FIELD OF INVENTION
The present invention relates to a simulation apparatus deployed for pre-setting and verification of operating parameters of seal oil system of a turbogenerator required at actual site conditions. More particularly, the invention relates to the creation of a simulation apparatus used for pre-setting and verification of operating parameters of seal oil unit of a turbogenerator at the manufacturing plant itself before installation at thermal power station. Simulation apparatus is used to simulate the manufactured seal oil system (as a whole) with actual site conditions and testing parameter beforehand.
BACKGROUND OF INVENTION
Double flow Seal oil system installed at the power station consist of three sub parts: seal oil unit air side, seal oil unit h2 side, seal oil valve rack. Seal oil unit is used to seal the hydrogen gas in the generator, in addition to ensuring minimum mixing in the sealing layer of oil at the rotor shaft which could deteriorate the purity of hydrogen gas in the generator. Double flow seal oil system maintain better hydrogen purity during longer duration and thus in turn reduces the consumption of hydrogen cylinders used to maintain the purity of hydrogen in generator casing which is approx. 99.99 %. The working of seal oil system is essential to generation of thermal power station. Malfunctioning of single component in the seal oil system could result in the likely leakage of hydrogen gas from the generator resulting in the shutdown of power generation at the power plant.

Seal oil system manufactured in the shop was tested only hydraulically to check any leakage and to ensure that it could withstand the temporarily increase in the pressure in the system during any malfunctioning. however, parameters required at the site were set at the site only. setting of seal oil unit parameters at the site involved considerable time and excess work because seal oil system is installed at site in different levels and setting the system to desired working condition at site is strenuous exercise.
The invention (i.e. seal oil unit testing station) provides a comprehensive arrangement to simulate the seal oil system to site conditions. Simulation apparatus can be used to observe, analyse and preset the required parameters at the site beforehand at the seal oil unit testing station. seal oil unit testing station can be used for carrying out qualitative and quantitative analysis and can be used in deciding the optimal setting parameters of component. Performance parameters/healthiness of individual components of seal oil system can be checked at the testing station.
Complete set up of Seal Oil Test Station for double flow seal oil system provides a simulated system/set up for observing, checking & monitoring the appropriate functioning of control instruments of Seal Oil System (Double Flow, as a whole) in synchronization with Turbo-Generator under actual power plant conditions.
Critical devices like AC/DC Seal Oil Pumps, Constant Pressure Regulator Valves, Differential Pressure Control Valves, Flow Regulators, Filling & Drain Float Valves of Seal Oil Tank are checked, monitored & regulated to actual working conditions.

Therefore, it is an object of the invention to propose a simulation apparatus deployed for pre-setting and verification of operating parameters of seal oil system of a turbogenerator required at actual site conditions which is capable of observing, analyzing and presenting the parameters required at the site before hand at the seal oil unit testing station.
Another object of the invention to propose a simulation apparatus deployed for pre-setting and verification of operating parameters of seal oil system of a turbogenerator required at actual site conditions which is able to eliminate strenuous exercise and time consuming process in setting the seal oil system to desired working condition at site.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig.1 - Shows Seal oil unit – air side
Fig.2 - Shows Seal oil unit – H2 side
Fig.3 - Shows Seal oil valve rack.
Fig.4 - Shows Seal oil unit testing apparatus
Sketch I - Shows the seal oil unit air side, seal oil unit H2 side and Seal oil valve
rack connected for hydraulic testing.
Sketch II - Shows functional testing of Seal oil unit.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

The simulation apparatus comprises of a Technological tank, pump and control valves with piping’s set up as shown in Fig.4.
Seal oil unit testing apparatus comprises of several components as shown in Figure-4. key components of which are detailed as below:
(1) TECHNOLOGICAL TANK: Technological tank (1) in Figure-4 is used as oil reservoir in the seal oil system. Technological tank provides the desired head and oil input required for the seal oil motor in the seal oil system and to Technological motor pump set (8). Technological tank replicates the function of seal oil storage tank at the site.
(2) TECHNOLOGICAL MOTOR-PUMP SET: Technological motor pump set (8) is used to pressure the seal oil system during hydraulic testing procedure. Technological motor pump set takes the seal oil from technological tank (1) and feeds into the seal oil system at the desired pressure. The pressure fed into the system can be measured by the calibrated pressure gauge (25). Seal oil unit testing apparatus provides two outputs of motor-pump set (8) E and F. Bypass Valves, valve V1 and valve V3 are provided to bypass the excess pressure back to the technological tank (1). Thus desired seal oil pressure can be generated and released via operation of valves V1 and V2.
Technological motor pump is mounted on a table of low height keeping in mind the safety of operator. Being of low height, table can easily be used by the operator.
(3) ISOLATION VALVES (V1, V2, V3, V4, V5): Isolation valves are used in the
system so as to regulate the flow of seal oil and to ease of dismantling the system
during maintenance. Valve V4 and V3 are used to isolate the technological

tank (1) from the motor-pump set (8) during maintenance/cleaning of the seal oil unit testing apparatus.
Valve V5 is used as an inlet for the seal oil motors mounted in the seal oil system during functional test (setting of parameters) of seal oil unit. Functional test of seal oil unit is done after hydraulic test of seal oil unit.
(4) OUTLET/INLET CONNECTIONS OF SEAL OIL UNIT TESTING
APPARATUS:
POINT A: Point A is outlet of apparatus and is used as inlet for the seal oil motor pump set in the seal oil system during functional testing.
POINT B: Point B is outlet of apparatus and is used as inlet for the seal oil motor pump set (8) of testing apparatus.
POINT C: Point C is inlet of apparatus and is used as inlet of oil after circulation of oil in closed loop during functional testing of seal oil system.
POINT D: Point D is inlet of apparatus and is used as inlet of bypassed oil during running of seal oil motor pump set (8).
POINT E: Point E is outlet of apparatus and is used to send the pressurized seal oil by seal oil motor pump set (8) in the seal oil unit during hydraulic testing. POINT F: Point F is another outlet of apparatus and is used to send the pressurized seal oil by seal oil motor pump set (8) in the seal oil unit during hydraulic testing.
POINT G, H & I: Point G, H & I is inlet of apparatus and is used as inlet of oil after circulation of oil in closed loop during functional testing from different point of seal oil system.

(5) MISCELLANOUS ITEMS: Oil Level indicator (3) is used to check the level of oil in the Technological tank (1). Mesh Cover (2) is used to pour the oil into the Technological tank (1).
Seal oil unit testing procedure HYDRAULIC TESTING:
Seal oil unit air side, seal oil unit H2 side and seal oil valve rack are to
be connected as per SKETCH-1 for hydraulic testing:
1) Pressure Test at 20 kg/cm2 for 10 minutes: Pressure test, Technological Pump takes Seal oil from Point B of Technological Tank & give output to Seal Oil System though flanged connection E or F. After Pressure test, oil is returned to Technological Tank via Point D. (Refer Figure- 4). Pressure test checks for healthiness of PHE Coolers, Duplex Oil Filters, all control valves & complete piping system free from any leakage.
Functional Testing
As shown in Sketch 2 and Sketch 3 Above 3 parts are to be functionally tested as following:
2) Safety Relief Valve Setting of 3 no. Air Side Seal oil Pumps
3) Functional of 3 no. Constant Pressure Regulator (CPR)Valves of Air Side Seal Oil Unit
4) Functioning of 3 no. Differential Pressure Regulator (DRR) Valves of Seal Oil Valve Rack
5) Functioning of 2 no. Flow Regulators of Seal Oil Valve Rack

♦ For Point No. 2 to 5, Seal Oil Pump, i.e. either of SOP-1, SOP-2 or SOP-3 draws Oil from technological Tank from Point A through Flexible Steel Pipe of NB150. There are two discharges from Seal Oil System back to Technological Tank via PHE Coolers & Duplex Oil Filters.
■ The oil discharge from Safety Relief Valves of Pumps & CPRs are returned back to Technological Tank at Point C via line 283 by Flexible Pipe of NB50.
■ The oil discharge from line 69A & 69B; 70A & 70B are returned back to Technological Tank at either of Points G, H or I by Flexible Pipe of NB50.

6) Functioning of 2 no. Float Valve in Seal Oil Tank of H2 Side Seal Oil Unit: Make Up & Drain Float Valves are set as such as to keep the oil level at a predetermined level, thus preventing gas from entering the suction pipe of the seal oil pump (hydrogen side). The low level float-operated valve compensates for the low oil level in the tank by admitting oil from the air side seal oil circuit via terminal 438. The high level float-operated valve drains excess oil into the technological tank via terminal 79.
7) Safety Relief Valve Setting of H2 side Seal Oil Pump
8) Functional of Constant Pressure Regulator (CPR)Valves of H2 Side Seal Oil Unit
For Point No. 7 & 8, H2 Side Seal Oil Pump is run & draws Oil from Seal oil Tank & returns back oil to Seal oil Tank itself via termination 75 & 78.

Reference numerals related to testing apparatus shown in Fig.4
(1) Technological tank
(2) Technological tank mesh cover
(3) Oil level indicator
(4) Needle valve
(5) Resting plate for Technological tank
(6) Technological tank support structure beam
(7) Technological Motor-pump set mounting table
(8) Technological Motor-pump set
(9) Glove valve

(10) Glove valve
(11) Inlet connection for seal oil unit motor pump set
(12) Flange
(13) Upper support for Technological tank
(14) Flange
(15) Outlet oil bypass piping from Technological Motor-pump set
(16) Tee
(17) Bend
(18) Gasket
(19) Globe valve
(20) Connection pipe
(21) Reducer
(22) Needle valve
(23) Flange
(24) Gasket
(25) Pressure gauge
(26) piping
(27) piping
(28) bend
(29) Piping
(30) piping
(31) Piping
(32) piping

WE CLAIM
1. A simulation apparatus deployed for pre-setting and verification of operating parameters of seal oil system of a turbogenerator required at actual site conditions, the said simulation apparatus consisting of;
a technological tank (1) disposed as oil reservoir in the system for providing desired head and oil input required for seal oil motor and technological motor pump set (8) during testing and for working as a replica of seal oil storage tank at the site;
a technological motor pump set (8) for providing pressure to the seal oil system during hydraulic testing procedure;
valves (V1, V3) provided for bypassing the excess pressure back to the technological tank (1);
valves (V1, V2) disposed for generating and releasing the desired seal oil pressure;
isolation valves (V1-V5) configured in the system for regulating flow of seal oil and for case of dismantling the system during maintenance;
isolation valves V3 and V4 provided for isolating the technological tank (1) from the motor pump set (8) during maintenance;
isolation valve V5 configured as an inlet for the seal oil motors mounted in the seal oil system during functional test for setting parameters of seal oil unit;
a plurality of inlet and outlet connections of seal oil unit testing apparatus at points A to I;
an oil level indicator (3) for checking the level of oil in the technological tank (1);
a mesh cover (2) for pouting the oil into the technological tank (1);

wherein,
the technological motor pump set (8) is provided with two output flanges at E and F for delivering pressurized seal oil in the seal oil unit during hydraulic testing and is configured in the system for feeding the seal oil from technological tank (1) to the seal oil system at desired pressure when a calibrated pressure gauge (25) is disposed for measuring the pressure fed into the system.
2. The simulation apparatus as claimed in claim 1, wherein output pipe connection from tank at A and B are disposed as inlet for the seal oil motor pump set (8) in the seal oil system during functional testing.
3. The simulation apparatus as claimed in claim 1, wherein inlet pipe connections (33, 34) at point D and C are disposed as inlet of oil after circulation of oil in closed loop during functional testing of seal oil system.