown Checklist
When not required for operation, the generator system is maintained in a layup condition. The Seal Oil
and Hydrogen System is also maintained in layup condition to preserve its integrity and to prevent internal
deterioration and contamination of the generator’s internal components. The type of layup required is
determined by the time period the system is estimated to be out of service. If it is estimated that the generator
is to be out of service less than three months, a short term layup must be performed. If three or more months
are anticipated, a long term layup will be required.
5.4.1
Short Term
When the is to be taken out of service for a short time period, the hydrogen gas can be removed from
the generator once the generator is removed from service. The seal oil system may be shut down when the
generator is sufficiently purged and replaced with carbon dioxide or air.
5.4.2
Long Term
When the unit is to be shut down for a long duration, the lube oil system and the turning gear should
be operated for several hours each month. During this operational period, the operator should look and listen
for any signs of deterioration and abnormal operation. The Seal Oil and Hydrogen System is kept in service
during this operation period.
6.0
ALARM RESPONSES
6.1 Summary of Alarms
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Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
ALARM CONDITIONS
Alarms
Hydrogen Annunciator Panel Alarm
Hydrogen Purity High/Low
Hydrogen Pressure High
Hydrogen Supply Pressure Low
Water Detector High
Hydrogen Temperature High
Defoaming Tank Level High
Air Side Seal Oil Pump Off
Seal Oil Pressure Low
Hydrogen Side Level Low
Seal Oil Turbine Backup Pressure Low
Hydrogen Side Seal Oil Pump Off
Air Side Seal Oil Backup Pump Running
Draft
Initiating Device(s)
Control Room (BTG) Alarms
Hydrogen Panel
Hydrogen Control Panel
Purity Meter
Hydrogen Pressure
Transmitter
PS-3
ASH614A/B/C
n/a
LS-6
PDS-7
PDS-8
LS-9
PS-10
PDS-11
PDS-8
Device Setpoint(s)
n/a
> 100%
< 90%
56 High
18 Low
75 psig
High
45 C
High
5 psi
8 psi
Low
70 psig at seals
5 psi
8 psi
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Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Hydrogen Annunciator Panel Alarm
Initiating Device(s): Hydrogen Panel
Setpoint(s): n/a
Possible Causes
1.
2.
3.
Hydrogen system malfunction.
Seal oil system malfunction.
Hydrogen control panel malfunction.
Consequences
1.
2.
Loss of seal oil to generator.
Loss of hydrogen pressure/purity to generator.
Immediate Operator Action
1.
Investigate actual alarm at hydrogen control panel.
Follow Up Operator Action
1.
2.
Draft
Follow response procedure for specific alarm.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
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Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Hydrogen Purity High/Low
Initiating Device(s): Purity Meter
Setpoint(s): above 100%/below 90%
Possible Causes
1.
2.
3.
4.
5.
6.
Improper valve alignment.
Equalizing valve malfunction.
Purity meter blower malfunction.
Generator gas system malfunction.
Generator hydrogen side seal oil drain regulator malfunction.
Initiating device malfunction.
Consequences
1.
2.
Generator overheating.
Reduction in generator load.
Immediate Operator Action
1.
2.
3.
Verify generator hydrogen purity.
Add/vent hydrogen.
Adjust load as required.
Follow Up Operator Action
1.
2.
3.
Draft
Periodically monitor generator hydrogen purity.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Inform Maintenance Department to check/repair/calibrate purity meter, if necessary.
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Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Hydrogen Pressure High/Low
Initiating Device(s): Pressure Transmitter
Setpoint(s): 56 high/18 low
Possible Causes
1.
2.
3.
4.
5.
6.
Hydrogen regulator malfunction.
Sudden reduction/increase in load.
Improper valve alignment.
Hydrogen leak.
Low/high hydrogen temperature.
Pressure switch malfunction.
Consequences
1.
2.
3.
Reduction in hydrogen purity.
Generator overheating.
Reduction in generator load.
Immediate Operator Action
1.
2.
3.
4.
5.
Verify hydrogen pressure.
Adjust regulator, if required.
Adjust hydrogen cooler operation, if required.
Verify hydrogen supply pressure.
Verify valve alignment.
Follow Up Operator Action
1.
2.
3.
Draft
Adjust generator load, if required.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Inform Maintenance Department to check/repair/calibrate temperature control valve, if
necessary.
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August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Hydrogen Supply Pressure Low
Initiating Device(s): PS-3
Setpoint(s): 75 psig
Possible Causes
1.
2.
3.
4.
Insufficient hydrogen bottles.
Supply header leak.
Improper valve alignment.
Pressure switch malfunction.
Consequences
1.
2.
3.
Loss of generator gas pressure.
Reduced hydrogen purity.
Generator overheating.
Immediate Operator Action
1.
2.
3.
4.
Verify hydrogen supply pressure.
Verify valve alignment.
Increase bottles of hydrogen.
Reduce generator load, if required.
Follow Up Operator Action
1.
2.
3.
4.
Draft
Verify pressure return to normal.
Verify purity returns to normal.
Order more hydrogen bottles, if required.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Page 18
A.B. Hopkins Generating Station
August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Water Detector High
Initiating Device(s): ASH614A/B/C
Setpoint(s): High
Possible Causes
1.
2.
3.
4.
Oil/Water in liquid level detector(s).
Hydrogen cooler leak.
Gland seal overflow.
Liquid level detector float malfunction.
Consequences
1.
2.
Oil/Water in generator.
Emergency shutdown of generator.
Immediate Operator Action
1.
2.
3.
Verify which detector(s) are initiating the alarm.
Verify cause water/oil.
Verify if detector will immediately fill up after draining, if so shutdown will be required.
Follow Up Operator Action
1.
2.
3.
Draft
Verify gland seals operation.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Inform Maintenance Department to check/repair hydrogen cooler, if necessary.
Page 19
A.B. Hopkins Generating Station
August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Hydrogen Temperature High
Initiating Device(s): n/a
Setpoint(s): 45 C
Possible Causes
1.
2.
3.
4.
3.
Hydrogen cooler fouling.
Condensate cooling water temperature control valve malfunction.
Generator overload.
Low hydrogen purity.
Initiating device malfunction.
Consequences
1.
2.
Loss of generator capabilities.
Generator overheating.
Immediate Operator Action
1.
2.
3.
4.
Verify hydrogen temperature.
Verify hydrogen purity.
Verify hydrogen cooler temperature control valve.
Reduce load, if required.
Follow Up Operator Action
1.
2.
3.
4.
Draft
Continuously monitor hydrogen temperature.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Inform Maintenance Department to check/repair/calibrate temperature control valve, if
necessary.
Inform Maintenance Department to check/repair hydrogen cooler(s), if necessary.
Page 20
A.B. Hopkins Generating Station
August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Defoaming Tank Level High
Initiating Device(s): LS-6
Setpoint(s): High
Possible Causes
1.
2.
3.
Clogged defoaming tank overflow.
Improper valves alignment.
Level switch malfunction.
Consequences
1.
2.
3.
Backup of oil into seals.
Insufficient return to hydrogen side drain regulator.
Possible reduction of load of generator.
Immediate Operator Action
1.
2.
3.
4.
Verify level in each defoaming tank.
Verify valve alignment.
Verify level in drain regulator and turbine oil loop seal return tank.
Adjust generator load if required.
Follow Up Operator Action
1.
2.
Draft
Frequently observe level in defoaming tanks.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Page 21
A.B. Hopkins Generating Station
August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Air Side Seal Oil Pump Off
Initiating Device(s): PDS-7
Setpoint(s): 5 psid
Possible Causes
1.
2.
3.
Air side seal oil pump malfunction or trip.
Improper valve alignment.
Pressure switch malfunction.
Consequences
1.
2.
3.
Reduce air side seal oil pressure.
Air side seal oil backup pump starts.
Reduced load capacity.
Immediate Operator Action
1.
2.
3.
4.
Verify air side seal oil pressure.
Check air side seal oil pump operation.
Check air side seal oil backup pump operation.
Reduce load if required.
Follow Up Operator Action
1.
2.
Draft
Restart air side seal oil pump.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Page 22
A.B. Hopkins Generating Station
August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Seal Oil Pressure Low
Initiating Device(s): PDS-8
Setpoint(s): 8 psid
Possible Causes
1.
2.
3.
4.
Pressure Switch malfunction.
Improper valve alignment.
Seal oil pressure regulator malfunction.
Air side seal oil pump and/or backup pump malfunction or trip.
Consequences
1.
2.
3.
No consequence if air side seal oil backup pump start maintains seal oil pressure.
Possible loss of hydrogen from generator.
Possible load reduction.
Immediate Operator Action
1.
2.
3.
4.
5.
Verify air side seal oil backup pump running.
Prepare for load reduction.
Check for oil leaks.
Verify seal oil differential pressure 12 psid above machine gas pressure.
Check air side seal oil pump and motor.
Follow Up Operator Action
1.
2.
Draft
Monitor seal oil pressure.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Page 23
A.B. Hopkins Generating Station
August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Hydrogen Side Level Low
Initiating Device(s): LS-9
Setpoint(s): Low
Possible Causes
1.
2.
3.
Feed valve malfunction.
Dump valve malfunction.
Level switch malfunction.
Consequences
1.
2.
3.
Low hydrogen seal oil pump side suction head.
Loss of hydrogen side seal oil.
Possible reduced load.
Immediate Operator Action
1.
2.
3.
4.
Verify operation of hydrogen side drain regulator.
Manually adjust feed or dump valve.
Adjust generator load if required.
Verify hydrogen side pump operation.
Follow Up Operator Action
1.
2.
Draft
Adjust hydrogen side drain regulator level.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Page 24
A.B. Hopkins Generating Station
August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Seal Oil Turbine Backup Pressure Low
Initiating Device(s): PS-10
Setpoint(s): 70 psig at seals
Possible Causes
1.
2.
3.
4.
Pressure switch malfunction.
Turbine lube oil system malfunction.
Improper valve alignment.
Pressure regulator (291) malfunction.
Consequences
1.
2.
Possible loss of hydrogen from generator.
Possible load reduction.
Immediate Operator Action
1.
2.
3.
4.
5.
Verify air side seal oil pump or backup pump is running.
Prepare for load reduction.
Check for oil leaks.
Verify seal oil differential pressure 12 psid above machine gas pressure.
Check pressure regulator (219).
Follow Up Operator Action
1.
2.
3.
Draft
Monitor seal oil pressure.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Inform Maintenance Department to check/repair pressure regulator, if necessary.
Page 25
A.B. Hopkins Generating Station
August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Hydrogen Side Seal Oil Pump Off
Initiating Device(s): PDS-11
Setpoint(s): 5 psid
Possible Causes
1.
2.
3.
Hydrogen side seal oil pump malfunction or trip.
Improper valve alignment.
Pressure switch malfunction.
Consequences
1.
2.
3.
Reduce hydrogen side seal oil pressure.
Loss of hydrogen from generator.
Reduced load capacity.
Immediate Operator Action
1.
2.
3.
Verify hydrogen side seal oil pressure.
Check hydrogen side seal oil pump operation.
Reduce load if required.
Follow Up Operator Action
1.
2.
Draft
Restart hydrogen side seal oil pump.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Page 26
A.B. Hopkins Generating Station
August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Alarm: Air Side Seal Oil Backup Pump Running
Initiating Device(s): PDS-8
Setpoint(s): 8 psid
Possible Causes
1.
2.
3.
4.
5.
6.
Pressure Switch malfunction.
Pressure Differential Switch malfunction
Improper valve alignment.
Seal oil pressure regulator malfunction.
Air side seal oil pump malfunction or trip.
Loss of AC power.
Consequences
1.
2.
3.
No consequence if air side seal oil backup pump start maintains seal oil pressure.
Possible loss of hydrogen from generator.
Possible load reduction.
Immediate Operator Action
1.
2.
3.
4.
5.
Verify air side seal oil backup pump running.
Prepare for load reduction.
Check for oil leaks.
Verify seal oil differential pressure 12 psid above machine gas pressure.
Check air side seal oil pump and motor.
Follow Up Operator Action
1.
2.
Draft
Monitor seal oil pressure.
Inform Maintenance Department to check/repair/calibrate initiating device, if necessary.
Page 27
A.B. Hopkins Generating Station
August 1 2014
7.0
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
CHECKLISTS AND TABLES
Table 1 - Power Supply Checklist
Breaker Location
MCC 2-2, 4B
MCC 2-2, 1K
MCC 2-1, 1H
DCB
MCC 2-2
MCC 2-2
Description
Hydrogen Vapor Extractor
Motor
Air Side Seal Oil Pump
Motor
Hydrogen Side Seal Oil
Pump Motor
Air Side Seal Oil Backup
Pump
Gas Dryer
Hydrogen Control Panel
Voltage
480 VAC
Breaker Position
ON, Reset
480 VAC
ON, Reset
480 VAC
ON, Reset
120 VDC
ON
ON
ON
Table 2 - Prestart Valve Lineup Checklist
Valve No.
Location
1
First Floor
2
3
First Floor
First Floor
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
Draft
Description
Generator Gas System
Purity meter blower carbon dioxide header
return
Purity meter blower hydrogen header return
Purity meter blower carbon dioxide header
suction
Purity meter blower hydrogen header suction
Carbon dioxide downstream supply
Carbon dioxide manifold vent
Hydrogen manifold vent
Hydrogen downstream supply
Gas dryer supply
Gas dryer return
Dual element transmitter low pressure supply
Dual element transmitter high pressure supply
Liquid level detector (turbine end) isolation
Liquid level detector (turbine end) isolation
Liquid level detector (turbine end) drain
Liquid level detector (middle) isolation
Liquid level detector (middle) isolation
Liquid level detector (middle) drain
Liquid level detector (exciter end) isolation
Gas dryer inlet
Gas dryer outlet
Open
Closed
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
absorb
absorb
Page 28
A.B. Hopkins Generating Station
August 1 2014
22
23
24
40
41
First Floor
First Floor
First Floor
First Floor
First Floor
42
First Floor
43
44
50
51
52
53
60
61
62
63
64
65
66
67
68
69
70
71
72
73
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
200
201
202
203
204
205
208
209
211
212
213
214
Second Floor
Second Floor
Second Floor
Second Floor
Second Floor
Second Floor
Second Floor
Second Floor
First Floor
First Floor
First Floor
First Floor
215
First Floor
218
First Floor
Draft
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Liquid level detector (exciter end) isolation
Liquid level detector (exciter end) drain
Generator exciter end vent
Dual element transmitter bypass
Dual element transmitter low pressure
isolation
Dual element transmitter high pressure
isolation
Dual element transmitter low pressure drain
Dual element transmitter high pressure drain
Hydrogen pressure regulator supply valve
Hydrogen pressure regulator vent
Hydrogen pressure regulator bypass
Hydrogen bulk supply isolation
Carbon dioxide main isolation
Carbon dioxide relief valve
Carbon dioxide supply header vent
Carbon dioxide bottle 1 isolation
Carbon dioxide bottle 2 isolation
Carbon dioxide bottle 3 isolation
Carbon dioxide bottle 4 isolation
Carbon dioxide bottle 5 isolation
Carbon dioxide bottle 6 isolation
Carbon dioxide bottle 7 isolation
Carbon dioxide bottle 8 isolation
Carbon dioxide bottle 9 isolation
Carbon dioxide bottle 10 isolation
Carbon dioxide bottle 11 isolation
Generator Seal Oil System
Air side seal oil pressure indicator isolation
Air side seal oil pressure indicator isolation
Seal oil equalizing valve 210 root isolation #1
Seal oil equalizing valve 210 root isolation #2
Seal oil equalizing valve 217 root isolation #1
Seal oil equalizing valve 217 root isolation #2
Exciter end defoaming tank drain
Turbine end defoaming tank drain
Equalizing valve 210 outlet
Equalizing valve 210 actuator upper isolation
Equalizing valve 210 actuator lower isolation
Equalizing valve 210 pressure indicator upper
isolation
Equalizing valve 210 pressure indicator lower
isolation
Equalizing valve 217 outlet
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Page 29
A.B. Hopkins Generating Station
August 1 2014
219
220
221
First Floor
First Floor
First Floor
222
First Floor
231
232
233
239
240
241
242
243
244
236
237
247
248
238
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
249
First Floor
250
251
252
254
253
263
265
266
273
274
262
277
278
279
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
First Floor
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Equalizing valve 217 actuator upper isolation
Equalizing valve 217 actuator upper isolation
Equalizing valve 217 pressure indicator lower
isolation
Equalizing valve 217 pressure indicator upper
isolation
Drain regulator drain
Drain regulator fill
Hydrogen side seal oil pump suction
Hydrogen side seal oil cooler outlet
Hydrogen side seal oil cooler inlet
Hydrogen side seal oil cooler bypass
Hydrogen side seal oil pump recirculation
Pressure switch (11) isolation 1
Pressure switch (11) isolation 2
Air side pressure indicator isolation
Backup regulator actuator lower isolation
Pressure switch PS-8 isolation
Test leg isolation
Differential pressure regulator actuator lower
isolation
Differential pressure regulator actuator upper
isolation
Air side seal oil cooler outlet
Air side seal oil cooler inlet
Air side seal oil cooler bypass
Air side seals oil pump discharge
Air side seal oil pump suction
Backup regulator outlet
Backup regulator inlet
Backup regulator bypass
Test gauge isolation
Pump test
Pressure switch PS-10 isolation
Pressure switch PS-7 isolation 1
Pressure switch PS-7 isolation 2
Valve 291 test gauge isolation
X
X
X
X
AUTO
AUTO
X
X
X
X
1/2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Table 3 - Local Indicating Instruments
Instrument
n/a
n/a
Draft
Function/Description
Seal Oil System
Gland Seal Oil Collector End Pressure
Air Side Seal Oil Pressure
Normal Range
± 2 "H2O
60 - 65 psig
Page 30
A.B. Hopkins Generating Station
August 1 2014
n/a
n/a
n/a
n/a
n/a
n/a
n/a
Hydrogen Panel
Hydrogen Panel
n/a
n/a
n/a
n/a
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
Gland Seal Oil Turbine End Pressure
Pressure Regulator Actuator Pressure
Air Side Discharge Pressure
Hydrogen Side Discharge Pressure
Hydrogen Side Temperature
Air Side Temperature
Hydrogen Downstream Pressure
Generator Gas System
Purity Meter
Hydrogen and Fan Pressure
Hydrogen (Control Regulator) Pressure
CO2 Pressure
Generator
Seal Oil Pressure (Turbine End)
Seal Oil Pressure
± 2 "H2O
55 - 65 psig
55 - 65 psig
90 - 100 psig
90 - 100 F
90 - 100 F
120 - 130 psig
100 % Hydrogen
Fan 50 - 60 "H2O
H2 45 - 55 psig
45 - 55 psig
0
55 - 65 psig
55 -65 psig
Table 4 - Control Room Indicating Instruments
Instrument
n/a
Function/Description
Seal Oil System
Normal Range
None
Generator Gas System
n/a
n/a
8.0
Hydrogen Pressure
Hydrogen Purity
45 - 55 psig
100 % Hydrogen
REFERENCES
8.1 P&ID
a. Westinghouse, Gas Diagram, 1109F69-2
b. Westinghouse, Seal Oil Diagram, 1109F67-2
8.2 Electrical One Line Diagrams
a. Reynolds, Smith, and Hill, Unit No. 2 Addition, Generator, Step-up Transformer Single Line, E-1,
Rev. 0
b. Reynolds, Smith, and Hill, Unit No. 2 Addition, Station Service Equipment Single Line, E-2, Rev. 0
c. Reynolds, Smith, and Hill, Unit No. 2 Addition, 480 V Unit Substations Single Line and Arrangement
Diagram, E-4, Rev. 0
8.3 Control Diagrams
a. Reynolds, Smith, and Hills, Seal Oil Pump Hydrogen Side, S-114
Draft
Page 31
A.B. Hopkins Generating Station
August 1 2014
Seal Oil and Hydrogen System
Operating Procedure Unit 2 HPA
b. Reynolds, Smith, and Hills, Seal Oil Backup Pump, S-188
c. Reynolds, Smith, and Hills, Hydrogen Vapor Extractor, 191
d. Reynolds, Smith, and Hills, Seal Oil Pump Air Side, S-188
8.4 Instrument Loop Diagrams
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Hydrogen Coolers Temperature Control, Loop 41
Hydrogen Purity, Loop 200
Hydrogen Pressure, Loop 231
Hydrogen Seal Oil Pump Off, Loop 617
Hydrogen System DC Power Failure, Loop 619
Air Side Seal Oil Pump Off, Loop 625
Seal Oil Pressure Low, Loop 626
Hydrogen Side Seal Oil Level, Loop 627
Seal Oil Backup Pressure Low, Loop 628
Hydrogen Side Seal Oil Pressure Low, Loop 629
Air Side Seal Oil Backup Pump Running, Loop 630
8.5 Instruction Manuals
a. Westinghouse, Generator Instruction Book, City of Tallahassee, A.B. Hopkins Station, Unit 2, 21011,
December 1975
b. Westinghouse, Steam Turbine-Generator Startup, City of Tallahassee, A.B. Hopkins Station, Unit 2,
1250-C917, October 1976
8.6 Miscellaneous
a. Reynolds, Smith, and Hills, Connection Diagrams, C-1 through C-198
b. Unit 2 Steam Turbine System Description and Operating Procedure, 2-ST-SD and 2-ST-OP
c. Unit 2 Electrical Distribution System Description and Operating Procedure, 2-ED-SD and 2-ED-OP
Draft
Page 32