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OPERATION & MAINTENANCE

MANUAL
FOR

500 MW TURBOGENERATOR
WITH
WATER COOLED STATOR WINDING &
DIRECT HYDROGEN COOLED ROTOR WINDING

Project : KHAPERKHEDA TPS EXP
Customer : M/s MAHARASHTRA STATE
POWER GENERATION CO.LTD
BHEL Order no :10553P12901

HARIDWAR
BHARAT HEAVY ELECTRICALS LIMITED
Heavy Electrical Equipment Plant

Turbogenerators

Table of Contents

General
Cover Sheet

0.0-0000

GENERAL
Table of Contents . . . . . . . . . . . . . . . . . .
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes on the Use of the Manual . . . . . . . . .
Operation Beyond Contract Commitment . .
Safe Disposal of Turbogenerator Items

2.0-0010
2.0-0030
2.0-0040
2.0-0050
2.0-0200

DESCRIPTION
Brief Description
Rating Plate Data . . . . . . . . . . . . . . . . . . .
Generator Cross Section . . . . . . . . . . . .
Generator Outline Diagram . . . . . . . . . .
Exciter Outline Diagram . . . . . . . . . . . . .
Design and Cooling System . . . . . . . . .
Generator Cooling Gas Circuit . . . . . . .
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator Winding . . . . . . . . . . . . . . . . . . . . .
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrogen Cooler . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . .
Oil Supply for Bearings and Shaft Seals . .
Seal Oil System (Simplified Diagram)
Gas System . . . . . . . . . . . . . . . . . . . . . . .
Gas System (Simplified Diagram) . . . .
Primary Water System . . . . . . . . . . . . . .
Primary Water System (Simplified Diagram) .

2.1-1002
2.1-1050
2.1-1056
2.1-1058
2.1-1100
2.1-1150
2.1-1210
2.1-1230
2.1-1300
2.1-1440
2.1-1450
2.1-1460
2.1-1510
2.1-1511
2.1-1520
2.1-1521
2.1-1530
2.1-1531

Technical Data
General and Electrical Data . . . . . . . . .
Mechanical Data . . . . . . . . . . . . . . . . . .
Seal Oil System . . . . . . . . . . . . . . . . . . .
Gas System . . . . . . . . . . . . . . . . . . . . . . .
Primary Water System . . . . . . . . . . . . . .
Waste Gas System . . . . . . . . . . . . . . . .
Excitation System . . . . . . . . . . . . . . . . . .
Cooler Data . . . . . . . . . . . . . . . . . . . . . . .
Reactive Capability Curve . . . . . . . . . . .
Load Characteristic of pilot exciter . . .
Gas Specification . . . . . . . . . . . . . . . . . .
Primary Water Specification . . . . . . . . .
Specification for Ion Exchange Resins
Additive Specification for Alkalizer Unit

2.1-1810
2.1-1820
2.1-1825
2.1-1826
2.1-1827
2.1-1828
2.1-1829
2.1-1830
2.1-1850
2.1-1860
2.1-1883
2.1-1885
2.1-1887
2.1-1888

Stator
Stator Frame . . . . . . . . . . . . . . . . . . . . . .

BHEL,Haridwar

Stator End Shields . . . . . . . . . . . . . . . . .
Generator Terminal Box . . . . . . . . . . . .
Hydraulic Testing and Anchoring of Stator
Anchoring of Generator on Foundation
Stator Core . . . . . . . . . . . . . . . . . . . . . . . .
Mounting of Stator Core in Stator Frame
Spring Support of Stator Core . . . . . . . .
Stator Winding . . . . . . . . . . . . . . . . . . . . .
Connection Diagram of Stator Winding
Stator Slot . . . . . . . . . . . . . . . . . . . . . . . . .
Transposition of Stator Bars . . . . . . . . .
Micalastic High Voltage Insulation . . . .
Construction of High Voltage Insulation
Corona Protection . . . . . . . . . . . . . . . . . .
Coil and End Winding Support System
Stator End Winding. . . . . . . . . . . . . . . . .
Electrical Connection of Bars, Water Supply
and Phase Connectors . . .
Electrical Bar Connections and Water Supply
Terminal Bushings. . . . . . . . . . . . . . . . .
PW Connection for Terminal Bushings and
Phase Connectors . . . . . . . . . .
Cooling of Terminal Bushings . . . . . . .
Components for Water Cooling of Stator
Winding . . . . . . . . . . . . . . . . . .
Grounding of Stator Cooling Water Manifold . .

2.1-2150
2.1-2170
2.1-2190
2.1-2191
2.1-2200
2.1-2201
2.1-2220
2.1-2300
2.1-2301
2.1-2303
2.1-2305
2.1-2320
2.1-2321
2.1-2330
2.1-2340
2.1-2341
2.1-2350
2.1-2351
2.1-2370
2.1-2371
2.1-2372
2.1-2380
2.1-2389

Rotor
Rotor Shaft . . . . . . . . . . . . . . . . . . . . . . . .
Cooing of Rotor Winding . . . . . . . . . . . .
Cooling Scheme of Rotor Winding . . . .
Rotor Winding. . . . . . . . . . . . . . . . . . . . . .
Rotor Slot . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor End Winding . . . . . . . . . . . . . . . . .
Rotor Retaining Ring . . . . . . . . . . . . . . .
Rotor Field Connections . . . . . . . . . . . .
Electrical and Mechanical Connection of EE
Coupling . . . . . . . . . . . . . . . . .
Rotor Fan . . . . . . . . . . . . . . . . . . . . . . . . .

2.1-3000
2.1-3100
2.1-3101
2.1-3300
2.1-3301
2.1-3310
2.1-3350
2.1-3370
2.1-3373
2.1-3600

Cooler
Hydrogen Cooler (Description) . . . . . . .
Hydrogen Cooler (Drawing) . . . . . . . . .

2.1-4000
2.1-4001

Generator Bearings
Generator Bearing (Description) . . . . .
Generator Bearing (Drawing) . . . . . . . .
Measurement of Bearing Temperature
Generator Bearing Insulation . . . . . . . .

2.1-5000
2.1-5001
2.1-5003
2.1-5005

2.1-2100
2.0-0010-0553/1
0709E

Shaft Seal
Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal (Drawing) . . . . . . . . . . . . . . .

2.1-6000
2.1-6001

Seal Oil System
Seal Oil System . . . . . . . . . . . . . . . . . . .
Differential pressure Valve A . . . . . . . . .
Differential Pressure Valve C . . . . . . . .
Pressure Equalizing Control Valve. . .
Seal Oil System Schematic Diagram .
List of Valves for Seal Oil System. . . .
Bearing Vapour Exhauster. . . . . . . . . . .
Seal Oil Pumps. . . . . . . . . . . . . . . . . . . .
Seal Oil Cooler and Seal Oil Filter. . . .
Seal oil Cooler (Drawing) . . . . . . . . . . .
Seal Oil Filter (Drawing) . . . . . . . . . . . .
Differential Pressure Meter Syste. . . .

2.1-7100
2.1-7101
2.1-7103
2.1-7104
2.1-7111
2.1-7112
2.1-7120
2.1-7123
2.1-7130
2.1-7131
2.1-7132
2.1-7150

Gas System
Gas System. . . . . . . . . . . . . . . . . . . . . . .
Gas System Schematic Diagram. . . .
List of Valve for Gas System. . . . . . . . .
CO2 Vaporiser. . . . . . . . . . . . . . . . . . . .
Gas Dryer (Refrigeration type) . . . . . .

2.1-7200
2.1-7211
2.1-7212
2.1-7230
2.1-7270

2.1-7300
2.1-7311
2.1-7312
2.1-7320
2.1-7330
2.1-7340
2.1-7341
2.1-7343
2.1-7344
2.1-7345
2.1-7349

Automatic Controls
Coolant Temperature Control. . . . . . . .

2.1-8010

Protective Devices
Safety Equipment for Hydrogen Operation. .
Waste Gas System. . . . . . . . . . . . . . . . .
List of Valves for Waste Gas System .
Generator Waste Fluid System . . . . . .
Generator Mechanical Equipment Protection.
Tripping Scheme for Generator Mechanical
Equipment Protection
Generator Mechanical Equipment Protection .
Generator Electrical Protection. . . . . . .
2.0-0010-0553/2
0709E

2.1-8331
2.1-8350
2.1-8351

Measuring Devices and Supervisory
Equipment
Introduction. . . . . . . . . . . . . . . . . . . . . . . .
Temperature Transducers. . . . . . . . . . .
Supervision of Generator. . . . . . . . . . . .
Generator measuring points. . . . . . . . .
Supervision of Bearings. . . . . . . . . . . . .
Supervision of Seal Oil System. . . . . .
Supervision of Gas System. . . . . . . . .
Supervision of Primary Water System
Supervision of Exciter. . . . . . . . . . . . . .
Exciter Measuring Points. . . . . . . . . . .

2.1-8400
2.1-8410
2.1-8420
2.1-8422
2.1-8440
2.1-8450
2.1-8460
2.1-8470
2.1-8490
2.1-8491

Excitation System

Primary Water System
Primary Water System. . . . . . . . . . . . . .
Primary Water System Schematic Diagram. .
List of Valves for Primary Water System
Primary Water Pumps. . . . . . . . . . . . . .
Primary Water Cooler. . . . . . . . . . . . . . .
Primary Water Treatment System. . . .
Alkalizer Unit for Primary Water Circuit
Primary Water Filters. . . . . . . . . . . . . . .
Primary Water Main Filter. . . . . . . . . . . .
Primary Water Fine Filter. . . . . . . . . . . .
Protective Screens at Primary Water Inlet
and Outlet. . . . . . . . . . . . . . . . .

Tripping Scheme for Generator Electrical
Protection . . . . . . . . . . . . .
Rotor Grounding System . . . . . . . . . . .
Arrangement of Brush Holders for Rotor
Grounding System. . . . . . . . .

2.1-8310
2.1-8311
2.1-8312
2.1-8315
2.1-8320
2.1-8321
2.1-8323
2.1-8330

Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Arrangement of Brushless Excitation
System. . . . . . . . . . . . . . .
Rectifier Wheels. . . . . . . . . . . . . . . . . . .
Rectifier Wheels and Coupling. . . . . .
Permanent-Magnet Pilot Exciter Rotor & Fan
Exciter Cross Section. . . . . . . . . . . . . .
Exciter Cooling Air Circuit. . . . . . . . . . .
Stroboscope for Fuse Monitoring . . . .
Exciter Drying . . . . . . . . . . . . . . . . . . . . .
Ground Fault Detection System for Exciter
Field Circuit. . . . . . . . . . . . .
Arrangement of Bursh Holders for Ground
Fault Detection System . .
Brush Holders for Ground Fault Detection
System. . . . . . . . . . . . . .

2.1-9100
2.1-9101
2.1-9102
2.1-9103
2.1-9104
2.1-9110
2.1-9120
2.1-9140
2.1-9150
2.1-9180
2.1-9181
2.1-9182

Operation
Operating and Setting Values-General
Gas Quantities. . . . . . . . . . . . . . . . . . . .
Measuring Point List of Generator . . .
Running Routine-General. . . . . . . . . .
Operating Log-Generator Supervision
Operating Log-Seal Oil System . . . . .
Operating Log-Gas System . . . . . . . .
Operating Log-Primary Water System
Operating Log-Exciter Supervision . .

2.3-4000
2.3-4010
2.3-4030
2.3-4100
2.3-4120
2.3-4150
2.3-4160
2.3-4170
2.3-4190

Start-up
Preparations for Starting-Introduction
Hints for Cooler Operation. . . . . . . . . .
Filling and Initial Operation of Air Side Seal
Oil Circuit. . . . . . . . . . . . . . . . .

2.3-5000
2.3-5003
2.3-5110

Turbogenerators

Filling and Initial Operation of Hydrogen
Side SealGeneral
Oil Circuit . . .
2.3-5120
Venting of Seal Oil Circuits. . . . . . . . . .
2.3-5130
Setting of Seal Oil Pressures. . . . . . .
2.3-5150
Setting of Operating Values for Seal Oil System 2.3-5160
Measurement of Seal Oil Volume Flows
2.3-5163
Functional Testing of Pumps and Exhausters 2.3-5180
Startup of Air Side Seal Oil Circuit . . .
2.3-5210
Startup of Hydrogen Side Seal Oil Circuit. . . . 2.3-5220
Venting of Seal Oil Circuits and Checking of
Seal Oil Pressures . .
2.3-5230
Checking Automatic Operation of Seal Oil
Pumps. . . . . . . . . . . . . . . .
2.3-5280
Positions of Multi-Way Valves in Gas System 2.3-6107
Scavenging the Electrical Gas Purity Meter
System . . . . . . . . . . . . .
2.3-6110
Setting Electrical Zero of Electrical Gas Purity
Meter System . . . . . . . .
2.3-6120
Purity Measurement During CO2 Filling
2.3-6130
Purity Measurement During H2 Filling
2.3-6140
Purity Measurement During H2 Operation
2.3-6150
Gas Filling-Replacing Air With CO2. . . . . .
2.3-6310
Gas Filling-Replacing CO2 With H2. . . . . .
2.3-6320
N2 Purging After Filling of Primary Water
System . . . . . . . . . . . . . . . . . .
2.3-6810
Filling and Initial Operation of Primary Water
SystemPreparatory Work . . . . . . . . . . . . . . . . . .
Filling External Part of Primary Water Circuit
Filling the Water Treatment System . .
Filling the Terminal Bushings and Phase
Connectors . . . . . . . . . . . . .
Filling the Stator Winding . . . . . . . . . . .
Filling Primary Water Coolers on Cooling
Water Side . . . . . . . . . . . . .
Activating Primary Water System After a
Shutdown of Less Than 48 Hours
Activating Primary Water System After a
Shutdown of More Than 48 Hours
Activating the Primary Water Conductivity
Meter System . . . . . .
Activating the Primary Water Volume Flow
Meter System . . . . . . . . . . . . .
Initial Operation of Primary Water System Checks Prior to Startup . .
Turning Gear Operation and Runup of
Generator . . . . . . . . . . . . . . . . . . . . .
Generator Startup Diagram . . . . . . . . .
Permissible Synchronizing Criteria . .

2.3-7100
2.3-7110
2.3-7120
2.3-7150
2.3-7160
2.3-7180
2.3-7210
2.3-7220
2.3-7530
2.3-7540

BHEL,Haridwar

2.3-8184
2.3-8187
2.3-8188
2.3-8190
2.3-8191

Shutdown
Shutdown of Generator . . . . . . . . . . . . .
Generator Shutdown Diagram . . . . . .

2.3-8310
2.3-8311

Supervision of Generator during Standstill
General . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolers . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Oil System . . . . . . . . . . . . . . . . . . .
Shutdown of Seal Oil System . . . . . . .
Draining the air Side Seal Oil Circuit
Draining the Hydrogen Side Seal Oil Circuit
Draining the Seal Oil Signal Lines and Seal
Ring Relief Piping . . . . .
Gas System . . . . . . . . . . . . . . . . . . . . . .
Gas Removal-Lowering Hydrogen Gas
Pressure in Generator . . . . . . .
Gas Removal-Replacing H2 with CO2
Gas Removal-Replacing CO2 With Air
N2 Purging Before Draining of Primary
Water System . . . . . . . . . .
Primary Water System . . . . . . . . . . . . .
Shutdown of Primary Water System for Less
Than 48 Hours . . . . . . . .
Shutdown of Primary Water System for More
Than 48 Hours . . . . . . . .
Draining the Primary Water System- PW
Coolers (Cooling Water Side) . . . .
Draining the Primary Water System- Stator
Winding . . . . . . . . . . . . . . . . .
Draining the PW System-Terminal Bushings
and Phase Connectors
Draining the Primary Water System- Water
Treatment System . . . . . . . .
Draining the Primary Water System- External
Part of Primary Water Circuit
Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3-8400
2.3-8440
2.3-8500
2.3-8510
2.3-8520
2.3-8521
2.3-8522
2.3-8600
2.3-8610
2.3-8620
2.3-8630
2.3-8650
2.3-8700
2.3-8720
2.3-8730
2.3-8732
2.3-8734
2.3-8738
2.3-8746
2.3-8748
2.3-8900

2.3-7610
Fault Tracing
2.3-8010
2.3-8011
2.3-8081

On-Load Running
Permissible Load Limits of Generator
Permissible Loading at Rated PF During
Voltage and Frequency Deviations . .

Generator Capability With Hydrogen Coolers
out of Service on Water Side
Unbalanced Load-Time Curve . . . . . .
Current Overload Capability . . . . . . . . .
Runback for loss of stator coolant . .
Unloading schedule for increased cooling
water inlet temperature . .

2.3-8170
2.3-8181

General . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator and Generator Supervisory Equipment
Coolant Temperature Control. . . . . . .
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolers . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Vapour Exhausters . . . . . . . . .
Seal Oil Pumps . . . . . . . . . . . . . . . . . . .

2.3-9000
2.3-9200
2.3-9280
2.3-9310
2.3-9440
2.3-9450
2.3-9521
2.3-9523

2.0-0010-0553/3
0709E

Seal Oil Pressures and Temperatures
Relief Valves in Seal Oil System
Oil Level in Seal Oil System . . . . . . . .
Gas Pressures . . . . . . . . . . . . . . . . . . .
Gas Purity Meter System . . . . . . . . . . .
Primary Water Pumps . . . . . . . . . . . . . .
Water Pressures and Temperatures in
Primary Water System . . . . . . . .
Filters in Primary Water System . . . . .
Water Level in Primary Water Tank . . .
Conductivity in Primary Water System
Volume Flow Rates in Primary Water System
Alkalizer Unit for Primary Water System
Fuses on Rectifier Wheels . . . . . . . . .
Exciter Temperatures . . . . . . . . . . . . . .
Exciter Cooler . . . . . . . . . . . . . . . . . . . . .
Stroboscope . . . . . . . . . . . . . . . . . . . . . .
Exciter Drying System . . . . . . . . . . . . .
Ground Fault Detection System in Exciter
Field Circuit . . . . . . . . . . . . .

2.3-9531
2.3-9551
2.3-9561
2.3-9640
2.3-9680
2.3-9720
2.3-9730
2.3-9740
2.3-9760
2.3-9782
2.3-9784
2.3-9785
2.3-9901
2.3-9911
2.3-9914
2.3-9941
2.3-9955
2.3-9980

Maintenance and supervisionIntroduction. . . . . . . . . . . . . . . . . . . .
Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Coolers . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Oil Pumps & Bearing Vapour Exhauster
Seal Oil Coolers . . . . . . . . . . . . . . . . . . .
Seal Oil Filters . . . . . . . . . . . . . . . . . . . .
Gas Consumption . . . . . . . . . . . . . . . . .
Primary Water Pumps . . . . . . . . . . . . . .
Primary Water Filters . . . . . . . . . . . . . . .
Primary Water Coolers. . . . . . . . . . . . .
Water Level in Primary Water Tank . . .
Concutivity Meter System. . . . . . . . . . . .
Alkalizer Unit . . . . . . . . . . . . . . . . . . . . . .
Fuses on Rectifier Wheels. . . . . . . . . .
Exciter Dryer . . . . . . . . . . . . . . . . . . . . . .
Ventilation and Make-Up Air Filters
Exciter Coolers . . . . . . . . . . . . . . . . . . . .
Ground Fault Detection System. . . . . .

2.4-4200
2.4-4210
2.4-4240
2.4-4250
2.4-4310
2.4-4520
2.4-4540
2.4-4550
2.4-4610
2.4-4720
2.4-4740
2.4-4750
2.4-4760
2.4-4780
2.4-4785
2.4-4910
2.4-4925
2.4-4930
2.4-4940
2.4-4990

Inspection
Introduction. . . . . . . . . . . . . . . . . . . . . . . .
Determination of Dewpoint Temperature
Packing,Transport, Storage of Gen Rotors
Preventive Measures for Transport and
Storage of Generator Rotors .
Checking Desiccant in Gen Rotor Packing
Insulation Resistance Measurements on
Rotor and Exciter Windings. . . .
Preparation of Machinery Parts . . . . . .
Checking the Bearing and Seal Insulation . .
Test Norms During Overhaul . . . . . . . .
Leakage Tests of Generator and Gas System
Flushing the Oil Piping . . . . . . . . . . . . .
2.0-0010-0553/4
0709E

2.5-0010
2.5-0019
2.5-0030
2.5-0031
2.5-0032
2.5-0033
2.5-0200
2.5-0300
2.5-0305
2.5-0310
2.5-0320

Measures to Prevent Corrosion During
Inspecitons . . . . . . . . . . . . .
2.5-1003
Preventive Measures to Avoid Stress
Corrosion . . . . . . . . . . . . . . .
2.5-1005
Inspection Schedule-Foreword . . . . . .
2.5-1010
Inspection Schedule-Stator . . . . . . . . .
2.5-1020
Inspection Schedule-Rotor . . . . . . . . .
2.5-1030
Inspection Schedule-Coolers . . . . . . .
2.5-1040
Inspection Schedule-Bearings . . . . . .
2.5-1050
Inspection Schedule-Shaft Seals . . . .
2.5-1060
Inspection Schedule-Seal Oil System
2.5-1071
Inspection Schedule-Gas System . . .
2.5-1072
Inspection Schedule-Primary Water System 2.5-1073
Inspection Schedule-Generator Supervisory
Equipment. . . . . . . . . .
2.5-1080
Inspection Schedule-Excitation System
2.5-1090
Measures for Preservation of Generator
During Standstill. . . . . . . . . . . . . . . . .
2.5-1100
Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5-2000
Cementing the Joints of Profiled Gaskets. .
2.5-2120
Sealing Generator End Shield Joints .
2.5-2160
IR Measurements on Stator Winding
2.5-2300
Procedure for carrying out Tan delta test with
End Winding Vibration probes in position 2.5-2305
Drying the Windings . . . . . . . . . . . . . . .
2.5-2310
Test Instruction for Stator Slot Support System
With Top Ripple Springs . .
2.5-2340
Stator Slot Support System-Radial Wedge
Movements-Test Record . .
2.5-2341
Test Equipment for Stator Slot Support System 2.5-2342
Instructions for Checking the Stator Slot
Support System. . . . . . . . . . . . .
2.5-2343
Rewedging of Stator Winding. . . . . . . .
2.5-2345
Cementing Stator Slot End Wedges at Turbine
and Exciter Ends. . . . . .
2.5-2346
Treatment of Bolted Contact Surfaces
2.5-2350
Rotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5-3000
Insulation Resistance Measurements on Rotor
and Exciter Windings
2.5-3300
Ultrasonic Examination of Rotor Retaining
Rings at Power Plant . . .
2.5-3357
Hydrogen Coolers. . . . . . . . . . . . . . . . . .
2.5-4000
Insertion and Removal of Hydrogen Coolers 2.5-4100
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . .
2.5-5000
Shaft Seals. . . . . . . . . . . . . . . . . . . . . . . .
2.5-6000
Seal Oil System. . . . . . . . . . . . . . . . . . . .
2.5-7100
Seal Oil Pumps & Bearing Vapour Exhausters 2.5-7120
Seal Oil Coolers. . . . . . . . . . . . . . . . . . .
2.5-7130
Gas System. . . . . . . . . . . . . . . . . . . . . . .
2.5-7200
Primary Water System. . . . . . . . . . . . . .
2.5-7300
Primary Water Pump. . . . . . . . . . . . . . . .
2.5-7320
Primary Water Coolers . . . . . . . . . . . . .
2.5-7330
Treatment and Cleaning of Pipes in Primary
Water Circuit . . . . . . . . .
2.5-7381
Flushing External Part of Primary Water Circuit2.5-7382
Leakage Test of External Primary Water Circuit2.5-7384
Excitation System-Exciter . . . . . . . . . . .
2.5-9000
Checking the Insulation Resistance of Heat
Sink Insulation . . . . . . . . . .
2.5-9010
Checking the Insulation at Rectifier Wheels
2.5-9011

Turbogenerators

Preface

General

This manual contains information on
operation and maintenance of Turbogenerator
and its auxillary systems.
The information has been prepared on the
assumption that the operating and
maintenance personnel have a basic
knowledge of power plant engineering and
operation. It is an essential prerequisite for
satisfactory operation and maintenance of the
turbogenerator that the operating and

BHEL,Haridwar

maintenance personnel are fully familiar with
the design of the turbogenerator plant and
have aquired thorough training in operation
and maintaining the unit.
The manual is subdevided into following
main sections
-General
-Description
-Operation
-Maintenance
-Inspection

2.0-0030-0500/1
0709E

Turbogenerators

Notes on the Use of the Mannual

General

The turbogenerator instruction manual consists
of the following manual sections:
Q
Q
Q
Q
Q

2.0
2.1
2.3
2.4
2.5

General
Description
Operation
Maintenanceand Supervision
Inspection

For the user of the manual, the identification
n u m b e r i s a s u ff i c i e n t r e f e r e n c e f o r l o c a t i n g a
particular instruction number must be indicated.

Instruction Number
The instruction number consists of the manual
section number, the identification number, the variant
number, the page number, and the date with the
language symbol.

Each section contains a number of separate
instructions.

Manual section number
Identification number

The manual contains a Table of Contents together
with a List of Effective Pages. Please check your
manual against this list and advise if there are any
omissions.

Identification Number
The identification number consists of the above
mentioned section number, supplemented by a fourdigit code number. It is indicated in the bottom most
line of the pages.

BHEL,Haridwar

Variant number
Page number

2.0 - 0040 - 0009 / 1
1205 E

Language (English)
Date (mm yy)

2.0-0040-0500/1
0709E

Turbogenerators
General

The Turbogenerator set has been designed and
manufactured to meet the contract commitment as
regards to the capability for the continuous operation
or variable load operation below maximum continuous
rating with an aim to achieve objective of securing
long life and trouble free operation.
Because of the margin provided in the design, it
may be possible to operate the turbogenerator at
overloads for the time specified in the manual.
However, such operations although possible for the
short time will encroach upon the design margin built
into the generator.
The Turbogenerator is designed to operate within
the temperature rise in accordance with EC standard.
Operating the generator in excess of the capability
curves which are part of this O & M Manual will cause

BHEL,Haridwar

Operation Beyond Contract
Commitment

increase in Copper temperature, thermal expansion
and higher insulation stresses. Such operation is not
permitted by the manufacturer.
Continued operation of unit without recommended
scheduled maintenance will eventually result in
increased maintenance and reduction in the useful
life of the machine. BHEL cannot be responsible for
any malfunctioning occurring as a result of operation
beyond the contract limits and operation of machine
without carrying out scheduled maintenance/
inspection. Such operation if undertaken by the user
must be at his own risk.
BHEL reserves the right of changing the operation
and maintenance instructions based on experience
gained.

2.0-0050-0500/1
0709E

rubbers etc. glass etc. 2.Haridwar 2. in extreme case of fire etc.send the used oil to parties who are licensed to handle and dispose used lubricating oil.physio-chemical treatment for further use in noncritical applications. Non. Non Metals: Rubber. Metals: Structured steel. After it has become unserviceable. brass. c) Plastics and glass: Guidelines given in the following paragraphs can go a long way in planning the activity of scrapping the hazardous material effectively in an echo friendly manner.Metals: a) Rubber: To be recycled after cleaning as far as possible. 2. . bronze etc.Turbogenerators Safe Disposal of Turbogenerator Items General In line with ISO 14001 requirements HEEP-BHEL. exposure of fluoro-elastomers like O-rings. such as very high incineration. . which are scrapped during inspections and capital overhaul after consumption of their useful life.burn off the discarded oil in boiler furnace by mixing with fuel oil. The materials. May be disposed as scrap material for recycling and reuse. Metals: May be disposed as scrap metal for recycling and reuse. Forged steel. These items can be disposed/recycled/ reused as follows: a) Lubricating Oil : Generator is manufactured mainly from three types of items namely. plastics. reuse as low-grade Residue of fluoro-elastomer products. 3. it may be disposed as follows: Send the discarded oil to registered refiners who have facilities to reclaim the oil by . 3. are disposed in an environment friendly manner to protect our natural resources and control environment pollution. Cast steel. b) Insulation: Insulation material should be disposed by very high incineration. at very high temperature above 400 degree C. 1. b) Grease: It may be disposed for lubrication. obtained by BHEL. insulation. Haridwar has adopted an Environmental policy and has pledged to fulfil its responsibility of protecting and conserving the environment around itself. Disposal of Generator wastes: 1. Lubricating Oil and Grease: A proper system of waste disposal should also be evolved and its compliance ensured and necessary precautions as published from time to time adhered to while disposing hazardous material. should be disposed with great care.0-0200-0500/1 0709E . Lubricating oil and Greases.

000 Phase 3 KW 500.: IS:5422 IEC:34 MADE IN INDIA BHEL.P.F.85 LAG Hz 50 588.Turbogenerators Rating Plate Data for Generator General Project name: KHAPERKHEDA TPS EXP:500 MW BHARAT HEAVY ELECTRICALS LTD R.000 P.5 Kg/cm2 (g) Volts 340 Insulation : Class F Amps 4040 Specn.1-1002-10553/1 0709E .M 3000 0.Haridwar Connections : Division: Haridwar 2. KVA Type: THDF 115/59 Stator Rotor YY Volts 21000 Coolant : Hydrogen & Water Amps 16166 Gas Pressure : 3.

1-1050-0500/1 0709E .Turbogenerators Generator Cross Section General BHEL.Haridwar 2.

Haridwar 2.1-1056-0500/1 0709E .Turbogenerators General Outline Drawing General BHEL.

Turbogenerators Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 General Weights: Total Weight Rotor Coolers (without water) BHEL.Haridwar 39 300 kg 7 550 kg 1 860 kg 2.1-1058-0500/1 0709E .

The hydrogen coolers are arranged vertically inside the turbine end stator end shield. particularly to the copper conductors. From these frame compartments the gas then flows into the air gap through slots in the core where it absorbs 2. Turbogenerators General Design Features General Design and Cooling System General The two-pole generator uses direct water cooling for the stator winding. where it is re-cooled and then divided into three flow paths after each cooler. are also dissipated through hydrogen. Flow path III is directed to the stator end winding space at the excitor end through guide ducts in the frame for cooling of the exciter end half of the rotor and of the core end portions. The gas of the first cooling zone is discharged from the coils at the pole center into a collecting compartment within the pole area below the end winding. The generator frame is pressure-resistant and gas tight and equipped with one stator end shield on each side. Each coil quarter is divided into two cooling zones. Cooling of Rotor For direct cooling of the rotor winding.Haridwar by the fan from the air gap and delivered to the coolers. cold gas is admitted to the individual frame compartments via separate cooling gas ducts. The rotor winding is symmetrical relative to the generator center line and pole axis. The losses in the remaining generator components. windage losses and stray losses.1. The hot gas of the second cooling zone is discharged into the air gap at mid-length of the rotor body through radial openings in the hollow conductors and wedges. Hydrogen Cooling Circuit The hydrogen is circulated in the generator interior in a closed circuit by one multi-stage axial-flow fan arranged on the rotor at the turbine end.) through hydrogen and primary water. condensate etc.1-1100-0500/1 0709 E . The hydrogen flows through each individual conductor in closed cooling ducts. From there the hot gas passes into the air gap through pole face slots at the end of the rotor body. Flow path II is directed from the coolers to the individual frame compartments for cooling of the stator core. The three flows mix in the air gap. 5. cold gas is directed to the rotor end windings at the turbine and excitor ends. Direct cooling essentially eliminates hot spots and differential temperatures between adjacent components which could result in mechanical stresses. Flow path I is directed into the rotor at the turbine end below the fan hub for cooling of the turbine end half of the rotor. 4. insulation. Cold gas is directed to each cooling zone through separate openings directly before the rotor body end. The first cooling zone consists of the rotor end winding and the second one of the winding portion between the rotor body end and the mid-point of the rotor. The heat removal capacity is selected such that approximately identical temperatures are obtained for all conductors. 3. The gas is then returned to the coolers via the axial-flow fan. The generator consists of the following components : • Stator Stator frame End shields Stator core Stator winding Hydrogen coolers • Rotor Rotor shaft Rotor winding Rotor retaining rings Field connections • Bearings Shaft seals The following additional auxiliaries are required for generator operation : • • • • Oil system Gas system Primary water system Excitation system 2 Cooling System The heat losses arising in the generator interior are dissipated to the secondary coolant (raw water. such as iron losses. The cooling water flow through the hydrogen coolers should be automatically controlled to maintain a uniform generator temperature level for various loads and cold water temperatures. Cooling of Stator Core For cooling of the stator core. rotor body and stator core. phase connectors and bushings and direct hydrogen cooling for the rotor winding. Hot gas is drawn BHEL.

Flow path 2 cools the phase connectors and bushings. The bushings and phase connectors consist of thick-walled copper tubes through which the cooling water is circulated. The gas is then returned to the coolers via the axial-flow fan. To ensure that the cold gas directed to the exciter end cannot be directly discharged into the air gap. only a minimum temperature rise is obtained for both the coolant and the bars. Primary Cooling water Circuit in the Generator The treated water used for cooling of the stator winding phase connectors and bushings is designated as primary water in order to distinguish it from the secondary coolant (raw water. etc. Since a single pass water flow through the stator is used. Inside the bars the cooling water flows through hollow strands. The secondary water flow through the primary water cooler should be controlled automatically to maintain a uniform generator temperature level for various loads and cold water temperatures. Another flow path is directed from the stator end winding space past the clamping fingers between the pressure plate and core end section into the air gap. Relative movements due to different thermal expansions between the top and bottom bars are thus minimized. All the flows mix in the air gap and cool the rotor body and stator bore surfaces. Flow path 1 cools the stator windings. To dissipate the higher losses in the core ends. The six bushings and the phase connectors arranged in a circle around the stator end winding are hydraulically interconnected so that three parallel flow paths are obtained. the cooling gas slots are closely spaced in the core end sections to ensure effective cooling.1-1100-0500/2 cooled water flow is divided into two flow paths as described in the following paragraphs.). an air gap choke is arranged within the range of the stator end winding cover and the rotor retaining ring at the exciter end. The primary water enters three bushings and exits from the three remaining bushings. At the turbine end. This flow path first passes to a water manifold on the excitor end of the generator and from there to the stator bars via insulated hoses. condensate. These ventilating ducts are supplied with cooling gas directly from the end winding space. 6. The 2. the water is passed through similar hoses to another water manifold and then returned to the primary water tank.the heat from the core. The pump is supplied with hot primary water from the primary water tank and delivers the water to the generator via the coolers. A further flow path passes into the air gap along either side of the flux shield. The primary water is circulated in a closed circuit and dissipates the absorbed heat to the secondary cooling water in the primary water cooler. Each individual bar is connected to the manifold by a separate hose. .

1-1150-0500/1 0709 E .Haridwar 2.Turbogenerators Generator Cooling Gas Circuit General Section A-B Section E-F Note: The cross section may not match with the generator described in this manual BHEL.

which are insulated from the core. The stator is firmly connected to the foundation with anchor bolts through the feet. The flat springs are tangentially arranged on the circumference in sets with three springs each. i.e. Feet are welded to the stator frame and end shields to support the stator on the foundation. the stator end shields contain the shaft seal and bearing components. pressure plates. BHEL. Turbogenerators General Design Features General Stator Stator Frame The stator frame consists of a cylindrical section body and two end shields which make the stator gastight and pressure-resistant. Axial compression of the stator core is obtained by clamping fingers. the stator core and the stator windings.1-1210-0500/1 0709 E .. The supporting rings form part of an inner frame cage. The pressure plates and end portions of the stator core are effectively shielded against stray magnetic fields.Haridwar 2. Both the gas ducts and a large number of welded circular ribs provide for the rigidity of the stator frame. The generator cooler is subdivided into cooler sections arranged vertically in the turbine side stator end shield.1. i. The stator end shields are joined and sealed to the stator frame with an O-ring and bolted flange connection. and non-magnetic through-type clamping bolts. This cage is suspended in the outer frame by a large number of separate flat springs distributed over the entire core length. In addition. The stator frame accommodates the electricity active parts of the stator. 2.e. two vertical supporting springs on both sides of the core and one horizontal stabilizing spring below the core. The springs are so arranged and tuned that forced vibrations of the core resulting from the magnetic field will not be transmitted to the frame and foundation. The flux shields are cooled by flow of hydrogen gas directly over the assembly. Stator Core The stator core is stacked from insulated electrical sheet-steel laminations and mounted in supporting rings over insulated dovetailed guide bars. Ring-shaped supports for resilient core suspension are arranged between the circular ribs.

The water manifolds are insulated from the stator frame.Haridwar a s p r e s s u r i z i n g m e d i u m ( V P I p r o c e s s ) . With this insulating system. Micalastic High-Voltage Insulation High-voltage insulation is provided according to the proven Micalastic system. The gaps between the bars in the stator end windings are completely filled with insulating material which in turn is fully supported by the frame. Current transformers for metering and relaying purposes can be mounted on the bushings. mechanical and thermal properties in addition to being fully waterproof and oil-resistant. the end turns are likewise bonded together with baked synthetic resin fillers. the water manifolds are grounded. The bars are dried under vacuum and impregnated with epoxy resin which has very good penetration properties due to its low viscosity. 3. The bars consist of hollow and solid strands distributed over the entire bar cross-section so that good heat dissipation is ensured. 2. The high-voltage insulation obtained is nearly voidfree and is characterized by its excellent electrical. a final coat of semiconducting varnish is applied to the surfaces of all bars within the slot range. The mica tape is built up from large area mica splittings which are sandwiched between two polyester backed fabric layers with epoxy as an adhesive. To minimize corona discharges between the insulation and the slot wall. In order to minimize the stray losses. the bars are subjected to pressure. The number of layers. Turbogenerators General Design Features General Stator Winding Construction Stator bars. with nitrogen being used BHEL. the bars are composed of separately insulated strands which are transposed by 540° in the slot portion and bending. the thickness of the insulation depends on the machine voltage.. The bars are clamped to the support ring with pressure plates held by clamping bolts made from a high-strength insulating material.1-1230-0500/1 0709 E . At the bar ends. The stator winding connections are brought out to six bushings located in a compartment of welded non-magnetic steel below the generator at the exciter end. Bar Support System To protect the stator winding against the effects of magnetic forces due to load and to ensure permanent firm seating of the bars in the slots during operation. permitting the insulation resistance of the water-filled winding to be measured.e. After impregnation under vacuum. all the solid strands are jointly brazed into a connecting sleeve and the hollow strands into a water box from which the cooling water enters and exits via teflon insulating connection between top and bottom bars is made by a bolted connection at the connecting sleeve. several half-overlapped continuous layers of mica tape are applied to the bars. i. Hot-curing conforming fillers arranged between the stator bars and the support ring ensure a firm support of each individual bar against the support ring. The support ring is free to move axially within the stator frame so t h a t m o v e m e n ts o f t h e w i n d i n g d u e t o t h e r m a l expansions are not restricted. the bars are inserted with a top ripple spring located beneath the slot wedge. In addition. phase connectors and bushings are designed for direct water cooling. all bars are provided with an end corona protection. During operation. 2. to control the electric field at the transition from the slot to the end winding and to prevent the formation of creepage spark concentrations.1. The impregnated bars are formed to the required shape in molds and cured in an oven at high temperature.

Rotor Winding 4. After completion. The retaining rings are made of non-magnetic high-strength steel in order to reduce stray losses. 3. The longitudinal slots poles are obtained. The retaining ring is secured in the axial position by a snap ring. Each retaining ring with its shrink-fitted insert ring is shrunk onto the rotor body in an overhung position.1.Haridwar Field Connections The field current is supplied to the rotor winding through radial terminal bolts and two semicircular conductors located in the hollow bores of the exciter and rotor shafts. The rotor winding consists of silver-bearing deoxidized copper hollow conductors with two lateral cooling ducts. The seat of the retaining ring is silver-plated to ensure a good electrical contact between the slot wedges and rotor retaining rings. 2. L-shaped strips of laminated epoxy glass fiber fabric with Nomex filler are used for slot insulation. each of which consists of two half turns which are connected by brazing in the end section. the rotor is balanced in various planes at different speeds and then subjected to an overspeed test at 120% of rated for two minutes. BHEL. The field current leads are connected to the exciter leads at the exciter coupling with multicontact plug-in contact which allow for unobstructed thermal expansion of the field current leads. To ensure that only high-quality forging is used. The rotor poles are designed with transverse slots to reduce twice system frequency rotor vibrations caused by deflections in the direction of the pole and neutral axis. Turbogenerators General Design Features General Rotor Rotor Shaft The rotor shaft is a single-piece solid forging manufactured from a vacuum casting. Slots for insertion of the field winding are milled into the rotor body. Retaining Rings The centrifugal forces of the rotor end windings are contained by single-piece rotor retaining rings. This system has long proved to be a good damper winding. The rotor winding consists of several coils which are inserted into the slots and series connected such that two coil groups form one pole.1-1300-0500/1 0709 E . 2. strength tests. Each coil consists of several series connected turns. material analysis and ultrasonic tests are performed during manufacture of the rotor. The slot wedges are made of high-conductivity material and extend below the shrunk seat of the retaining ring.

The cooling water flows through the tubes. while the hydrogen is passed around the finned tubes. while the attachment at the lower water channel permits them to move freely to allow for expansion. The cooler sections are solidly bolted to the upper half stator end shield. The required cooling water flow depends on the generator output and it is adjusted by control valves on the hot water side. Controlling the cooling water flow on the outlet side ensures an uninterrupted water flow through the cooler sections so that proper cooler performance will not-be impaired. Shut-off valves are installed in the lines before and after the cooler sections.1 BHEL. 1 2 1 Cooler 2 Stator end shield Fig. The cooler sections are parallel-connected on their water sides.1-1440-0500/1 0709 E .Haridwar Arrangement of Hydrogen Cooler 2. The hydrogen cooler is subdivided into identical sections which are vertically mounted in the turbine-end stator end shield. The heat removed from the hydrogen is dissipated through the cooling water.Turbogenerators General Design Features General Hydrogen Cooler The hydrogen cooler is a shell and tube type heat exchanger which cools the hydrogen gas in the generator.

The bearings have provisions for fitting vibration pickups to monitor bearing vibrations.Haridwar Bearing 2. 1 2 3 1 Connection for shaft lift oil 2 Thermocouple 3 Bearing sleeve Fig.1-1450-0500/1 0709 E . all bearings are insulated from the stator and base plate.Turbogenerators General Design Features General Bearings The sleeve bearings are provided with hydraulic shaft lift oil during start-up and turning gear operation.1 BHEL. To eliminate shaft currents. Measurement and any required recording of the temperatures are performed in conjunction with the turbine supervision. respectively. The temperature of the bearings is monitored with thermocouples embedded in the lower bearing sleeve so that the measuring points are located directly below the babbitt.

the seal oil pressures in the annular gap are maintained at a higher level than the gas pressures within the generator casing. The gap between the seal ring and the shaft is sealed withseal oil on hydrogen side and air side. Shaft Seal 7 Rotor shaft 8 Oil wiper ring (H2 side) 9 Seal ring carrier 10 Annular groove for hydrogen side seal oil 11 Seal oil inlet bore (H2 side) 12 Annular groove for hydrogen side seal oil 13 Annular groove for air side seal oil 14 Babbit 15 Seal ring 16 Annular groove for pressure oil 17 Oil wiper ring (air side) 18 Seal oil groove 2.Turbogenerators General Design Features General Shaft Seals The points where the rotor shaft passes through the stator casing are provided with a radial seal ring. The seal ring is lined with babbitt on the shaft journal side. This seal oil is fed to the hydrogen side annular groove in the seal ring and from there to the sealing gap via several bores uniformly distributed on the circumference. The air side seal oil is supplied to Fig. The seal ring is guided in the seal ring carrier which is bolted to the seal ring carrier flange and insulated to prevent the flow of shaft currents.1-1460-0500/1 0709 E . The oil drained on the air side is returned to the seal oil storage tank together with the bearing oil. To ensure effective sealing. This ensures free movement of the seal ring in the radial direction.Haridwar the sealing gap from the seal ring chamber via radial bores and the air side annular groove in the seal ring. pressure oil is supplied laterally to the seal ring via an annular groove. The hydrogen side seal oil is returned to the seal oil system through ducts below the bearing compartments. The hydrogen side seal oil is supplied to the seal ring via an annular groove in the seal guide. The air side seal oil pressure is set at slightly higher than the hydrogen side seal oil pressure. On the air side.1 1 2 3 4 5 6 Seal ring carrier flange Seal Insulation Seal ring chamber Inner labyrinth ring Seal strip BHEL.

seal oil pump 2 automatically takes over the seal oil supply. the required pressure difference between seal oil pressure and hydrogen pressure.e. i. Upon failure of seal oil pump 2. In the event of its failure.1 Turbogenerators General Design Features General Oil supply for Bearings and Shaft Seals Bearing Oil System The generator and exciter bearings are connected to the turbine lube oil supply.3 Air Side Seal Oil Circuit The air side seal oil is drawn from the seal oil storage tank and delivered to the seals via a cooler and filter by seal oil pump 1. The associated seal oil pump returns the oil to the shaft seals via a cooler and filter. the high level float-operated drain valve is usually open to return the excess air side seal oil. to the air side seal oil circuit. the preset difference between air side and hydrogen side seal oil pressures. i. Hydrogen Side Seal Oil Circuit : Q Q Q Q Q Q Q Q Seal oil tank Seal oil pump Oil cooler 1 Oil cooler 2 Seal oil filter Differential pressure valve C Pressure equalizing valve TE Pressure equalizing valve EE. 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. when the seal oil for the seals is obtained from the standby seal oil pump. During normal operation. In the event of a failure. differential pressure valve A2 takes over this automatic control function. Two float-operated valves keep the oil level at a predetermined level. 2 Seal Oil System 2. the seal oil is taken from the air side seal oil circuit. which flowed to the hydrogen side via the annular gaps of the shaft seals. The air side seal oil pressure required at the seals is controlled by differential pressures valve A1 according to the preset value. Oil drained from the hydrogen side is returned to the seal oil tank via the generator pre-chambers.e.1 Construction The shaft seals are supplied with seal oil from two seal oil circuits which consist of the following principal components. thus preventing gas from entering the suction pipe of the seal oil pump (hydrogen side).1-1510-0500/1 0709 E . BHEL. The hydrogen side seal oil pressure required downstream of the pump is controlled by differential pressure valve C according to the preset reference value. the standby seal oil pump is automatically started and takes over the seal oil supply to the shaft seals. The high level float-operated valve drains excess oil into the seal oil storage tank. The hydrogen entrapped in the seal oil comes out of the oil in the seal oil storage tank and is extracted by the bearing vapor exhauster for being vented to the atmosphere above the power house roof. In the event of a failure of the seal oil pump of the hydrogen side seal oil circuit.Haridwar 2. The seal oil drained from the air side of the shaft seals is directly returned to the seal oil storage tank. according to the preset pressure difference between the hydrogen side and air side seal oil. Air Side Seal Oil Circuit : Q Q Q Q Q Q Q Q Q Seal oil storage tank Seal oil pump 1 Seal oil pump 2 Standby seal oil pump Oil cooler 1 Oil cooler 2 Seal oil filter Differential pressure valve A1 Differential pressure valve A2 2.2 Hydrogen Side Seal Oil Circuit The seal oil drained towards the hydrogen side is collected in the seal oil tank. 2.e. i. The hydrogen side seal oil pressure required at the seals is controlled separately for each shaft seals by respective pressure equalizing valves.

Turbogenerators Seal Oil System General (Simplified Diagram) Air side seal oil circuit Hydrogen side seal oil circuit 1 2 3 4 5 6 7 8 9 10 11 12 13 Seal ring Seal oil storage tank Seal oil pump “A” valve Seal oil cooler Seal oil filter Generator Prechamber Pressure equalizing control valve Seal oil tank Seal oil filter “C” valve Seal oil cooler Seal oil pump Hydrogen side seal oil Air side seal oil Pressure oil for seal ring relief Hydrogen BHEL.1-1511-0500/1 0709 E .Haridwar 2.

To ensure that the primary water in the pump suction line is at a pressure above atmospheric pressure so as to avoid pump cavitation. 4 Compressed Air Supply To remove CO 2 from the generator. • • • 3 To prevent the formation of a vacuum due to different thermal expansions of the primary water & tank. and for operation of the generator filled with hydrogen.2 Primary Water Tank A nitrogen environment is maintained above the primary water in the primary water tank for the BHEL. the gas system includes a nitrogen (N 2 ) supply. the hydrogen in the generator is pressurized. Carbon Dioxide (CO 2) Supply As a precaution against explosive hydrogen air mixtures. 2. The generator must be filled with CO 2 until it is positively ensured that no explosive mixture will form during the subsequent filling or emptying procedures. The gas system consists of : • • • • • • • • • • 2 H 2 supply CO 2 supply N 2 supply Pressure reducers Pressure gauges Miscellaneous shutoff valves Purity metering equipment Gas dryer CO 2 flash evaporator Flowmeters Hydrogen (H 2 ) Supply 2.1-1520-0500/1 0709 E .1 Generator Casing The heat losses arising in the generator are dissipated through hydrogen. compressed air is to be admitted into the generator. 5 Nitrogen (N 2) Supply Nitrogen is required for removing the hydrogen or air during primary water filling and emptying procedures. a compressed air filter is installed in the filter line. hydrogen or air and removal of these media. The compressed air must be clean and dry. For more effective cooling.Haridwar following reasons.1 Turbogenerators General Design Features General Gas System General T h e g a s s y s t e m c o n ta i n s a l l e q u i p m e n t necessary for filling the generator with CO 2 . To ensure that the primary water circuit is at a pressure above atmospheric pressure so as to avoid the ingress of air on occurrence of a leak. the generator must be filled with an inert gas (CO 2 ) prior to H 2 filling and H 2 removal. In addition. 2. The heat dissipating capacity of hydrogen is eight times higher than that of air. For this reason.

1-1521-0500/1 0709 E .Haridwar H2 bottle H2 pressure reducer N2 bottle N2 pressure reducer Primary water tank Pressure controller Upper generator gas header Lower generator gas header Gas drier heater 10 11 12 13 14 15 16 17 18 Gas drier fan Gas drier chamber CO2/H2 purity transmitter Dehydrating filter for measuring gas Pressure reducer for measuring gas Compressed air hose Compressed air filter CO2 flash evaporator CO2 bottle 2.Turbogenerators Gas System General Simplified Diagram 1 2 3 4 5 6 7 8 9 BHEL.

2.1 Turbogenerators General Design Features General Primary Water System General The primary water required for cooling is circulated in a closed circuit by a separate pump. 3 Primary Water Treatment System The direct contact between the primary water and the high-voltage windings calls for a low conductivity of the primary water. the electrical conductivity should be maintained below a value of approximately 1 µmho/cm.Haridwar returned to the primary water tank. During operation. After having performed its cooling function. In the event of a failure of one pump. Each pump is driven by a separate motor. The gas pressure above the water level in the primary water tank is maintained constant by a pressure regulator. thus forming the highest point of the entire primary water circuit in terms of static head. the standby pump is immediately ready for service and cuts in automatically. a small quantity of the primary water flow should therefore be continuously passed through the ion exchanger located in the bypass of the main cooling circuit. the conductivity will rise very slowly. since with the water treatment system out of service. In order to maintain such a low conductivity it is necessary to provide for continuous water treatment. the water is BHEL. the primary water admitted to the pump from the tank is first passed via the cooler and fine filter to the water manifold in the generator interior and then to the bushings. two fullcapacity pumps are provided. The ion exchanger resin material required replacement during operation of the generator. During operation. 2 Primary Water Tank The primary water tank is located on top of the stator frame on an elastic support. T h e p r i m a r y w a t e r s y s t e m c o n s i s ts o f t h e following principal components : • • • • • • • Primary water tank Primary water pumps Cooler Primary water filter Fine filter Ion exchanger Alkalyser unit As illustrated in the diagram. To ensure uninterrupted generator operation. pipes and instruments coming into contact with the primary water are made from stainless steel material.1-1530-0500/1 0709 E . All valves.

general Coolant flow : stator winding Coolant flow : main bushings and phase connectors Water treatment Waste gas Hydrogen 1 2 3 4 5 6 Primary water tank Pressure regulator Waste gas to atmosphere Pump Cooler Filter BHEL.Turbogenerators Primary Water System General (Simplified Diagram) Primary water circuit.Haridwar 7 8 9 10 11 12 13 Bypass line Cooling water for stator winding Ion exchanger Cooling water for main bushings and phase connectors Teflon hose Cooling water manifold Alkaliser unit 2.1-1531-0500/1 0709 E .

00046 9 ohms Rectifier Wheel Number of fuses 30 per rectifier wheel (800 V.067873 ohms V-W 0.002579 ohms W-0 0. replace fuses and diodes.Haridwar 2.5 bar (g) - - 8% - - Cont. perm. BHEL.0014747 ohms Pilot Excitor U-0 0.000469 ohms Rotor Winding U-W 0.1-1810-10553/1 0709 E .002579 ohms F1-F2 0.05 kV 340 V 220 V + 22 V Speed 50s-1 50s-1 50 s-1 Frequency 50 Hz - 400 Hz Power factor 0.85 (lag) - - YY - - Inner connection of stator winding H2 pressure 195 A 3. 800 A) Fuse. The field current is no criterion of the load carrying capacity of the turbogenerator.00046 9 ohms F1-F2 0.6036 ohms W-Z 0.002579 ohms U-V 0.166 kA 4040A Voltage 21 kV + 1. Resistance in Ohms at 25°C Turbogenerator Main Excitor U-X 0. 150 µ ohms Number of diodes per rectifier wheel 60 Action Required: Number of fuses blown per 2 fuses Switch off field forcing bridge arm and rectifier wheel 3 fuses Shutdown turbine-generator. resistance approx.0014747 ohms V-0 0.0014747 ohms Stator Winding V-Y 0.Turbogenerators Technical Data Description General and Electrical Data General K HAPERKHEDA TPS EXP:500MW Project name Generator Type THDF 115/59 Main Exciter Type ELR 70/90-30/6-20 Pilot exciter Type ELP 50/42-30/16 Year of manufacture 2009 Rated Data and Outputs Turbogenerator Main Exciter Apparent power 588 MVA 3780KVA Active power 500 MW - Pilot Excitor 65 kVA Current 16. unbalanced Load Rated field current for rated output 4040 A - - Rated field voltage 340 V - - The machines are designed in conformity with IEC-34 and should be operated according to these specifications.

With the unit on the turning gear.t. lower part. Critical Speed etc.1PF25 CuNi2Si X8CrMnN1818K CuAg0.)* Weight 360000 265000 22066 6665 24200 9950 68000 1770 950 320 250 90 7550 units kg kg kg kg kg kg kg kg kg kg kg kg kg Material 1.p. 0 C and 1.p.t. = Standard temperature and pressure.)* m3 (s.1-1820-10553/1 0709 E . CO2 quantity kept on stock must always be sufficient for removal of the existing hydrogen filling. upper part TE Stator end shield.t.p. TE Stator end shield. upper part EE Stator end shield. Torques and Speeds Units 14585 kNm 10000 864 2388 4680 kgm2 Maximum short-circuit torque of stator at line-to-line single-phase short-circuit Moment of inertia of generator rotor shaft Critical speed (calculated) (Generator + Exciter coupled) ηk1 ηk2 ηk3 Generator Volume and Filling Quantities Generator volume (gas volume) CO2 filling quantity*** H2 filling quantity (to 3. BHEL. the volume will be higher.1F25 Stator copper Bearing babbit Seal rings babbitt * ** *** RPM Volume 80 160 480 Units m3 3 m (s.5 W/Kg at 1 Tesla 0. All values are approximate.013 bar to DIN 1343 Volume required with unit at standstill.Haridwar 2.5 mm TK E-Cu58F20 Babbitt V 738 Babbitt V 738 o s. lower part. EE Rotor H2 cooler section.5 bar)** Weights Stator with end shields and coolers Shipping weight of stator Stator end shield. including water channels Gas dryer One seal oil cooler (air side) One seal oil cooler (H2 side) One primary water cooler Exciter rotor Component Material Component Rotor shaft 26NiCrMoV145 Electrical sheet-steel Rotor copper Rotor wedges Retaining rings Damper wedges CuAg0.Turbogenerators Technical Data Description Mechanical Data Torques.

Turbogenerators

Technical Data

Description

Seal Oil System

Design Data
Seal oil pumps -1,2 (Air Side) MKW 11 AP 001 and
MKW 21 AP 001
Kind of pump
Type
Capacity
Discharge pressure
Pump motor
Rating
Voltage/ frequency
Current
Speed
Type of enclosure
Nos.
Seal oil pump -3 ( Air side) MKW 31 AP 001
Kind of pump
Type
Capacity
Discharge pressure
Pump motor
Rating
Voltage
Current Armature
Speed

Type of enclosure
Nos.
Seal oil pump (H2 side) MKW 13 AP 001
Kind of pump
Type
Capacity
Discharge pressure
Pump motor
Rating
Voltage/ frequency
Current
Speed
Type of enclosure
Nos.
MKW 51 BT 001, MKW 51 BT 002,
MKW 53 BT 001 & MKW 53 BT 002
Kind of filter
Type
Volumetric flow rate
Degree of filtration
Pressure drop across filter
Nos. for air side
Nos. for H2 side

Three Screw pump
T3S - 52/54
258 LPM
12Kg/Cm2
CGL, ND132M
7.5 KW
415V, 3 Ph AC 50Hz
14.5 A
1500 RPM (Syn.)
TEFC, IP55

2x100% capacity

Three Screw pump
T3S - 52/54
258 LPM
12 Kg/cm2
CGL, AFS 225L
8.5 KW
220 V DC
67 A
1450 RPM
TEFC , IP55

1x100% capacity

Three Screw pump
T3S - 52/46
130 LPM
12 kg/cm2
CGL, ND 132M
4 KW
415V, 3 Ph AC 50Hz
9.3 A
940 RPM
TEFC, IP55

1x100% capacity

Seal oil filters

Strainer-type filter
BFD (M/s Boll & Kirch)

12 m 3/hr
100 microns
0.3 bar with clean filter *

2x100% capacity
2x100% capacity
* 1.2 bar with 100% blockage

BHEL,Haridwar

2.1-1825-10553/1
0709E

Turbogenerators

Technical Data

Description

Gas System

Design Data
CO 2 vapouriser MKG 51 AH 001
Rating
Voltage
Heat transfer liquid
Volume of heat transfer liquid
Hole in orifice

18 kW
415V, 3 Ph AC 50Hz
HYTHERM 500 (M/s HPCL)
25 dM 3
2.8 mm

Relief valve on high-pressure side
Relief valve on low-pressure side

175 bar
8 bar

Nos.

1x100% capacity

Refrigeration type gas drier
Rating and parameters

As per sub-supplier’s manual

Compressed air filter MGK 25 BT 001
Volume of activated carbon
Service hours
Throughput
Nos.

BHEL,Haridwar

3
3 dm
approx. 1500 hr to 2000 hr
3

80 m /hr at 8 bar
1x100% capacity

2.1-1826-10553/1
0709E

Turbogenerators

Technical Data

Description

Primary Water System
Design Data

Primary water pumps MKF12AP001 and MKF22AP001
Kind of pump

Centrifugal pump

Type

CPK-CM 65-250 (S) M/s KSB make

Speed

2950 RPM

Capacity

70 m /Hr

Discharge head

80 m

Pump motor

ND225 M (M/s Crompton Greaves Ltd)

Rating

37KW

3

Voltage

415V, 3 Ph AC 50Hz

Frequency

50 Hz

Speed

2950 RPM

Type of enclosure

TEFC

Nos.

1x100% capacity

Main filters MKF 52 BT 001 and MKF 52 BT 002
Kind of filter

Strainer-type filter with magnet bars

Type

1.53.1 (M/s Boll & Kirch)

Volumetric flow rate

25 dm /s max.

3

Degree of filtration

150 mm

Pressure drop across filter

0.1 bar with clean filter
1.2 bar with 100% fouling

Nos.

2x100% capacity

Fine filter MKF 60 BT 001
Kind of filter

1 plug. 1 cartridge

Type

1.55.1 (M/s Boll & Kirch)

Volumetric flow rate

0.42 dm /s max.

Pressure drop across filter

0.15 bar with clean filter

3

1.2 bar with 100% fouling
Nos.

1x100% capacity

Ion exchanger MKF 60 BT 001
Volume

83 litres

Resin

Lewatit

Resin volume

56 litres (45 kg)

Nos.

1x100% capacity

BHEL,Haridwar

2.1-1827-10553/1
0709E

Turbogenerators

Technical Data

Description

Waste Gas System

Design Data
Bearing vapor exhausters MKC 31 AN 001 and
MKQ 32 AN 001
Moter Rating

0.75kW

Voltage/frequency

415V, 3 Ph AC 50Hz

Current

1.8A

Speed

2780 RPM

Type of enclosure

IP 55

Type of exhausters

Radial-flow

Nos.

2x100% capacity

BHEL,Haridwar

2.1-1828-10553/1
0709 E

Turbogenerators

Technical Data

Description

Excitation System

Design Data
A-wheel (negative polarity)
No./Type of diodes
No./Type of fuses
Resistance/voltage/current per fuse
No. of RC networks

60 Nos./BHdL 1220 (BHEL EDN,Bangalore make)
30 Nos./3NC 9 538
approx. 150 μΩ, 800 V, 800 A
6 Nos.

B-wheel (positive polarity)
No./Type of diodes
No./Type of fuses
Resistance/voltage/current per fuse
No. of RC networks

60 Nos./BHdL 1320(BHEL EDN,Bangalore make)
30 Nos./3NC 9 538
approx. 150 μΩ, 800 V, 800 A
6 Nos.

Stroboscope
Type
Voltage
Frequency
No. of stroboscope

LX5-30/36-2
240 V
50/60 Hz
1 No.

Exciter air dryer
Type
Rating
Voltage
Frequency
Adsorption air flow rate
Regeneration air flow rate
No. of dryer

BA-1.5 A (M/S BRYAIR MAKE)
4,6 kW
230 V
50 Hz
120 m3/h
35 m3/h
1 No.

BHEL,Haridwar

2.1-1829-10553/1
0709 E

Turbogenerators

Technical Data

Description

Cooler Data

Design Data for the H2 Cooler,
Drg. No. 0-166-01-70006C
(4 x 25% each)

Units

Hydrogen pressure

3.5

Bar (g)

Gas flow (Total)

33

m /s

Heat dissipating capacity (Rated)

4640

kW

Cold gas temperature

44

°C

Hot gas temperature (max.)

72

°C

Gas pressure drop (approx.)

700

Pa

Cooling water flow (Total for 4 sections)

540

m3/hr

Cooling water inlet temperature (design)

38

°C

Water outlet temperature

45.4

°C

Water pressure drop

3.0

MWC

3

Units

Design Data for One Seal Oil Cooler (Air Side)
Drg. No. 0-165-03-70006 C (1 x 100% )
Oil flow

4.16

dm 3 /s

Heat dissipating capacity (Rated)

140

kW

Oil inlet temperature

70

°C

Oil Outlet temperature

50

°C

Oil pressure drop (approximate)

0.833

Bar

Cooling water flow

35

m3/hr

Cooling water inlet temperature (design)

38

°C

Water outlet temperature

41.4

°C

Water pressure drop (approximate)*

6.8

MWC

Design Data for One Seal Oil Cooler (H2 Side)
Drg. No. 0-165-03-70005 C (1 x100% )

Units

Oil flow

2.17

dm 3 /s

Heat dissipating capacity (Rated)

90

kW

Oil inlet temperature

70

°C

Oil outlet temperature

50

°C

Oil pressure drop (approximate)

0.85

bar

Cooling water flow

22

m3/hr

Cooling water inlet temperature (design)

38

°C

Water outlet temperature

41.5

°C

Water pressure drop (approximate)*

7.1

mWC

Materials and Pressures
Materials
Fins
Tubes
Tubesheets
Water channels

Copper
90/10 Cu-Ni
Carbon steel
Carbon steel

Pressures (Tube Side)
Design pressure
10 kg/cm2
Test pressure
15 kg/cm2

Materials and Pressures
Materials
Tubes
Tubesheets
Water channels

Admiralty Brass
Carbon steel
Carbon steel

Cooling water Pressures
Operating pressure 16 kg/cm2
Test pressure
24 kg/cm2
Oil Side Pressures
Operating pressure
Test pressure

16 kg/cm2
24 kg/cm2

Materials and Pressures
Materials
Tubes
Tubesheets
Water channels

Admiralty Brass
Carbon steel
Carbon steel

Cooling Water Pressures
Design pressure
16 kg/cm2
Test pressure
24 kg/cm2
Oil Side Pressures
Design pressure
Test pressure

16 kg/cm2
24 kg/cm2

Note: The specified cooler data refer to max. cooling water inlet temperatures. During operation the operating
values of the coolers may deviate from above design data.

BHEL,Haridwar

2.1-1830-10553/1
0709 E

Design Data for the Primary Water
Cooler, Drg. No. 0-165-41-70013 C
(2 x 100% )

Units

Primary water flow

18.06

dm 3 /s

Heat dissipating capacity (Rated)

1715

kW

Primary water inlet temperature

71.7

°C

Primary water outlet temperature

49

°C

Primary water pressure drop

1160

mbar

Cooling water flow

250

m3/hr

Maximum cooling water inlet temperature

38

°C

Cooling water outlet temperature

43.9

°C

Water pressure drop*

2.0

MWC

Design Data for the Exciter Air Cooler,
Drg. No. 0-166-05-70003C
(2 x 50% each)

Units

Hydrogen pressure

1

Bar (g)

Gas flow (Total)

15.5

m /s

Heat dissipating capacity (Rated)

500

kW

Cold gas temperature

45

°C

Hot gas temperature (max.)

74

°C

Gas pressure drop (approx.)

700

Pa

Cooling water flow (Total for 4 sections)

200

m3/hr

Cooling water inlet temperature (design)

38

°C

Water outlet temperature

40.2

°C

Water pressure drop*

3.0

MWC

* Flange to flange of equipment only

2.1-1830-10553/2
0709E

3

Materials and Pressures
Materials
Shell
Tubes
Tubesheets
Water channels

SS
SS
SS
Carbon Steel

Primary Water Side Pressures
Design pressure
10 kg/cm2
Test pressure
15 kg/cm2
Cooling Water Side Pressures
Design pressure
10 kg/cm2
Test pressure
15 kg/cm2

Materials and Pressures
Materials
Fins
Tubes
Tubesheets
Water channels

Copper
90/10 Cu-Ni
Carbon steel
Carbon steel

Pressures (Tube Side)
Design pressure
10 kg/cm2
Test pressure
15 kg/cm2

Turbogenerators

Technical Data

Description

Load Characteristic of Pilot Exciter

PMG Pilot Exciter Characteristic
240

235

PMG Voltage(volts)

230

225

220

215

210

205

200
0

50

100

150

200

250

PMG field current (amps)

BHEL,Haridwar

2.1-1860-10553/1
0709 E

the gas shall be made available at the following conditions: 1 to 2. Q The maximum total oil or hydrocarbon content. The remaining 0. 2. The maximum particle size in the air stream shall be five (5) micrometers. Compressed Air Q The compressed air shall be free of- Q Gauge pressure : Temperature : Volumetric flow rate : corrosive contaminants and hazardous gases.9% v/v. shall be as close to zero (0) w/w or v/v as possible. and under no circumstances shall it exceed one (1) ppm w/w or v/v under normal operating conditions.Haridwar 2. BHEL.5 bar 20 to 30 0C 144 to 216 m 3/h. In no case should the dew point at line pressure exceed 10 °C. H2O): not applicable The remaining 0. Carbon Dioxide (CO2) Q Q Q Q Q Q Carbon dioxide shall be made available with a purity ≥ 99.Turbogenerators Gas Specification Description 1. = standard temperature and pressure.01% v/v shall be free of corrosive contaminants. Contaminants (O2. If obtained from a central bulk supply. The dew point at line pressure shall be at least 15 K below the minimum possible generator temperature. The compressed air shall be available at a gauge pressure between 6 and 9 bar. flammable or toxic. exclusive of non-condensables.p. The gauge pressures and temperatures indicated are those at the inlets of the generator gas supply units. the hydrogen gas shall be made available at the following conditions: Gauge pressure : Volumetric flow rate : 4 Q 8 to 9 bar 144 to 216 m 3/h.99 % v/v. 3 Hydrogen (H2) Q Q The hydrogen gas shall be made available with a purity 99.1 % v/v shall be free of corrosive contaminants: traces of ammonia (NH3) and sulphur dioxide (SO 2) shall not be detectable by analysis. If obtained from a central bulk supply. The remaining 0. Nitrogen (N2) The nitrogen gas shall be made available with a purity of 99. The oxygen content of the expanded air shall be between 20 and 21% v/v. traces of ammonia (NH 3) and sulphur dioxide (SO 2) shall not be detectable by analysis. 1) s.t.1-1883-10553/1 0709 E .1 % v/v shall be free of corrosive contaminants: traces of ammonia (NH3) and sulphur dioxide (SO 2) shall not be detectable by analysis. 00C and 1. Volumetric flow rate: 144 to 216 m3/h. The compressed air shall be practically free of dust.9 % v/v.013 bar to DIN 1343.

BHEL Haridwar must be informed for their evaluation and approval. dissolved/ undissolved : Less than 20 ppb Fe. levoxine. phosphate. dissolved/ Undissolved : Less than 20 ppb Dissolved solids : The water shall not contain chemicals from treatment processes. If the water to be used does not meet these quality criteria. such as hydrazine. preferably less than 100 ppb Minimum.Turbogenerators Primary Water Specification Description The water used must not contain any contaminants that might have a harmful effect on the materials used in the primary water circuit. 2.1-1885-10553/1 0709 E . morpholine. For this reason. preferably 0. the water must have the following quality criteria : Conductivity : pH Dissolved O 2 Dissolved CO2 Chlorides and other anions Ammonia : : : : < 10 µ mho/cm. permissible conductivity after a strongly acidic cation exchanger < 0.5 µ mho/cm 6-8 Minimum.Haridwar Cu. BHEL.2 µ mho/cm Minimum. test with Nessler’s solution as a reagent shall not cause a change in color. etc.

General The primary water must have a low condictivity since it comes into direct contact with the high-voltage winding. The initial charge of the mixed-bed ion exchanger consists of the following types of resins. The ion exchange resins must be replaced at certain intervals. 50 gCaO/dm3 16 gCaO/dm3 Chloride content up to 50 mg/dm3 50 mg/dm3 Thermal stability up to 1200C 700C Unlimited Unlimited 5 years 3 years Stability in pH range Shelf life (in original packing at temperatures of +1oC to +40oC BHEL. Our recommendation to use Lewatit ion exchange resins is based on many years of service experience and the close cooperation between the resin supplier and many power plant operators as well as the high quality standard of the resins. since with the water treatment system out of service the conductivity will continue to rise only very slowly. 2. This is achieved by continuously passing a small primary water volume flow through a mixed bed ion exchanger arranged in the bypass of the main cooling circuit. use either the above types or resins available from other manufacturers which must comply with the specification below. The resins may be replaced while the generator is in operation.25) mm (0.1 .900) g/dm 3 (670 .1.2.1-1887-10553/1 0709 E .750) g/dm3 Resin form H-ions OH-ions 40 dm3 /h × dm3 40 dm3 /h × dm3 (1.Haridwar min.25) mm Bulk density of swollen resin (800 .6) mol/dm 3 Specific load up to Total capacity of swollen resin Useful capacity min.3 .2) mol/dm 3 (1. 2.Turbogenerators Specification for Ion Exchange Resins Description 1. Q Lewatit S 100 KR/H/chloride-free Q Lewatit M 500 KR/OH/chloride-free When replacing the resins. To maintain a low conductivity the primary water requires continuous treatment.9 . Cation exchanger Anion exchanger (Lewatit S100KR/H/chloride-free) (Lewatit M500 KR/OH/chloride-free) Functional group Strongly acidic Very strongly basic Grain shape Beads Beads Particle size (0.3 .1. Resin Specification The resins should contain no impurities or soluble substances having a detrimental effect on the materials used in the primary water circuit and thus on the availability of the generator.1.

quality.1-7341 Alkalizer Unit for Primary Water Circuit [2] 2. corrosion of copper in the primary water circuits of water-cooled windings. Operating the generator with alkaline water at pH 8 to 9 will improve the reliability and availability of the turbine generator. For operation of the alkalizer unit [1].A. Also refer to the following information [1] 2.Haridwar 2. the system becomes less susceptible to disturbances resulting from air in-leakage. NaOH : > 98% Carbonates [Na2CO3] : < 1% Water in conformity with the primary water specification [2]. containing.1-1888-10553/1 0709 E . Sodium hydroxide solution should be prepared from : Q Q Caustic Soda [NaOH] of P.Turbogenerators Description Despite the use of oxygen-poor water. In addition.1-1885 Primary Water Specification BHEL. The severity of the corrosion attack can be substantially reduced by alkalizing the oxygen-poor water. 2 Lime A lime filter to be provided in the NaOH tank vent serves to bind the carbon dioxide (CO2) contained in the inlet air in order to prevent the formation of carbonates in the sodium hydroxide solution. cannot be completely avoided. dilute sodium hydroxide for continuous injection into the primary water circuit and lime are required. The lime filter consists of equal parts of sodium hydroxide (NaOH) and calcium hydroxide (Ca(OH) 2 ). and in isolated cases the corrosion products can reduce the crosssectional flow area of the water distribution system. This mixture is commercially available and known as soda lime. 1 Sodium Hydroxide Solution The sodium hydroxide solution should have a Additive Specificaiton for Alkalizer Unit concentration of 10 to 20 g of NaOH per dm3.

resulting partly in greater wall thickness then required.Turbogenerators Stator Frame Description To facilitate manufacture. Access to the end winding compartments is possible through manholes in the end shields. BHEL. Additional openings in the housing. The natural frequency of the frame does not correspond to any exciting frequency. the use of hydrogen for the generator cooling requires the frame to be pressureresistant up to an internal pressure of approximately 10 bar (130 psi g). 1 1 3 Stator End shield Frame housing 2 3 2 4 Two lateral supports for flexible core suspension in the frame are located directly adjacent to the points where the frame is supported on the foundation. Due to the rigid design of the supports and foot portion. afford access to the core clamping flanges of the flexible core suspension system and permit the lower portion of the core to be inspected. The welded stator frame consists of the cylindrical frame housing. The connections of the manifolds are located side by side in the lower part of the frame housing. Manifolds are arranged inside the stator frame at the bottom and top for filling the generator with CO 2 and H2 . while the remaining frame parts are fabricated from structural steel.1-2100-0500/1 0709 E . which are sealed gastight by pressure-resistant covers. the stator consists of the following main components: Q Q Q Stator frame End shields Bushing compartment The stator frame with flexible core suspension components. Housing and ribs within the range of the phase connectors of the stator winding are made of nonmagnetic steel to prevent eddy current losses. In the lower part of the frame at the exciter end an opening is provided for bringing out the winding ends. from the point of view of mechanical strength.2 Stator Frame Interior 2. the forces due to weight and short-circuits will not result in any over-stressing of the frame. erection and transport. 4 Bushing compartment Stator foot Fig:1 Stator frame The arrangement and dimensionally of the ribs are determined by the cooling gas passages and the required mechanical strength and stiffness. two flanged rings and axial and radial ribs. The generator terminal box is flanged to this opening. A rigid frame is required due to the forces and torques arising during operation.Haridwar 1 1 2 3 4 2 3 4 Frame housing Clamp Supporting ring Dovetail bar Fig. In addition. Diminishing is also dictated by vibrational considerations. and stator winding is the heaviest component of the entire generator. core.

The bearing saddle supports the spherical bearing sleeve and insulates it from ground to prevent flow of shaft currents. Fig. The seal oil drained towards the hydrogen side is first collected in a gas and oil tight chamber below the bearing compartment for defoaming and then passed via a siphon to the seal oil tank of the hydrogen side seal oil circuit. Inside the bearing compartment the bearing saddle is mounted and insulated from the lower half end shield. The static and dynamic bearing forces are directly transmitted to the foundation via lateral feet attached to the lower half end shield.1-2150-0500/1 0709 E . The oil for the shaft seal is admitted via integrally welded pipes. The end shields are horizontally split to allow for assembly. Cooler wells are provided in the end shield on both sides of the bearing compartment for this purpose. The feet can be detached from the end shield. 2 TE Stator End Shield BHEL.Turbogenerators Description Stator End shields The ends of the stator frame are closed by pressure containing end shields. On the hydrogen side the bearing compartment is closed by the shaft seal and labyrinth rings. This results in a minimum distance between bearings and permits the overall axial length of the TE end shields to be utilized for accommodation of the hydrogen cooler sections.Haridwar EE Stator End Shield 2. The end shields contain the generator bearings. The bearing oil is supplied to the bearing via a pipe permanently installed in the end shield and is then passed on to the lubricating gap via ducts in the lower bearing sleeve. The bearing compartment is seated on the air side with labyrinth rings. The end shields feature a high stiffness and accommodate the generator bearings. shaft seals and hydrogen coolers. The bearing drain oil is collected in the bearing compartment and discharged from the lower half of the end shields via a pipe. since the end shields must be lowered into the foundation opening for rotor insertion.1 Fig. One manhole in both the upper and lower half end shield provided. The seal oil drained towards the air side is drained together with the bearing oil.

1-2170-0500/1 0709E .Haridwar magnetic steel plate.Turbogenerators Generator Terminal Box Description The phase and neutral leads of the three-phase stator windings are brought out of the generator through six bushings located in the generator terminal box at the exciter end of the generator. Six manholes in the terminal box provide access to the bushings during assembly and overhauling. The terminal box is a welded construction of non- 1 1 2 3 2 Flange for terminal box Phase connector Connection to bushing Fig.1 Phase Connector BHEL. Welded ribs are provided for the rigidity of the terminal box. This material reduces stray losses due to eddy currents.2 Terminal Box Interior 2. 3 1 1 2 3 2 3 Generator terminal box Manhole Flange for bushing Fig.

The stator end shields are aligned on the machine sole plates with shims. terminal box.1 Fig.g.2 2 Hydraulic Testing of Stator Frame Sealing of bolted flange joints Sealing the Bolted Flange Joints The bolted flange joints which must be gas tight (e. This test also checks for leakage at the weld seams. Fig.Turbogenerators Description 1 Hydraulic Testing of Stator Frame The empty stator frame with attached end shields and terminal box is subjected to hydraulic test at 10 bar to ensure that it will be capable of withstanding maximum explosion pressures. In addition. To e n s u r e a u n i f o r m transmission of forces these are arranged symmetrically about the anchor bolts. The spherical portions of the levelling screws ensure complete contact and thus a rigid connection between stator and foundation. The stator is therefore fixed in position in a manner allowing for expansion while retaining alignment.. Each O-ring packing is inserted into a groove of rectangular cross-section and compressed by the flanges. 3 Anchoring and Aligning the Stator Frame and End Shields to the Foundation The stator frame is anchored to the foundation with anchor bolts in conjunction with aligning elements and sole plates set in grout on the foundation. The elastic deformation of the O-ring packing provides for a sufficient sealing force. manhole covers) are BHEL. the welded structure is subjected to an air pressure test to check its gas tightness.Haridwar Hydraulic Testing and Anchoring of Stator Frame sealed with elastically deformed O-ring packings. Fixed keys located at the feet in the middle of the stator frame secure the frame axially in a central position.3 Feet at Stator Frame The levelling screws are screwed into the support foot of the frame and permit a rapid and exact a l i g n m e n t o f t h e s t a t o r.1-2190-0500/1 0709 E . Different thermal expansion of the stator and the foundation result in differential movements between the frame and machine sole plates. to allow for measurement of any permanent deformation. 2. end shields. The water pressure is increased in steps with pressure being reduced to atmospheric pressure after each step. Fig.

Foundation skid 9 Shims } Central positioning of stator Turbogenerators Anchoring of Generator On Foundation Description 2.Haridwar 8 End shield foot 7 Hydraulic jack } For erectioin only 10.1 2 3 Stator foot Anchor bolt Sole plate 4 Levelling screw 5 Conical seat 6 Spherical washer Alignign element } BHEL.1-2191-0500/1 0709 E .

divide the core into sections to provide radial passages for cooling gas flow.1 Segment with Spacers The segments are punched in one operation from 0. space segments.1-2200-0500/1 0709 E .2 Stator Core After Compression The pressure is transmitted from the pressure plates to the core by clamping fingers. Each lamination layer is made up from a number of individual segments. The clamping extend up to the ends of the teeth. thus ensuring a firm compression in the area of the teeth. 2.Turbogenerators Description In order to minimize the hysteresis and eddy current losses of the rotating magnetic flux which interacts with the core.Haridwar 1 2 3 4 5 6 Clamping finger Stator Slow Pressure Plate Stator core tooth Clamping bolt Shield Fig. the entire core is built up of thin laminations. Stator Core of non-magnetic steel and are insulated from the core and the pressure plates to prevent the claiming bolts from short-circuiting the laminations and allowing the flow of eddy currents. On the outer circumference the segments are stacked on insulated dovetail bars which hold them in position. In the core end portions. The complete stack is kept under pressure and located in the frame by means of clamping bolts and pressure plates. the pressure plates and core end portions are shielded by gas-cooled rings of insulation-bonded electrical sheet-steel.) thick electrical sheet-street laminations having a high silicon content. One dovetail bar is not insulated to provide for grounding of the laminated core. To remove the heat.02 in. the cooling ducts are wider and spaced more closely to account for the higher losses and to ensure more intensive cooling of the narrow core sections. contributes to a reduction of eddy current losses and local heating in this area. The clamping bolts running through the core made BHEL. The stator frame is turned on end while the core is stacked with lamination segments in individual layers. For protection against the effects of the stray flux in the coil ends.5 mm (0. Stacking guides inserted into the winding slots during stacking provide smooth slot walls. The stepped arrangement of the laminations at the core ends provides for an efficient support of the tooth portion and. The clamping fingers are made of nonmagnetic steel to avoid eddy current losses. To obtain the maximum compression and eliminate undue setling during operation. in addition. the laminations are hydraulically compressed and heated during the stacking procedure when certain heights of stack are reached. The segments are staggered from layer to layer so that a core of high mechanical strength and uniform permeability to magnetic flux is obtained. carefully debarred and then coated with insulating varnish on both sides. placed at intervals along the bore length. 1 2 3 4 5 6 Fig.

Turbogenerators Mounting of Stator Core in Stator Frame Description 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Stator frame Flat spring Cage Flux shied Insulated through bolt Pressure plate Clamping finger Core 3 2 1 BHEL.1-2201-0500/1 0709 E .Haridwar 2.

Each ring set consists of two supporting rings and two core clamping rings. The lower spring prevents a lateral deflection of the core. 1 2 3 4 5 6 1 2 3 BHEL. The clamping ring consists of two pa r t s w h i c h a r e h e l d t o g e t h e r b y t w o c l a m p s. the supporting ring is solidly pressed against the core by the clamping ring. Tightening the clamps reduces the gap between the ring segments so that the supporting ring is linked to the frame by three flat springs.Haridwar Clamp Stator frame Rib 4 5 6 Flat spring Cage Insert sleeve 2. resulting in a revolving and nearly elliptical deformation of the core which sets up a stator vibration at twice the system frequency. To reduce the transmission of these dynamic vibrations to the foundation. In the tangential direction they are however.1-2220-0500/1 0709E . The entire vibration system is tuned so as to avoid resonance with vibrations at system frequency or twice the system frequency. The flat spring are resilient to radial movements of the core suspension points and will largely resist transmission of double frequency vibration to the frame. the generator core is spring mounted in the stator frame. sufficiently rigid to take up the shortcircuit torque of the unit. The structural members to which the insulated dovetail bars are bolted are uniformly positioned around to supporting ring interior to support the core and to take up the torque acting on the core.Turbogenerators Spring Support of Stator Core Description The revolving magnetic field exerts a pull on the core. The core is supported in several sets of rings. For firm coupling of the ring sets to the core. The core is supported in the frame via two vertical springs in the vicinity of the generator feet.

In the straight slot portion the strands are transposed by 5400. the bars are subjected to numerous electrical and leakage tests for quality control. This arrangement and the shape of the bars at the ends result in a cone shaped winding having particularly favourable characteristics both in respect of its electrical BHEL. The alternate arrangement of one hollow strand and two solid strand ensure optimum heat removal capacity and minimum losses. τp=pole pitch Fig.1-2300-0500/1 0709 E .1 Lap type Winding The slot bottom bar and top bars are displaced from each other by one winding pitch and connected at their ends to from coil groups. Prior to applying the bar insulation. Contacts sleeves for electrical connection of the bars and the water boxes with cooling water connections are brazed to the bar ends. Each stator slot accommodates two bars. In the course of manufacture. since each coil consists of only main insulation identical. The coil groups are connected together with phase connectors inside the stator frame shown in the connection diagram. The bars afford maximum operating reliability. The individual layers are insulated from each other by a vertical separator. General.Haridwar At the Roebel crossover points the insulation is reinforced with insulating strip inserts. The strands of small rectangular cross-section are provided with a braided glass insulation and arranged side by side over the slot width. Conductor Construction The bar consists of a large number of separately insulated strands which are transposed to reduce the skin effect losses. The transposition provides for a mutual neutralization of the voltages induced in the individual strands due to the slot cross-field and end winding flux leakage and ensures that minimum circulation currents exist. The current flowing through the conductor is thus uniformly distributed over the entire bar cross-section so that the current-dependent losses will be reduced. 2. The bar ends are bent with a special care to ensure a uniform spacing of the bars over the entire length of the end turns after installation.Turbogenerators Stator Winding Description 1. To ensure that the strands are firmly bonded together are to give dimensional stability in the slot portion. 2. Connection The three-phase stator winding is a fractional-pitch twolayer type consisting of individual bars. properties and resistance to magnetically induced forces. the bars are cured in an electrically heated press.

Haridwar 2.1-2301-0500/1 0709E .Turbogenerators Connection Diagram of Stator Winding Description BHEL.

1-2303-0500/1 0709 E .Turbogenerators Stator Slot Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 BHEL.Haridwar 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Stator core Slot wedge Top strip Top ripple spring Side strip Semiconducting wrapper Vertical separating strip Top bar Center filler Bottom bar Solid strand Hollow strand Insulation Semiconducting side ripple spring Equallising strip 2.

BHEL.Turbogenerators Transposition of Stator Bars Description In slot portion: 540 o transposition of strands In end winding portion: transposition.1-2305-0500/1 0709 E .Haridwar 2. bar ends short circuit At the bar end all strands are brazed into a contact sleeve and thus short-circuited.

The number of layers. by reason of its low viscosity penetrates the insulation thoroughly and eliminates all voids. selected epoxy resins and a matching vacuum pressure impregnation (VPI) process are the characteristic features of the Micalastic insulation for large turbogenerators. i. A consistent development has led to a high-quality insulation system. the thickness of insulation. Following this.Haridwar epoxy resin to give it the mechanical strength required for further processing. is determined by the voltage of the machine. the conductor strands as well as the ventilating ducts are arranged together to form a compact assembly and set to the required shape.e.1-2320-0500/1 0709 E .Method of Insulation and Impregnation For insulation with Micalastic. After 2. The taped bars are then dried under vacuum and impregnated with epoxy resin which. several layers of mica tape are applied continuously.Turbogenerators Micalastic High Voltage Insulation Description High-quality mica. half-overlapped. upto the end portions of the bar.. the reliability of which is ensured by continuous quality control. This assembly is then baked with BHEL. The mica tape consists of a thin high-strength backing material to which the mica is bonded by synthetic resin.

8 1. The dielectric dissipation factor/test voltage curve of a typical stator 2.2 shows a mold loaded with bars ready for impregnation prior to insertion into the impregnating plant.4 Rated Voltage Fig. a semiconductive coating is also added on the slot-end sections to control the electric field and prevent the formation of creepage sparks during highvoltage tests. the insulation of each stator bar is subjected to a high.2 1.0 1. In case of indirectly or direct gas-cooled stator bars.voltage test at 150% of the winding test voltage (U P= 2 ×U N + 1 kV) for quality control. up to 20 stator bars are placed in molds with by insulation for impregnation and curing.Fig. the individual impregnated bars are brought to the required dimensions in processing moulds and cured in an oven at high temperature.4 0. the connections are provided with mica tapes and insulating caps.2 0. the insulation in the slot section is then provided with a coat of conductive varnish.6 0. For end corona protection at voltages above 6 kV. To minimize corona discharges between the insulation and the wall of the slot. 2 Impregnating and Curing Mould for 20 stator Bars in Front of Impregnating Tank tan δ 30 ×10 –3 20 10 5 0. 4 Cumulative frequency of Maximum increase in Dielectric Dissipation Factor of Bars in a 21 KV winding with Micalastic insulation . With indirectly cooled windings. Dependent on their geometrical configuration and dimensions.3 Dielectric Dissipation Factor of a Stator Bar with Micalastic Insulation for 21 KV as a Function of the Voltage Σ in % impegnatioin under vacuum. For assessment of the quality of the slot insulation. For direct cooled windings. Fig. the bars are subjected to pressure. Tests After insulation and curing. the connecting bus bars and phase connectors are a lso p rovided w ith an insulation bonded wi t h a thermosetting synthetic resin. The bars are now ready for insertion into the slots.1-2320-0500/2 Fig. the dielectic dissipatin factor tan δ is measured as a function of the voltage. with nitrogen being used as pressurizing medium (VPI process).

The method of impregnation. Micalastic does not burn. even after 5000 heat cycles. Efficient heat transfer is particularly important in machines that require a thick insulation because of the high voltages. In this manner is is possible to isulate windings for voltages of over 30 kV efficiently and reliably.g. e.. 5). The Properties of Micalastic Micalstic is an extremely dependable winding i n s u l a t i o n s y s t e m d e v e l o p e d f o r h i g h . Fig. and the use of a special impregnating resin enable the maximum increase in dielectric dissipation factor to be reduced considerably below the limits specified in section 33 of VDE 0530. generators driven by gas turbines or peak-load generators in steam power plants. Fire extinguishing 2. 110% U P after installation and blocking of top bars 105% U P after completion of winding. with 1000 cycles between 40 o C and 160 o C. Fig. During insertion of the stator bars. The result.4 shows the fluctuations due to manufacturing of the maximum increase in the dielectric dissipation factor up to rated voltage for the bars of a 21 kV winding. Micalastic has a long electerical life as determined on hunndreds of experimental bars and substantiated on numerous full-size bars (Fig. The composition of the insulation and synthetic resin impregnation permits the machine to be operated continuously under conditions corresponding to those for insulation class F. 100% U P after run of generator. Micalastic owes its insesitivity to high temperature and temperature changes to the cured synthetic resin. The insulation is applied from end to ened on the st ator gbars providing effedtive peotection against over voltages arising during normal operation and against the high stresses that may occur at the slot ends when high test voltages are applied. there is no displacement between the Micalstic insulationand the copper conductor.Turbogenerators Description bar with Micalastic insulation is shown in Fig. especially if these machines are not designed with direct conductor cooling.(Fig. Micalastic is highly resistant to high temperatures and temperature chages. which is exactly matched to the insulation.6 Dielectric Dissipation Factor of 27 kV Micalastic Insulation as a Function of the Temperature Micalastic insulation shows only an insignificant increase in the dielectric dissipation factor with inceasing temperature. Studies on models have provided information on the on the performance of Micalastic insulation under the effect of alternating thermal stresses. The flammability is so low that even on arcing it does not continue to burn once the arc is extinguished. 3. high-voltage tests of one minute duration are performed as follows : 115% U P after installation and blocking of bottom bars Mcalastic is a good conductor of heat by reason of the high mica content and the void free synthetic resin.6) The elasticity of Micalastic enables it to accomodate thermo-mechanical stesses.Haridwar Fig. This favourable performance under thermal stress is particularly advantageous for machines subject to frequent load changes. Heat cycles with large differences in temperature are generated by the alternate application of heating and colling.v o l t age turbogenerators.1-2320-0500/3 0709 E .5 Dielectric Dissipation Factor of 27 kV Micalastic Insulation as a Function of the Temperature BHEL.

lubrication oil and weak acids or alkalies. even after years of operation. Micalastic owes its insesitivity to high temperature and temperature changes to the cured synthetic resin. Micalastic provides protection against moisture due to its impregnation with synthetic resin which seal the winding completely. This favourable performance under thermal stress is particularly advantageous for machines subject to frequent load changes. do not attack the insulation. Corrosive gases. generators driven by gas turbines or peak-load generators in steam power plants.. . to which the windings of air-cooled machines may be exposed under unfavourable conditions. Evidence of its unchanging quality has been provided by repeated test carried out on machines over an operating period of several years. 2. Micalastic is highly resistant to chemical action.g.1-2320-0500/4 Micalastic retains its outstanding properties.systems. such as CO 2 systems. e. the impersonating resin behaves neutrally towards chemicals. vapours. are therefore not necessaryfor machines insulated with Micalastic.

BHEL.1-2321-0500/1 0709E . 1 2 3 4 5 6 7 Component Strand insulation Strand bonding Crossover insulation Profiled strip Internal potential grading wrapper Insulation Outer corona protection Insulant. vacuum impergnated with epoxy resin Semiconductive varnish Note: The number of conductors shown does not necessarily correspond to the number of conductors of the generator .Haridwar 2.Turbogenerators Construction of High Voltage Insulation Description Item No. semiconductive material Braided glass fiber insulation Epoxy resin Micanite Profiled micanite Semiconductive wrapping Mica tape.

the slot sections of the bars are provided will an outer corona protection. This ensures uniform control of the electric field BHEL.1 Typical Buildup of Corona Protection At the transition from the slot to the end winding portion of the stator bars a semi-conductive coating is applied. On top of this.2 Application Protection of Graded End Corona 2. several layers of semi conductive and corona protection coating are applied in varying length. A final wrapping of glass fabric tapes impregnated with epoxy resin serves as surface protection. highly flexible coating of conductive alkyd varnish containing graphite.Haridwar Fig.Turbogenerators Stator Winding Corona Protection Description To prevent potential differences and possible corona discharges between the insulation and the slot wall.1-2330-0500/1 0709 E . 7 Stator bar (slot end) High-voltage insulation Outer corona protection Transition coating End corona protection Glass tape-epoxy protective layer Stator bar (end winding) Fig. This protection consist of a wearresistant. 1 1 2 3 4 5 6 7 2 3 4 5 6 and prevents the formation of corona discharge during operation and during performance of high voltage tests.

The bars fit tightly in the slots. Tight seating is ensured by plastic filters on both sides of the bars which are cured on completion of winding assembly. selfsupporting arches of high rigidity which prevents bar vibrations during operation and can withstand shortcircuit forces. Each end winding thus forms compact. the end turn covering provides good protection against external damage. The specified preloading is checked at each slot wedge.Haridwar 2.2341 Stator End Winding BHEL. ensuring solid support of the cone-shaped top and bottom layers.1-2340-0500/1 0709 E . The design and construction of the end windings are illustrated in a separate drawing [2]. Manufacturing tolerances are compensated with semi-conducting filler strips along the bar sides which ensure good contact between the outer corona protection and the slot wall. With the windings placed in the slots.1. The supporting rings rest on supporting brackets which are capable of moving in the axial direction. Any gaps in the end winding due to the design or manufacturing are filled with curable plastic fillers. The two bar layers are braced with clamping bolts of high-strength fibre glass fabric against a rigid. The strip is cured after insertion of the bars. Stator with Complete Stator Winding 1 1 2 2 End turn covering Clamping bolt Fig. The location of the bars in the slots is illustrated in a separate drawing [1]. These measures prevent vibrations. A small cone taper is 1 1 2 2 Slot wedge End turn covering Fig. the bar ends form a cone-shaped end winding. Radial positioning of the bar is done with slot wedges.1-2303 Stator slot [2]. In addition. An equalizing strip is inserted at the slot bottom to compensate any unevenness in the bar shape and slot bottom surface during bar insertion. fiber glass fabric is arranged between the filler and slide strip which presses the bar against the slot bottom with a specific preloading.2 Covering and Locating the End Winding Also refer to the following information [1].Turbogenerators Coil and End Winding Support System Description The stator windings are placed in rectangular slots which are uniformly distributed around the circumference of the stator core. The bars are protected by a cemented graphitize paper wrapper over the slot portion of the bar. tapered supporting ring of insulating material.1 used to keep the stray losses at a minimum. 2. Below the longitudinally divided slot wedges a top ripple spring of high-strength. This allows for a differential movement between the end winding and the core as a result of different thermal expansions. 2.

1-2341-0500/1 0709 E .Turbogenerators Stator End Winding Description 1 2 3 14 13 12 1 Teflon hose 2 3 4 5 6 7 Water manifold Stator frame Core Clamping Pressure plate for core Insulated through bolt BHEL.Haridwar 11 10 9 8 8 9 10 11 12 13 14 7 6 5 4 Flux Shield Support ring Clamping bolt Bottom bar Top bar Pressure plate for stator bars Water box 2.

The phase connectors are mounted on end winding supporting ring over supporting brackets. 3 Fig. At the beginnings and ends of the phase connectors several layers of semi-conductive and corona protection is applied in varying lengths. the sleeve-shaped lower part enclosing the hollow strands and the cover-type upper part. For the spaces between the individual phases insulating caps. The exciter-end water boxes serve for water admission and distribute the cooling water uniformly to the hollow strands of the bar. are connected to the stator bars. Each water box is provided with a pipe connection of non-magnetic stainless steel for connection of the hose. The strand rows are separated from each other by splicers. The stator bar ends coupled to the phase connectors are provided with connecting fittings which are joined to the cylindrical contact surface with Belleville washers on the bolts to maintain a uniform and constant contact pressure. The tangential air clearance between the water boxes and bar connections within a coil group and the axial clearance relative to the inner shield. and that all strands are passed by identical water flows. Neighbouring phase connectors are separated with spacers and tied securely in position. The hot water is collected on leaving the hollow strands in the turbine-end water BHEL. with solid spencers inserted to compensate for the solid strands. In addition. the strand rows being separated from each other by spaces. After brazing of the upper part of the water box. which is at ground potential. This ensures a high short-circuit strength and differential movements between phase connectors and end windings are thus precluded. Special care is taken to obtain flat and parallel contact surfaces.2 Phase Connector Ends 2. The flow check ensures that no reduction in the cross sectional area of the strand ducts has occurred. Belleville washers are arranged on the clamping bolts which ensure a uniform and constant contact pressure. They consist of thick-walled copper tubes. The cooling water is then discharged from the generator via the hoses and the ring header.e. The contact surfaces of the connecting sleeves for the top and bottom bars are pressed against each other boxes. is so dimensioned that additional insulation is not required. i. Fig.Haridwar Phase Connectors The phase connector interconnect the coil groups and link the beginning and ends of the winding to the bushings. While the solid strands of the stator bars terminate at the connecting sleeve. all brazed joints are subjected to a helium leakage test followed by a thermal shock treatment. The phase connectors are provided with a Micalastic insulation. which enclose both the connecting sleeves and the water boxes. various checks are performed to ensure water tightness and unobstructed water passages. During manufacturing of the stator bars. As a result no electrical forces can act on the water connection. 2 Water Supply The water connection at the stator bar is separate from the electrical connection. In order to prevent an any reduction in contact pressure or any plastic deformations due to excessive contact pressure.1-2350-0500/1 0709 E .1 Electrical Bar Connections and Water Supply by non-magnetic clamping bolts.Turbogenerators Electrical Connection of Bars Water Supply and Phase Connectors Description 1 Electrical Connection of Bars The electrical connection between the top and bottom bars is by a bolted contact surface. a grounded outer corona protection consisting of a semiconducting coating is applied over the entire length. Each water box consist of two parts. At their ends the strands are brazed into a connecting sleeve. the hollow strands are brazed into water boxes.

Turbogenerators Electrical Bar Connection and Water Supply Description 1 2 3 4 5 6 7 9 10 11 12 14 15 1 2 3 4 5 Teflon Hose Crimping sleeve Cap nut Pipe connection Water box 6 7 8 9 10 Clamping bolt Connecting sleeve Clamping plate with through bore Intermediate member Clamping plate with threaded bore * BHEL.1-2351-0500/1 0709 E .Haridwar 11 12 13 14 15 Bottom bar Top bar Belleville washer Spring washer O-ring Contact surface 2.

Haridwar 5 1 2 3 4 5 Phase connector Teflon hose Flexible connector Manhole Terminal bushing Fig. To maintain a uniform and constant contact pressure Belleville washers are used for all bolted connections. It consists of impregnated capacitor paper with conducting fillers for equalization of the electrical direct-axis and quadrature-axis fields. Connection to the beginning and end each phase inside the terminal box and to the external bus in by means of flexible connectors. Covers with brazed sockets for connection to the water supply are flanged to the ends of the terminal BHEL. The customer's bus is connected to the air side connection flange of the bushings via terminal connectors. 1 2 3 4 2 Construction of Bushings The cylindrical bushing conductor consists of highconductivity copper with a central bore for direct primary water cooling.Turbogenerators Terminal Bushings Description 1 Arrangement of Terminal Bushings The beginnings and ends of the three phase windings are brought out from the stator frame through terminal bushings which provide for high-voltage insulation and seal against hydrogen leakage. The shrunk-on mounting sleeve consists of a gastight casting of nonmagnetic steel with a mounting flange and a sleeve-type extension extruding over entire height of the current transformers. The generator terminal box located beneath the stator frame at the exciter end is made from non-magnetic steel to avoid eddy-current losses resulting temperature rises. The insulator is wound directly over the conductor.1 Flexible Connection Between Bushing and Phase Connector 2.1-2370-0500/1 0709 E . Bushing-type generator current transformers. for metering and relaying are mounted on the bushings outside the generator terminal box. The bushings are bolted to the bottom plate of the generator terminal box by the mounting flanges. The cylindrical connection ends of the terminal bushing conductors are silver-plated and designed to accommodate bottle two-part cast terminal connectors.

terminal box Flexible connector PTFE insulating hose Water-cooled bushing Note: If required.Turbogenerators Description PW Connection for Terminal Bushings and Phase Connectors 1 2 Primary water inlet 3 4 5 Conventional Neutral connection 1 2 3 4 5 Phase connector H.1-2371-0500/1 0709 E . Mounting position of phase connectors and neutral connection may be changed as well.V. the H.V.Haridwar 2. BHEL. terminal box may be turned through 180 deg.

Turbogenerators Cooling of Terminal Bushing Description Primary water inlet Primary water outlet BHEL.1-2372-0500/1 0709E .Haridwar 2.

Haridwar Phase connectors and terminal bushing supplied with cooling water through pipes arranged outside the generator at the terminal bushing and generator terminal box and connected to the cooling water inlets and outlet of the cooling circuit through teflon hoses. The parallel-connected cooling circuit are checked for uniform water flows by a flow measurement system covering all three phase. The fittings are made from nonmagnetic stainless steel. The hoses.Turbogenerators Description 1 General The separate water cooling circuits are used for the stator windings and phase connectors and the bushings. 2. Components for Water Cooling of Stator Windings via the terminal bushings on the opposite side. one side of which is connected to ground. grounding is removed by opening the circuit outside the stator frame. This permits the insulation resistance of the water-filled stator winding to be measured. and a m i n i m u m h e a d l o s s . one side of which is connected to ground. For measurement of the insulation resistance. from the exciter and to the turbine end of the generator. The water manifold is mounted on the holding plates of the end winding support ring and connected to the primary water supply pipe. t h e t h e r m a l expansions of the stator bars are completely uniform. during inspections. M o r e o v e r. The cooling primary water flows through the stator bars. a minimum water velocity. consist of a metallic section to which the measuring potential is applied for measurement of the insulation resistance of the water-filled stator winding. The cooling water is admitted to three terminal bushings via a distribution water manifold flows through the attached phase connectors and is then passed to the distribution water manifold for water outlet via the terminal bushings on the opposite side. The flexible expansion joints and the hydraulically series-connected phase connector sections are connected by teflon hoses. e. 3 2 Phase Connector Cooling Circuit Winding Cooling Circuit The end windings are enclosed by an annular water manifold to which all stator bars are connected through hoses. This ensures a minimum temperature rise of the stator bars. The cooling water is admitted to three terminal bushings via a distribution water manifold flows through the attached phase connectors and is then passed to the distribution water manifold for outlet BHEL. which are hydraulically connected in parallel. The parallel-connected cooling circuit are checked for uniform water flows by a flow measurement system covering all three phase. All water connections between ungrounded parts and the distribution manifolds and water manifolds of the cooling circuits are insulated with teflon hoses. The hoses. consists of a metallic section to which the measuring potential is applied for measurement of the insulation resistance of the water-filled stator winding.g.1-2380-0500/1 0709 E . The water manifold is grounded during operation. The water connections are equipped with O-rings of Viton and Belliville washers to prevent loosening of the connection.

Haridwar 5 2.1-2389-0500/1 0709 E .Turbogenerators Grounding of the Stator Cooling Water Manifold Description Primary water outlet Primary water inlet 1 7 6 2 3 8 4 4 1 2 3 4 5 6 7 8 Primary water inlet / outlet Compensator Insulation Stator frame Water manifold Insulated ground connection Water manifold ground connection Stator frame ground connection BHEL.

and the two shaft journals.Turbogenerators Rotor Shaft Description The high mechanical stresses resulting from the centrifugal forces and short-circuit torques call for highquality heat-treated steel. the rotor shaft is forged from a vacuum cast steel ingot. Therefore. The solid poles are also provided with additional longitudinal slots to hold the copper bars of the damper winding. This in turn causes oscillating shaft deflections at twice the system frequency. Comprehensive tests ensure adherence to the specified mechanical and magnetic properties as well as a homogeneous forging. the deflection in the direction of the pole axis and the neutral axis are compensated by transverse slotting of the pole. Integrally forged flange couplings to connect the rotor to the turbine and exciter are located outboard of the bearings. different moments of inertia are obtained in the main axis of the rotor. Due to the non-uniform slot distribution on the circumference.Haridwar 2.1-3000-0500/1 0709E . Slot pitch is selected so 1 1 2 3 Shaft journal Rotor slot Pole Fig. The root shaft consists of an electrically active portion the so-called rotor body. BHEL. Approximately two-thirds of the rotor body circumference is provided with longitudinal slots which hold the field winding. 4 5 6 Transverse slot in pole Retaining ring seat Rotor tooth Rotor Shaft Note:Shaft and slots may vary from actual design. The rotor wedges act as a damper winding in the area of the winding slots.1 2 4 5 6 3 that two solid poles are displaced by 1800. To reduce these vibrations.

Turbogenerators Cooling of Rotor Winding Description Each turn is subdivided into eight parallel cooling zones. The cooling gas for the slot portion is admitted into the hollow conductors through milled openings directly before the end of the rotor body and flows 1 2 3 4 1 End winding 2 Gas inlet (cooling zone: slot portion) 3 Gas inlet (cooling zone: end winding) 4 Rotor tooth Fig. It flows through the conductors approximately up to the pole centre for being directed into a collecting compartment and is then discharged into the air gap via slots. The cooling gas passages are a r r a n g e d a t d i ff e r e n t l e v e l s i n t h e c o n d u c t o r assembly so that each hollow conductor has its own BHEL.1-3100-0500/1 0709 E . 1 2 3 4 5 6 7 1 2 3 4 5 Rotor winding Gas outlet in orator slot wedge Top strip Rotor tooth Rotor slot wedge Damper bar Rotor body Fig.2 6 7 Gas Outlets in Slot Portion At the end winding.Haridwar cooling gas outlet. 2. one hollow conductor passage of each bar is completely closed by a brazed copper filler section. One cooling zone includes the slots from the centre to the end of the rotor body.1 Gas Inlets at End Winding through the hollow conductors to the centre of the rotor body. The cooling gas for the end windings is admitted into the hollow conductors at the ends of the rotor body. The hot gas is then discharged into the air gap between the rotor body and the stator core through radial openings in the conductors and the rotor slot wedges. The enlargement of the conductor cross-section results in both a reduction of losses and increased conductor rigidity. while another covers half the end winding.

Turbogenerators Cooling Scheme of Rotor Winding BHEL.Haridwar Cooling zone: End winding Cooling zone : Slot portion 8 Parallel cooling zones per turn Description 2.1-3101-0500/1 0709E .

these turns are combined to form full turns.2 End Winding Bracing The spaces between the individual coils in the end winding are filled with insulating members which prevent coil movement. Location of Parts in the Rotor Winding 2. The hollow conductors have a trapezoidal crosssection and are provided with two cooling ducts of approximately semi-circular cross-section All conductors have identical copper and cooling duct cross-sections. 1 shows a typical rotor end winding with the fillers inserted. 1 2 3 4 5 1. silver-alloyed copper features high strength properties at higher temperatures so that coil deformations due to thermal stresses are eliminated. 2. The individual coils of the rotor winding are electricity seriesconnected. The slot wedges extend below the shrink seats of the retaining rings. The individual conductors are bent to obtain half turns. The coils are insulated from the rotor body with L-shaped strips of glass fibre laminate with Nomex filler.Haridwar 1 2 3 4 5 Rotor shaft Rotor slot wedge Filler Gas outlet Rotor end winding Fig. The coils are wound around the poles so that one north and one south magnetic pole are obtained. 1. the winding is secured in the slots with wedges. Fig. The rings act as shortcircuit rings to induced currents in the damper windings. the series-connected turns of one slot constituting one coil. and are used as damper winding bar. To obtain the required creepage paths between the coil and the frame. thick top strips of glass fibre laminate are inserted below the slot wedges.1-3300-0500/1 0709 E . 1 Rotor End Winding With Filler 2.1%. The slot wedges are made from a BHEL. copper-nickel-silicon alloy featuring high strength and good electrical conductivity.Turbogenerators Rotor Winding Description 1.1 Construction The field winding consists of several coils inserted into the longitudinal slots of the rotor body.1 Rotor Slot Wedges To protect the winding against the effects of the centrifugal force. After insertion into the rotor slots. Rotor Winding 1.2 Conductor Material The conductors are made of copper with a silver content of approximately 0.3 Insulation The insulation between the individual turns is made of layers of glass fibre laminate. As compared to electrolytic copper. 2.

BHEL.Turbogenerators Rotor Slot Description 7 8 9 1 2 3 4 5 6 1 2 3 4 5 Rotor slot wedge Top strip Hollow conductor Cooling gas duct Winding insulation 6 7 8 9 Slot liner Radial cooling gas outlet Cooling gas bore Rotor shaft Note: The number of conductors shown does not necessarily correspond to the number of conductors of the generator described.Haridwar 2.1-3301-0500/1 0709 E .

Haridwar Note: 1 1 2 3 4 Rotor body Snap ring Retaining rnig Rotor winding 3 4 5 6 7 8 5 End winding insulation Filler End ring Balancing slot 6 The number of conductors shown does not necessarily correspond to number of conductors of the generator described. 2 7 8 Turbogenerators Rotor End Winding Description 2.BHEL.1-3310-0500/1 0709 E .

2. To ensure low contact resistance. while the other end of the ring overhangs the end windings without contacting the shaft.Turbogenerators Rotor Retaining Ring Description The rotor retaining rings contain the centrifugal forces due to the end windings. such as ultrasonic examination and liquid penetrant examination.Haridwar against axial displacement of the retaining ring. the shrink seats of the retaining rings are coated with nickel. The retaining ring shrink-fit areas act as shortcircuit rings to induce currents in the damper system. The shrunk on end ring at the free end of the retaining ring serves to reinforce the retaining ring and secures the end winding in the axial direction at the same time. aluminium and silver by a three-step flame spraying process. Comprehensive tests. ensure adherence to the specified mechanical properties. A snap ring is provided for additional protection BHEL. To reduce the stray losses and retain strength. cold-worked material. the rings are made of non-magnetic.1-3350-0500/1 0709 E . One end of each ring is shrunk on the rotor body. This ensures an unobstructed shaft deflection at the end windings.

The hot gas is discharged into the air gap together with the gas used to cool the end winding. connection between the rotor winding and the exciter and consists of: Q Q Q Field current lead at end winding Radial bolts Field current lead in shaft bore 1. The hollow conductors are inserted into shaft slots and insulated. One end of each field current lead is brazed to the rotor winding and the other end is screwed to a radial bolt.1-3370-0500/1 0709 E . Contact pressure is maintained with a tension bolt and an expanding cone in each radial bolt.Haridwar 2.Turbogenerators Rotor Field Connections Description The field connections provide the electrical. 2. 3. Field Current lead at End Winding The field current lead at the end winding consists of hollow rectangular conductors. That are secured against the effects of centrifugal force by steel wedges. Field Current Lead in Shaft Bore The leads are run in the axial direction from the radial bolt to the exciter coupling. All contact surfaces are silver-plated to attain a low contact resistance. Cooling hydrogen is admitted into the hollow conductors via radial bolts. Contact pressures increase due to centrifugal force during operation. The field current leads are connected to the exciter leads at the coupling with multicontact plug-in contact which allow for unobstructed thermal expansion of the field current leads. The radial bolt is made from forged electrolytic copper. These consist of two semicircular conductors insulated from each other and from the shaft by a tube. Radial Bolts The field current leads located in the shaft bore are connected to the conductors inserted in the shaft slots through radial bolts which are secured in position with slot wedges. BHEL.

Haridwar 7 8 9 10 11 12 Exciter rotor Insulation Insulation Field current lead in exciter rotor shaft Insulation Field current lead in generator rotor shaft 2.Turbogenerators Electrical and Mechanical Connection of EE Coupling Description 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 Generator rotor Coupling bolt Shear bush H 2 seal between half couplings Multicontact plug-in socket strip Multicontact plug-in bolt BHEL.1-3373-0500/1 0709 E .

The moving blades of the fan are inserted into Tshaped grooves in the fan hubs. To augment the cooling of the rotor winding.Turbogenerators Rotor Fan Description conjunction with the gas expelled from the discharge ports along the rotor. The fan hubs are shrink-fitted to the shaft journal spider. t h e p r e s s u r e e s ta b l i s h e d b y t h e f a n w o r k s i n 1 1 2 3 Rotor shaft journal Balancing weight Gas inlet to rotor winding 2 3 4 4 5 6 5 6 Fan Hub Fan blade Rotor retaining ring (Covered) Note: Depending on generator size the rotor fan may be of three or five stages.Haridwar 2. BHEL.1-3600-0500/1 0709E . The generator cooling gas is circulated by one axial-flow fan located on the turbine-end shaft journal.

The return water channel is bolted to the upper tubesheet over a flat gasket. The cooling water flows through the tubes. The lower tubesheet is freely movable and capable of following the differential movement between stator frame and cooler due to the different thermal expansion resulting from the different materials and temperature. the fins being joined to the tubes by tinning. The two side walls of structural steel base the cooler and direct the hydrogen flow. The required cooling water volumetric flow depend on the generator output and is adjusted by a control valves on the heated water side. the return water channel and the inlet/outlet water channel. Gastight sealing of this tubesheet is done by a packing. The ends of the tubes are expanded into the upper and lower tube-sheets.Turbogenerators Hydrogen Cooler Description The hydrogen cooler is shell and tube type heat exchanger which cools the hydrogen gas in the generator. Each cooler consists of the tube bundle. While the attachment to the lower tubesheet permits them to move freely to allow for expansion of the tube bundle. This cooling water flow passage is obtained through a partition in the inlet/outlet water channel.1-4000-0500/1 0709 E . This arrangement permits the coolers to be mounted without an increase in the overall generator axial length or cross-sectional area of the stator frame. even when the generator is in operation and filled with hydrogen. Attached to the lower tubesheet is the inlet/outlet BHEL. after reversal in the return water channel. The cooler are parallel-connected on their water sides shut off valves are installed in the lines before and after each cooler. The cooler consists of individual sections for vertical mounting. the upper and lower tube-sheets. the heated water flows downwards on the hot gas side. The heat removed from the hydrogen is dissipated through the cooling water. The seal cap has opening for bringing out the cooling water pipes. thus preventing uncooled hydrogen from flowing past the cooler.1 Hydrogen Cooler Removed 2. The cold cooling water flows from the bottom to the top of the cooler on the cold gas side and. A seal cap is bolted over the inlet/outlet water channel. The upper tubesheet is larger than the cooler well opening and is used to fix the cooler.Haridwar water channel with its cooling water inlet and outlet pipes. While the hydrogen is passed around the finned tubes. Controlling the cooling water flow on the outlet side ensures an uninterrupted water flow through the coolers. They are solidly bolted to the upper tube-sheet. This arrangement permits the return water channel to be detached for cleaning. Gastight sealing is done by a gland type seal which i s s i m u l ta n e o u s l y p r e s s e d a g a i n s t t h e o u t e r circumference of the tubesheet and against the sealing face of the seal cap by a compression ring. with proper cooler performance not being impaired Fig. The tubes have copper fins to obtain a larger heat transfer surface. The hydrogen flows through the coolers in a horizontal direction. Flexible seal strips bolted to the side walls seal the gap between the cooler and the cooler well in the cooler assembly.

Haridwar 4 5 6 Cooling water connection Protective chamber Hydrogen seal 2.1-4001-0500/1 0709 E .Turbogenerators Hydrogen Cooler Description 1 2 3 6 4 5 1 2 3 Return water channel End shield Finned tube bundle BHEL.

All generator bearings are provided with a hydraulic shaft lift oil system to reduce bearing friction during startup. The rotor shaft is supported in sleeve bearings having forced-oil lubrication.Turbogenerators Generator Bearings Description The tangential locator is supported on the bearing saddleover a piece of insulating material. The bearings are located in the stator end shields. The bearing saddle is insulated from the stator end shield and the bearing brackets are insulated from the bearing sleeve to prevent the flow of shaft currents and to provide for double insulation of the generator bearing from ground. The lower bearing sleeve has a groove to admit the bearing oil to the bearing surface. The locator is adjusted to maintain the required clearance between the bearing sleeve and the insulation of the radial locator. lifting the rotor shaft to allow the formation of a lubricating oil film. The upper sleeve has a wide overflow groove through which the oil is distributed over the shaft journal and fed to the lubricating gap. Haridwar 2. A radial locator serves to locate the bearing in the vertical direction and is bolted to the upper half of the stator end shield. The oil is drained laterally from the lubricating gap. A tangential locator is located at the bearing sleeve joint to prevent the bearing from turning in the saddle. caught by baffles and returned to the turbine oil tank. 1 2 1 2 3 Stator End shield Shaft Seal Lower Bearing sleeve 3 4 4 5 6 7 5 6 7 Pressurised oil inlet for Hydraulic shaft lift oil system OIl Baffle Bearing oil inlet Outer labyrinth ring Fig. High pressure oil is forced between the bearing surface and the shaft journal. The lower bearing sleeve rests on the bearing saddle via three brackets with spherical support seat for self-alignment of the bearing.1 Generator Bearing BHEL. The bearing temperature is monitored with one double element thermocouple located approximately in the plane of maximum oil film pressure. The inner surface of the cast bearing sleeve body is provided with spiral dovetail grooves which firmly hold the babbitt liner to the bearing sleeve body.1-5000-0500/1 0709 E . The thermocouples are screwed in position on both sides of the lower bearing sleeve from outside with the detectors extending to the babbitt liner. The oil required for bearing lubrication and cooling is obtained from the turbine oil supply system and supplied to the lubricating gap via pipes permanently installed inside the lower half of the stator end shield and via grooves in the bearing saddle and lower bearing sleeve.

lower half Bearing oil drain Bearing insulation Bearing saddle Connections for jacking oil Rotor shaft Bearing oil wiper Outer labyrinth ring Bearing sleeve Tangential locator Radial locator Bearing cover End shield Upper half Shaft seal BHEL.Turbogenerators Description Generator Bearing (Insulation) 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 End shield.1-5001-0500/1 0709 E . Haridwar 2.

Haridwar 2.1-5003-0500/1 0709 E .Turbogenerators Measuring of Bearing Temperature Description Direction of Shaft rotation 4 1 2 3 4 End Shield Thermocouple lead Thermocouple Bearing Sleeve 1 2 3 4 BHEL.

1-5005-0500/1 0709 E .Turbogenerators Generator Bearing Insulation Description 5 6 6 8 4 7 2 3 1 Insulation 1 2 3 4 5 6 7 BHEL. Haridwar End shield or Bearing bracket Half Bearing ring Bearing sleeve Bearing oil wiper Bearing oil drain Bearing oil inlet Tangential locator 2.

A pressure equalizing valve maintains the oil pressure on the hydrogen side slightly below that on the air side. which is important during the starting and shutdown period. The clearance between shaft and seal ring is such that friction losses are minimized and an oil film of s u ff i c i e n t t h i c k n e s s i s m a i n t a i n e d w i t h o u t unnecessarily large oil flow. To accomplish this.4 bar above the generator hydrogen gas pressure at the shaft seal by means of a differential pressure valve ("A" valve) On the hydrogen side.1 Seal ring housing Seal ring Hydrogen side seal oil Air side seal oil Ring relief oil Interchange of Oil in Annular Groove of Shaft Seal The double-flow shaft seal is characterized by its short axial length. W i t h t h i s t y p e o f s h a ft s e a l . The oil is supplied to the shaft seal at three different pressures (air side seal oil pressures. The seal ring need to allow axial displacement of the generator shaft. respectively. In this way the oil and gas pressure acting on the seal ring are balanced. The seal ring is thus free to adjust its radial position. The seal ring will adjust its position according to the shaft position as dictated by the oil film thickness and the vibratory condition. higher pressure air side oil is supplied to the shaft seal for thrust load compensation of the seal ring. bolted to the end shield. The seal ring is BHEL. The air side and hydrogen side seal oil is admitted into the air side and hydrogen side annular grooves. the air side and the hydrogen side seal oil circuit. and low hydrogen losses due to absorption by the seal oil.Turbogenerators Shaft Seal Description Air side Hydrogen side The rotor shaft ends are brought out of the gastight enclosure through double-flow shaft seals. i. Haridwar relatively free to move in the radial direction. which is primarily caused by turbine expansion. 1 2 1 2 Fig. The seal ring housing. In addition. The air side seal oil pump delivers the oil at a pressure maintained at >1. is fed to the seal ring at a pressure slightly higher than the hydrogen pressure. thus keeping the interchange of oil between the air and hydrogen sides to a very small value. seal oil from two separate circuits. A continuous film of oil is maintained between the shaft and the seal ring. its independence from the respective axial and radial position of the shaft. but is restrained from rotating by use of a pin. The babbit lining of the seal ring ensure high reliability even in the event of boundary friction.e. of the seal ring via passage in the seal ring housing and seal ring. Air side seal oil for ring relief is fed to the annular groove in the air side seal ring carrier and forced between the seal ring and the seal ring housing. hydrogen side seal oil pressures and higher pressure oil for ring relief) over pipes and the mounting flange of the seal ring housing. This permits the shaft to slide through the seal ring without impairing the sealing effect.1-6000-0500/1 0709 E . is insulated to prevent the flow of shaft currents. Temperature rise of the seal oil is therefore small which contributes to reliable sealing. 2. The two halves of the babbited seal ring float on the shaft journal with a small clearance and are guided in the axial direction by a seal ring housing resistant to distortion and bending. and the friction between the seal and seal ring housing is reduced. the hydrogen-saturated seal oil is circulated in a closed circuit. t h e e s c a p e o f hydrogen between the rotating shaft and the housing is prevented by maintaining a continuous film of oil between the shaft and a non-rotating floating seal ring.

Haridwar 2.Turbogenerators Shaft Seal General H2 side Air side 1 2 3 4 7 8 5 9 6 10 Section G-H Section C-D 11 19 9 12 13 14 15 16 17 18 20 Section E-F Section A-B 1 2 3 4 5 6 7 End shield Packing Insulation Seal ring chamber Seal oil inlet bore Pressure oil groove Seal oil groove 8 9 10 11 12 13 14 Inner labyrinth ring Seal strip Rotor shaft Oil wiper ring (H2 side) Seal ring carrier Seal oil groove (H2 side) Seal oil groove (H2 side) 15 16 17 18 19 20 Seal oil groove (Air side) Babbit Seal ring Oil wiper ring (Air side) Seal oil inlet bore (air side) Pin Air Hydrogen Air side seal oil H2 side seal oil Pressure oil for seal ring relief BHEL.1-6001-0500/1 0709 E .

The seal oil supplied to the shaft seals which drains towards the air side through the annular gaps between the shaft and seal rings is returned to the seal oil storage tank. By separating the two seal oil circuits. For the air side seal oil circuit. Haridwar 2. becomes saturated with air. the seal oil supply is taken over by the stand-by pump without any interruption. The shaft seal is supplied with seal oil by a separate system consisting of a hydrogen side seal oil circuit and an air side seal oil circuit. the second pump automatically takes over. the air side seal oil pump (AC) draws the seal oil from the seal oil storage tank and feeds it to the shaft seals via coolers and filters. If both pumps fail. the hydrogen losses at the seals are kept to a minimum. Vacuum treatment of the seal oil and the resulting continuous hydrogen losses are thus avoided. By dividing the seal oil system into two separate circuits. As long as the seal oil pressure in the annular gap exceeds the gas pressure in the generator. 2 Hydrogen Side Seal Oil Circuit During normal operation. the hydrogen side pump draws the seal oil from the seal oil storage tank and feeds it to the shaft seal via coolers and filters. The seal oil supplied to the shaft seals which drains towards the hydrogen side through the annular gaps between the shaft and the seal rings is first collected in the generator pre-chambers and then returned to the seal oil tank. it is saturated with hydrogen and contains no air.Turbogenerators Seal Oil System Description Shaft seals supplied with pressurized seal oil are provided to prevent hydrogen losses at the shaft and the ingress of air into the hydrogen-cooled generator. In the event of a failure of the pump in service due to a mechanical or electrical failure. three seal oil pumps are provided with one of the three pumps always in operation. no hydrogen will escape from the generator housing. entry of air to the hydrogen compartment is kept to a minimum 1 Seal ring Air side seal oil circuit 2 3 4 5 6 Seal oil storage tank Seal oil pump DPR-A valve Oil cooler Seal oil filter Hydrogen side seal oil circuit 7 8 9 10 11 12 13 Generator prechamber Pressure equalising valve Seal oil tank Seal oil filter DPR-C Valve Oil cooler Seal oil pump Air side seal oil Hydrogen side seal oil Pressure oil for Seal oil ring relief Hydrogen Fig-1: Seal oil diagram (Simplified) BHEL.1-7100-0500/1 0709 E . Since the hydrogen side seal oil comes into contact with only the hydrogen gas. which is only in contact with air. The oil in the seal oil system is the same as that used in the turbine-generator journal shown. The air side seal oil. Details of the shaft seal are given in a separate description in this manual. 1 Air Side Seal Oil Circuit During normal operation.

The constant differential pressure between the air side and the hydrogen side oil is controlled by separate pressure equalizing control valves for each shaft seal. A float valve in seal oil tank returns the excess oil to the seal oil storage tank. Accordingly. the oil flows are combined and returned into the seal oil tank. The valve opens further with a downward movement of the valve stem (occurs at rising air side seal oil pressure). with the only difference being that the air side seal oil pressures are used as impulse. One seal oil pump is used for oil circulation in the hydrogen side oil circuit. This oil flow throttling results in a rise of the air side seal oil pressure at the shaft seals. The valve cone is arranged so that the valve closes further for a downward movement of the valve stem (occurs at rising gas pressure or falling seal oil pressure). Setting of the desired differential pressure (set valve) to be maintained by the valve is done by a corresponding pre-loading of the main bellows. Down-stream of the pre-chambers. The seal oil storage tank is connected to the bearing vapour-exhausters which also vent the generator prechambers. a very small quantity of oil flows from the air side to the hydrogen side in the annular gap resulting in a gradual increase in the amount of oil in the hydrogen side oil circuit. Depending on the valve setting and the impulse oil pressure prevailing (seal oil pressure and hydrogen casing pressure). The function of the "A" valves is illustrated in the attached diagram. If an excessive amount of oil is supplied to the seal oil tank. a float valve allows some oil to return to the seal oil storage tank. in contact in the annular gaps between the shaft seal. The pressure after the stand-by seal oil pump is separately controlled by the second "A" valve. 4 Seal Oil Drains The oil drains from the air side of the shaft seals discharges to the generator bearing space and is returned to the turbine oil tank via the seal oil storage tank together with the bearing oil. the upper end of which is rigidly connected to the valve yoke. In case of prolonged operation. the valve stem is moved upwards or downwards when these pressures are unbalanced. 5 Seal Ring Relief To ensure free movement of the seal ring. In the event of a failure of this pump. The small amount of hydrogen escaping from the generator together with the oil does not present a danger to the generator surrounding since the oil drained on the hydrogen side is returned to the turbine oil tank only via the seal oil storage tank where the majority of the entrapped hydrogen is removed. . The interchange of oil between the two circuit is so small that the aforementioned advantages of two separate circuit are not impaired. the valve stem is moved upwards or downwards when these pressure become unbalanced. a s l o w deterioration of the hydrogen purity in the generator will take place. since the oil flowing towards the hydrogen side will introduce air. The oil drained from the hydrogen side of the shaft seals is discharged into the generator pre-chambers. Setting of the desired differential pressure to be maintained by the valve is done by a corresponding pre-loading of the control piston. Oil pressures which exceed the generator gas pressure are required to ensure proper sealing of the generator. The first "A" valve controls the seal oil pressure after two equal-priority ac air side seal oil pumps.1-7100-0500/2 0709 E linked to the valve stem by means of an adjusting nut. a larger or smaller amount of oil is returned to the suction pipe so that the required seal oil pressures is established at the shaft seals. however. The function of the pressure equalizing control valve is illustrated in the attached diagram.thereby maintaining good hydrogen purity. it may eventually become necessary to improve the hydrogen purity by gas scavenging. 3 Seal Oil Pressure Regulation The air side and the hydrogen side seal oil circuits are. Due to the fact that the air side and hydrogen side seal oil pressures act in opposite directions. the seal oil to the hydrogen side annular derived from the air side oil supply circuit. resulting in a raise of the hydrogen side seal oil pressure. the shaft seals are provide with pressure oil for ring relief. Since the gas pressure and the impulse oil pressure act in opposite directions. the seal oil pressure is controlled by differential pressure valves "A" ("A" valve). The pre-loading is adjusted with a compression spring. The seal oil pressures at the shaft seal are set so that the air side seal oil pressure is slightly higher than the hydrogen side seal oil pressure. W h e n o p e r a t i n g i s t h i s m a n n e r. With the seal oil pumps in operation. As may be seen on the attached diagram. The required pressure setting for each shaft seal is accomplished separately. Float valves keep the oil level in the tank at a predetermined level. which will come out of the oil in the hydrogen atmosphere due to the change in pressures. The oil supply for ring relief is obtained from the air side oil circuit. while its lower end is 2. differential pressure valve "C" ("C" valve) serves to control the seal oil pressure in the hydrogen side seal oil circuit and operates on the same principle. The pre-chambers reduce the oil flow which permits the escape of entrapped gas bubbles and de-foaming of the oil.

Haridwar 2.Turbogenerators Differential Pressure Valve A Description ** 4 5 1 Hydrogen 2 Seal oil ** 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 * ** Connection for gas signal pipe Connection for oil signal pipe Oil inlet Valve head Main Bellow Upper sealing bellows Valve stem Compression spring Adjusting nut Lock nut Yoke Lower sealing bellows Valve Housing Valve cone Oil inlet Vent connection Screw plug 8 9 10 11 12 13 14 3 15 BHEL.1-7101-0500/1 0709 E .

Turbogenerators Differential Pressure Valve C Description * 4 5 1 2 * 6 7 8 1 9 10 2 11 12 13 3 14 15 BHEL. Haridwar 3 4 5 6 7 8 9 10 11 12 13 14 15 Connection for air side seal oil signal Connection for hydrogen side seal oil signal Hydrogen side seal oil inlet Valve head Main Bellow Upper sealing bellows Valve stem Compression spring Adjusting nut Lock nut Yoke Lower sealing bellows Valve Housing Valve cone Hydrogen side seal oil inlet * ** Vent connection Screw plug 2.1-7103-0500/1 0709 E .

Turbogenerators

Pressure Equalizing Control Valve

Description

2
3

1

4
5
6

17

16
15

14
13

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Connection for air side signal pressure
Cap
Lock nut
Threaded spindle
Compression spring
Piston housing
Oil outlet
Compression spring
Threaded spindle
Lock nut
Cap
Valve cone
Oil inlet
Valve housing
Connection for Hydrogen side signal pressure
Valve cone stem
Control piston

7
12

8

9

10

11

BHEL, Haridwar

2.1-7104-0500/1
0709 E

Turbogenerators

List of Valves for Seal oil System

Description
SL
VALVE
NO. DESIG

TYPE OF VALVE

1

MAV 72
AA513

NEEDLE VALVE

15
2.5

CS
SC

SHUT OFF VALVE IN U LOOP DRAIN

PIPE LINE

2

MKW01
AA503

GATE VALVE

80
2.5

CS
FL

SHUT OFF TO SEAL OIL PUMPS

PIPE LINE

3

MKW01
AA504

NEEDLE VALVE

15
2.5

CS
SC

SHUT OFF VALVE FOR SOST DRAIN

PIPE LINE

4

MKW03
AA001

FLOAT VALVE

50
1.6

CS
FL

FLOAT VALVE FOR SOST DRAIN

SEAL OIL UNIT

5

MKW03
AA002

FLOAT VALVE

50
1.6

CS
FL

FLOAT VALVE FOR SOT SUPPLY FROM
AIR SIDE CIRCUIT

SEAL OIL UNIT

6

MKW03
AA 501

GATE VALVE

50
4.0

CS
FL

SHUT OFF VALVE IN DRAIN LINE OF
S O T CIRCUIT

SEAL OIL UNIT

7

MKW03
AA502

GATE VALVE

50
4.0

CS
FL

SHUT OFF VALVE FOR SEAL OIL SUP
PLY TO SOT

SEAL OIL UNIT

8

MKW03
AA503

NEEDLE VALVE

15
2.5

CS
SC

DRAIN VALVE FOR H2 SIDE SEAL OI
L DRAIN LOOP

PIPE LINE

9

MKW03
AA504

GLOBE VALVE

50
4.0

CS
FL

SHUT OFF VALVE IN DRAIN BYPASS A
T SOT

SEAL OIL UNIT

10

MKW03
AA505

GLOBE VALVE

20
2.5

CS
FL

SHUTOFF VALVE FOR OIL LEVEL IND
ICATOR FOR S O TANK

SEAL OIL UNIT

11

MKW03
AA506

GLOBE VALVE

20
2.5

CS
FL

SHUT OFF VALVE FRO OIL LEVEL IND
ICATOR ,BOTTOM

SEAL OIL UNIT

12

MKW11
AA001

RELIEF VALVE

20
2.5

CS
FL

RELIEF VLV FOR AC SOP-1(AIR SIDE
)

SOP UNIT

13

MKW11
AA002

DPR VALVE

25
1.6

CS
FL

FOR MAINTAINING CONSTANT PRESS D
IFFERENCE

SEAL OIL UNIT

14

MKW11
AA507

GLOBE VALVE

8
2.5

CS
BW

SEAL OIL IMPULSE OF DPRV

SEAL OIL UNIT

15

MKW11
AA003

CHECK VALVE

50
4.0

CS
FL

CHECK VALVE AFTER AC SOP-1 AIR S
IDE

SEAL OIL UNIT

16

MKW11
AA508

GATE VALVE

50
4.0

CS
FL

SHUT OFF VALVE IN BYEPASS LINE

SEAL OIL UNIT

17

MKW11
AA501

GATE VALVE

80
4.0

CS
FL

INLET TO SOP-1 AIR SIDE

SEAL OIL UNIT

18

MKW11
AA505

GATE VALVE

50
4.0

CS
FL

SHUT OFF VALVE AFTER DPRV

SEAL OIL UNIT

19

MKW11
AA506

GLOBE VALVE

10
2.5

CS
BW

SHUT OFF VALVE IN OIL IMPULSE LI
NE OF DPRV

SEAL OIL UNIT

20

MKW11
AA004

SHUT OFF VALVE

50
2.5

CS
FL

NR SHUT OFF VALVE AFTER AIR SID
E SOP-1&2

SEAL OIL UNIT

21

MKW11
AA504

GATE VALVE

50
4.0

CS
FL

SHUT OFF VALVE BEFORE DPRV

SEAL OIL UNIT

22

MKW13
AA001

RELIEF VALVE

20
2.5

CS
FL

BLOW OFF OF OIL FOR SOP(H2 SIDE)

SEAL OIL UNIT

23

MKW13
AA002

DPR VALVE

25
1.6

CS
FL

FOR MAINTAINING CP DIFFERENCE

SEAL OIL UNIT

BHEL, Haridwar

NB mm
NP MPA

BODY mat
END conn

FUNCTION

LOCATIOIN

2.1-7112-10553/1
0709 E

SL
VALVE
NO. DESIG

TYPE OF VALVE

24

MKW13
AA003

CHECK VALVE

50
4.0

CS
FL

CHECK VALVE AFTER H2 SIDE SOP

SEAL OIL UNIT

25

MKW13
AA501

GATE VALVE

50
4.0

CS
FL

SHUT OFF VALVE BEFORE H2 SIDE SE
ALOIL PUMP

SEAL OIL UNIT

26

MKW13
AA503

GATE VALVE

50
4.0

CS
FL

SHUT OFF VALVE FOR SEAL OIL BEF
ORE H2 SIDE COOLERS

SEAL OIL UNIT

27

MKW13
AA505

GLOBE VALVE

50
4.0

CS
FL

SHUT OFF VALVE IN AIR SIDE IMPUL
SE LINE

SEAL OIL UNIT

28

MKW13
AA511

GLOBE VALVE

50
4.0

CS
FL

SHUT OFF VALVE IN H2 SIDE SEAL O
IL DRAIN LINE

SEAL OIL UNIT

29

MKW13
AA507

GLOBE VALVE

10
2.5

CS
BW

EQUALISING VALVE IN BYE PASS OF
IMPULSE LINE

SEAL OIL UNIT

30

MKW13
AA508

NEEDLE VALVE

8
2.5

CS
BW

SEAL OIL VENT VALVE AT DPRV AIR
SIDE

SEAL OIL UNIT

31

MKW13
AA509

GLOBE VALVE

8
2.5

CS
BW

SEAL OIL VENT VLV AT DPRV H2 SID
E

SEAL OIL UNIT

32

MKW13
AA510

GATE VALVE

25
4.0

CS
FL

SHUT OFF VLV IN H2 SIDE DPRV BY
PASS LINE TO SOT

SEAL OIL UNIT

33

MKW13
AA506

GLOBE VALVE

10
2.5

CS
BW

SHUT OFF VALVE IN H2 SIDE IMPUL
SELINE

SEAL OIL UNIT

34

MKW21
AA001

RELIEF VALVE

20
0.0

CS
FL

RELIEF VLV FOR AC SOP-2 (AIR SIDE
)

SOP UNIT

35

MKW21
AA002

CHECK VALVE

50
4.0

CS
FL

CHECK VLV AFTER AIR SIDE SOP-2

36

MKW21
AA501

GATE VALVE

80
4.0

CS
FL

INLET TO SOP-2(AIR SIDE)

37

MKW21
AA503

GATE VALVE

50
4.0

CS
FL

AIR SIDE & H2 SIDE OIL INTERCONN

SEAL OIL UNIT

38

MKW23
AA503

GLOBE VALVE

8
25.0

CS
SC

H2 IMPULSE TO DPRV

SEAL OIL UNIT

39

MKW23
AA504

GLOBE VALVE

8
25.0

CS
SC

H2 IMPULSE TO DPRV

SEAL OIL UNIT

40

MKW31
AA001

RELIEF VALVE

20
2.5

CS
FL

RELIEF VLV FOR SOP-3 (AIR SIDE)

41

MKW31
AA506

GLOBE VALVE

10
2.5

CS
BW

SHUT OFF VLV IN OIL IMPULSE LINE
OFDPRV

SEAL OIL UNIT

42

MKW31
AA002

DPR VALVE

25
1.6

CS
FL

FOR MAINTAINING CP DIFFERENCE

SEAL OIL UNIT

43

MKW31
AA507

GLOBE VALVE

8
2.5

CS
BW

SEAL OIL IMPULSE VENT OF DPRV

SEAL OIL UNIT

44

MKW31
AA004

NR SHUT OFF VALVE

50
2.5

CS
FL

NON RETURN SHUT OFF VLV AFTER AI
R SIDE SEAL OIL PUMP

SEAL OIL UNIT

45

MKW31
AA504

GATE VALVE

50
4.0

CS
FL

SHUT OFF VLV BEFORE DPRV

SEAL OIL UNIT

46

MKW31
AA505

GATE VALVE

50
4.0

CS
FL

SHUT OFF VLV AFTER DPRV

SEAL OIL UNIT

47

MKW31
AA003

CHECK VALVE

50
4.0

CS
FL

CHECK VLV AFTER SOP-3(AIR SIDE)

SEAL OIL UNIT

48

MKW31
AA501

GATE VALVE

80
4.0

CS
FL

INLET TO SOP-3(AIR SIDE)

SEAL OIL UNIT

2.1-7112-10553/2
0709 E

NB mm
NP MPA

BODY mat
END conn

FUNCTION

LOCATIOIN

SEAL OIL UNIT
SOP UNIT

SOP UNIT

Turbogenerators

List of Valves for Seal oil System

Description
SL
VALVE
NO. DESIG

TYPE OF VALVE

49

MKW51
AA501

DOUBLE CHG OVER
VLV

50
1.6

CS
FL

3-WAY CHANGE OVER VLV AT SEAL OI
L COOLER (AIR SIDE)

SEAL OIL UNIT

50

MKW51
AA502

DOUBLE CHG OVER
VLV

50
1.6

CS
FL

3-WAY CHANGE OVER VLV AT SEAL OI
L COOLER (AIR SIDE)

SEAL OIL UNIT

51

MKW51
AA503

GLOBE VALVE

8
2.5

CS
BW

FILLER VLV FOR AIR SIDE S.O.COOL
ER

SEAL OIL UNIT

52

MKW51
AA504

GLOBE VALVE

8
2.5

CS
BW

S.O.DRAIN VLV AT AIR SIDE COOLER
-2

SEAL OIL UNIT

53

MKW51
AA505

GLOBE VALVE

8
2.5

CS
BW

S.O.DRAIN VLV AT AIR SIDE COOLER
-1

SEAL OIL UNIT

54

MKW51
AA506

GLOBE VALVE

8
2.5

CS
BW

COOLING WATER DRAIN VLV AT COOLE
R-2 AIR SIDE

SEAL OIL UNIT

55

MKW51
AA512

DOUBLE CHG OVER
VLV

50
1.6

CS
FL

CHANGE OVER VALVE FOR SEAL
OIL FILTER-1 (AIR SIDE)

SEAL OIL UNIT
WITH FILTER

56

MKW51
AA513

DOUBLE CHG OVER
VLV

50
1.6

CS
FL

CHANGE OVER VALVE FOR SEAL
OIL FILTER-2 (AIR SIDE)

SEAL OIL UNIT
WITH FILTER

57

MKW51
AA508

GLOBE VALVE

8
2.5

CS
BW

COOLING WATER VENT VLV AT COOLE
R-2 (AIR SIDE)

SEAL OIL UNIT

58

MKW51
AA510

GLOBE VALVE

8
2.5

CS
BW

SEAL OIL VENT VLV INLET AT COOL
ER-2 (AIR SIDE)

SEAL OIL UNIT

59

MKW51
AA511

GLOBE VALVE

8
2.5

CS
BW

SEAL OIL VENT VLV FROM COOLER-1
(AIR SIDE)

SEAL OIL UNIT

60

MKW51
AA507

GLOBE VALVE

8
2.5

CS
BW

COOLING WATER DRAIN VLV AT COOLE
R-1 (AIR SIDE)

SEAL OIL UNIT

61

MKW51
AA509

GLOBE VALVE

8
2.5

CS
BW

COOLING WATER VENT VLV AT COOLE
R-1 (AIR SIDE)

SEAL OIL UNIT

62

MKW53
AA501

DOUBLE CHG OVER
VLV

50
1.6

CS
FL

CHANGE OVER VALVE AT SEAL OIL CO
OLER (H2 SIDE)

SEAL OIL UNIT

63

MKW53
AA502

DOUBLE CHG OVER
VLV

50
1.6

CS
FL

CHANGE OVER VALVE AT SEAL OIL CO
OLER (H2 SIDE)

SEAL OIL UNIT

64

MKW53
AA503

GLOBE VALVE

8
2.5

CS
BW

FILLER VLV FOR H2 SIDE S.O.COOLE
R

SEAL OIL UNIT

65

MKW53
AA504

GLOBE VALVE

8
2.5

CS
BW

SEAL OIL DRAIN VALVE AT H2 SIDE
COOLER-2

SEAL OIL UNIT

66

MKW53
AA505

GLOBE VALVE

8
2.5

CS
BW

SEAL OIL DRAIN VALVE AT H2 SIDE
COOLER-1

SEAL OIL UNIT

67

MKW53
AA506

NEEDLE VALVE

8
2.5

CS
BW

COOLING WATER DRAIN VLV AT COOLE
R-2 (H2 SIDE)

SEAL OIL UNIT

68

MKW53
AA513

DOUBLE CHG OVER
VLV

50
1.6

CS
FL

CHANGE OVER VLV FOR SEAL OIL FI
LTER-2 (H2 SIDE)

SEAL OIL UNIT
WITH FILTER

69

MKW53
AA507

GLOBE VALVE

8
2.5

CS
BW

COOLING WATER DRAIN VLV AT COOLE
R-1(H2 SIDE)

SEAL OIL UNIT

70

MKW53
AA509

GLOBE VALVE

8
2.5

CS
BW

COOLING WATER VENT VLV AT COOLER
-1(H2 SIDE)

SEAL OIL UNIT

71

MKW53
AA510

GLOBE VALVE

8
2.5

CS
BW

SEAL OIL VENT VALVE AT COOLER-2
(H2SIDE)

SEAL OIL UNIT

BHEL, Haridwar

NB mm
NP MPA

BODY mat
END conn

FUNCTION

LOCATIOIN

2.1-7112-10553/3
0709 E

SL
VALVE
NO. DESIG

TYPE OF VALVE

72

MKW53
AA511

GLOBE VALVE

8
2.5

CS
BW

SEAL OIL VENT VALVE AT COOLER-1
(H2SIDE)

SEAL OIL UNIT

73

MKW53
AA512

DOUBLE CHG OVER
VLV

50
1.6

CS
FL

CHANGE OVER VLV AT SEAL OIL FIL
ETR-1(H2 SIDE)

SEAL OIL UNIT

74

MKW53
AA508

GLOBE VALVE

8
2.5

CS
BW

COOLING WATER VENT VLV AT COOLE
R-2(AIR SIDE)

SEAL OIL UNIT

75

MKW71
AA511

3-WAY VALVE

50
1.6

CS
FL

3-WAY VLV TE(AIR SIDE)

SOV RACK

76

MKW71
AA512

GATE VALVE

50
4.0

CS
FL

SHUT OFF VLV FOR SEAL OIL,TE (AI
R SIDE)

SOV RACK

77

MKW71
AA513

GLOBE VALVE

10
2.5

CS
BW

SHUT OFF VLV IN SEAL OIL IMPULSE
LINE,TE (AIR SIDE)

SOV RACK

78

MKW71
AA514

GLOBE VALVE

8
2.5

CS
BW

VENT FOR EQUALISING VLV TE (AIR
SIDE)

SOV RACK

79

MKW71
AA521

3-WAY VALVE

50
1.6

CS
FL

3-WAY VLV,EE (AIR SIDE)

SOV RACK

80

MKW71
AA522

GATE VALVE

50
4.0

CS
FL

SHUT OFF VLV FOR SEAL OIL,EE (AI
R SIDE)

SOV RACK

81

MKW71
AA523

GLOBE VALVE

10
2.5

CS
BW

SHUT OFF VLV IN SEAL OIL IMPULSE
LINE,EE (AIR SIDE)

SOV RACK

82

MKW71
AA524

GLOBE VALVE

8
2.5

CS
BW

VENT FOR EQUALISING VLV EE (AIR
SIDE)

SOV RACK

83

MKW71
AA551

NEEDLE VALVE

15
2.5

CS
SC

FIRST SHT OFF VLV FOR PR.MSRMENT
BEF.AIR SIDE MNFLD

PIPE LINE

84

MKW71
AA552

NEEDLE VALVE

15
2.5

CS
SC

FIRST SHUT OFF VLV FOR AIR SIDE
SO PR MSRMENT,TE

PIPE LINE

85

MKW71
AA553

NEEDLE VALVE

15
2.5

CS
SC

FIRST SHUT OFF VLV FOR AIR SIDE
S O PR MSREMENT,EE

PIPE LINE

86

MKW73
AA011

EQUALISING VALVE

50
2.5

CS
FL

EQUALISING VLV FOR S.O.PRESSURE
TE(H2 SIDE)

SOV RACK

87

MKW73
AA021

EQUALISING VALVE

50
2.5

CS
FL

EQUALISING VLV FOR S.O.PRESSURE
EE(H2 SIDE)

SOV RACK

88

MKW73
AA511

3-WAY VALVE

50
1.6

CS
FL

3-WAY VLV TE (H2 SIDE)

SOV RACK

89

MKW73
AA512

GATE VALVE

50
4.0

CS
FL

SHUT OFF VLV FOR SEAL OIL IMPULS
E LINE, TE (H2 SIDE)

SOV RACK

90

MKW73
AA513

GLOBE VALVE

10
2.5

CS
BW

SHUT OFF VLV FOR SEAL OIL IMPULS
E LINE, TE (H2 SIDE)

SOV RACK

91

MKW73
AA514

GLOBE VALVE

8
2.5

CS
BW

VENT FOR EQUALISING VALVE TE (H2
SIDE)

SOV RACK

92

MKW73
AA521

3-WAY VALVE

50
1.6

CS
FL

3-WAY VLV,EE (H2 SIDE)

SOV RACK

93

MKW73
AA522

GATE VALVE

50
4.0

CS
FL

SHUT OFF VLV FOR SEAL OIL EE (H
2 SIDE)

SOV RACK

94

MKW73
AA523

GLOBE VALVE

10
2.5

CS
BW

SHUTOFF VALVE IN SEAL OIL IMPULS
E LINE,EE (H2 SIDE)

SOV RACK

95

MKW73
AA524

GLOBE VALVE

8
2.5

CS
BW

VENT FOR EQUALISING VALVE EE (H2
SIDE)

SOV RACK

96

MKW76
AA511

GATE VALVE

25
1.6

CS
FL

MULTIWAY SHUT OFF VALVE FOR R.R.
FLOW METERS (TE)

SOV RACK

2.1-7112-10553/4
0709 E

NB mm
NP MPA

BODY mat
END conn

FUNCTION

LOCATIOIN

Turbogenerators

List of Valves for Seal oil System

Description
SL
VALVE
NO. DESIG

TYPE OF VALVE

NB mm
NP MPA

BODY mat
END conn

FUNCTION

LOCATIOIN

97

MKW76
AA512

GATE VALVE

25
4.0

CS
FL

SHUT OFF VALVE AFTER R.R.FLOW ME
TER(TE)

SOV RACK

98

MKW76
AA513

REGULATING

25
4.0

CS
FL

REGULATING VALVE FOR RING RELIEF
OIL,TE

SOV RACK

99

MKW76
AA521

GATE VALVE

25
1.6

CS
FL

MULTIWAY SHUT OFF VALVE FOR R.R.
FLOW METERS (EE)

PIPE LINE

100 MKW76
AA522

GATE VALVE

25
4.0

CS
FL

SHUT OFF VALVE AFTER R.R.FLOW ME
TER(EE)

PIPE LINE

101 MKW76
AA523

REGULATING VALVE

25
4.0

CS
FL

REGULATING VALVE FOR RING RELIEF
OIL,TE

PIPE LINE

102 PGB51
AA501

3-WAY VALVE

65
1.6

CS
FL

3-WAY VLV FOR COOLING WATER INLE
T (H2 SIDE)

SEAL OIL UNIT

103 PGB52
AA501

REGULATING VALVE

65
1.6

CS
FL

REGULATING VALVE AFTER SEAL OIL
COOLER-1, H2 SIDE

SEAL OIL UNIT

104 PGB52
AA502

REGULATING VALVE

65
1.6

CS
FL

REGULATING VALVE AFTER SEAL OIL
COOLER-2,H2 SIDE

SEAL OIL UNIT

105 PGB61
AA501

3-WAY VALVE

65
1.6

CS
FL

3-WAY VLV FOR COOLING WATER INLE
T (AIR SIDE)

SEAL OIL UNIT

106 PGB62
AA501

REGULATING VALVE

65
1.6

CS
FL

REGULATING VALVE AFTER SEAL OIL
COOLER-1,AIR SIDE

SEAL OIL UNIT

107 PGB62
AA502

REGULATING VALVE

65
1.6

CS
FL

REGULATING VALVE AFTER SEAL OIL
COOLER-2,AIR SIDE

SEAL OIL UNIT

Legend
FL
SC
CS
CR
GM

= Flanged
= Screwed
= Carbon Steel
= Cromium Steel
= Gun Metal

RT = Room Temperature

BHEL, Haridwar

2.1-7112-10553/5
0709 E

Turbogenerators

Bearing Vopour Exhauster

Description
6

The bearing vapour exhauster establishes a
vacuum in the generator bearing compartments
which prevents the escape of oil from the bearing
compartments along the shaft. In addition, the
bearing vapour exhausted draws off any hydrogen
gas which may be admitted into the bearing
compartments in the event of a shaft seal failure.
The bearing vapour exhauster embodies optimum
safeguards permitting it to be used for extracting
hydrogen gas from the bearing compartments.
The exhauster is driven by a three-phase motor
attached perpendicular to the exhauster housing.
Flanged connections are provided for the suction and
delivery pipes.
The fan impeller is directly mounted on the motor
shaft. The shaft is sealed with a double-acting
grease-lubricated axial seal which works via a
packing washer which is forced in the axial direction
against the seal collar. A spring provides for a highly
flexible seal.

1

2

4

4
Drive motor
Regressing device
Suction branch
Delivery branch

Fig.1

Bearing Vapour Exhauster

BHEL, Haridwar

7

3

3

1
2
3
4

5

1
2
3
4
5
6
7

21

Packing washer
Seal collar
Motor shaft
Motor flange
Regressing device
Exhauster housing
Fan Impeller

Fig.2

Bearing Vapour Exhauster
2.1-7120-0500/1
0709 E

The thread flanks transmit only the torque resulting from fluid friction. One double-thread driving rotor and two driven idler screw dare closely meshed and run with a close clearance in the casing insert. Oil lubricated radial seals at the rotor shaft ends prevent the hydrogen gas from escaping from the generator to the atmosphere.1-7123-0500/1 0709 E .1 1 2 3 4 Screw Pump With Relief Valve BHEL. while rotating progress completely uniformly and without undue stressing from the suction to the discharge end. Haridwar 2. The crew pump is suitable for rigorous service and. The main components of the pump are illustrated in the sectional view of a screw pump. Dummy pistons compensate for the axial thrust on the thread flank faces at the discharge end. due to the absence of control parts sensitive to dirt. allows for relatively large variations of seal oil viscosity. Seal oil pumps are used to supply the seal oil to the shaft seals in a closed circuit. By internalising. The screw pumps are driven by electric motors through a coupling. which ensures very quiet running. the helical passages in the rotors are divided into compartments completely sealed which. thus acting like a piston.Turbogenerators Seal Oil Pumps Description 1 General High speeds are readily attainable because all moving parts perform rotary movements only. The pump casing accommodates the casing insert and is closed off by covers at the drive end and nondriver end. The motor speed and rating are matched to the expected delivery flow and heads. The idler screw are hydraulically driven due to suitable screw dimensions. Axial thrust on the deep-groove ball bearing is thus eliminated. 1 2 3 4 Idler screw Driving rotor Dummy pastor Shaft seal (sliding ring gland) Fig. 2 Construction and Mode of Operation The seal oil pumps are three-screw pumps.

Turbogenerators Seal Oil Cooler and Seal Oil Filter Description 1 Seal Oil Coolers The air side and hydrogen side oil coolers are each full-capacity coolers. one of the two filters can always be maintained in operation. The change-over valve assembly at the filters allows one filter to be out of service for cleaning without interruption of the oil flow.1-7130-0500/1 0709 E . The seal oil flow can be changed over from one cooler to the other by means of two interlocked three-way rotary transfer valves. 7 8 1 2 3 4 Valve assembly Position indicator Pressure equalizing valve Differential pressure indicator Fig. The filters have a fine mesh screen which serves to prevent damage to the shaft seals by foreign particles entrained in the oil. One is always in operation. Haridwar 5 6 7 8 Transfer valve assembly Valve lever Filter housing Oil outlet flange Seal Oil Filter 2.1 BHEL. 2 1 2 3 4 5 6 Seal Oil Filters The seal oil filters are arranged directly after the seal oil coolers. supplying filtered oil to the shaft seals. while the second one serves as a stand-by. By connecting two separate filters in series.

Cooler base 10. Oil inlet 2. Water channel 11. 5. 4.1-7131-0500/1 0709 E . Lower tubesheet 12. 2. 7. 6. Oil outlet 13. Upper tubesheet Support plate Return water channel Partition ring Inspection port Tube bundle Cooler shell BHEL. Haridwar 8. Cooling water connection 9. 3.Turbogenerators Seal Oil Cooler Description 1.

1-7132-0500/1 0709 E .Turbogenerators Seal Oil Filter Description 1 2 3 4 5 6 7 1 2 3 4 5 6 7 BHEL. Haridwar 8 Position indicator Eyebolt Filter valve Strainer Filter housing Support Vent plug 9 10 11 12 8 9 10 11 12 13 Drain plug Changeover valve assembly Oil outlet flange Valve lever Oil inlet flange Signal line for differential pressure 2.

Vents are provided at the pressure gauges.1-7150-0500/1 0709 E . Q Q Q Differential pressure transmission lines Equalizing valve assembly Differential pressure gauges The seal oil pressures are transmitted to the diaphragms of the pressure gauges via the BHEL. Haridwar transmission lines and equalizing valve assembly.Turbogenerators Differential Pressure Meter System Description 1. T h e r e s u l t i n g m o v e m e n t i s transmitted to the pointer mechanism for direct indication of the differential pressure. A complete system for measurement of the seal oil differential pressures consists of the following components. With the force set up by the differential pressure producing a deflection of t h e e l a s t i c b o d y. The point has a deflection of 270 degrees. 2. General The pressures of the hydrogen side and air side seal oil circuits are applied to differential pressure measurement devices. 2. D i f f e r e n t i a l Indication Pressure Meters for Direct The two input pressures to be compared act on the diaphragms on both sides.

The bottles should be provided with risers to ensure complete emptying. is fed to the gas valve rack via a shutoff valve.1-7200-0500/1 0709 E . air must never be directly replaced with hydrogen during generator filling not the hydrogen replaced directly with air during the emptying procedure. the generator must be scavenged or purged with an inert gas. 5. 2. the gas valve rack is furnished with a mini diagram on the face of the panel. The liquid CO2. 3. One safety valve each on the highpressure and low-pressure sides protects the pipe system against inadmissible high pressure. a compressed air supply with compressed air filter is connected to the general air system of the power plant. Haridwar liquid state. 5. Carbon Dioxide Supply As a precaution against explosive mixtures. and allows large volume flow quantities of hydrogen to be reduced in pressure during the hydrogen filling procedure.3 Electrical Purity meter System The transmitter for the CO2 / H2 purity meter system on the gas valve rack is also of an explosion proof design. Gas Valve Rack and Gas Monitoring Equipment 5. Under all operating conditions. the pressure transmitter is of an explosion proof design. All pressure reducers are of identical design. 3. and the CO2 is admitted into the generator at the proper temperature.1 H2 Bottle Rack The H2 bottles are connected to the manifold on the bottle rack. The valves used in the gas system have rubber/metalsealed valve seats to ensure gas tightness.Turbogenerators Gas System Description 1. Part 3 and with the German pressure vessel code. The hydrogen is stored in the steel bottles at a very high pressure. 5. The arrangement of the CO 2 bottle rack corresponds to that of the H2 bottle rack. The meter system operates on the thermal conductivity method. except for CO 2 purging. This visible break is to ensure that no air can be admitted into a hydrogen-filled generator. Single-stage construction of the pressure reducers ensures a constant pressure. A temperature control is provided so that freezing of the flash evaporator is prevented. Valves on the bottles and valves on the manifold allow replacement of individual bottles during operation. 2. the compressed air hose between the filter and the generator pipe system should be disconnected. 4 Compressed air Supply To remove the CO2 from the generator. In both cases. Hydrogen Supply The hydrogen for the generator is supplied from a hydrogen bottle rack. Q Q Q Q Q General The gas system consists of the following components: CO2 bottle rack H2 bottle rack N2 bottle rack Gas dryer Gas valve rack The design of the gas system complies with the safety regulations according to VDE 0530. For safety.1 Gas Valve Rack To aid in operation of the gas system. which is stored under pressure.2 CO 2 Vaporiser At the gas valve rack the liquid CO2 is evaporated and expanded in a CO2 vapouriser. 3.2 Casing Pressure Measurement For measuring and checking the gas pressure in the generator. The hydrogen gas available in the manifold at bottle pressure is passed to two parallel-connected pressure reducers for expansion to the required intermediate pressure and is then passed to pressure reducers on the gas valve rack for expansion to the pressure required for generator operation.1 CO2 Bottle Rack The carbon dioxide is supplied in steel bottles in the BHEL. the gas rack is provided with a pressure transmitter and pressure gauges for local measurement. carbon dioxide (CO 2) being used for this purpose. The meter system measures the H2 content of the gas in the generator as well as the composition of gas mixtures (CO2 / air and H2 / CO2) during filling and emptying 2. even under low or no flow conditions. The hydrogen should have a minimum purity of 99.7%. Relief valves on the low-pressure sides of all pressure reducers are connected to an outlet pipe system through which any excess hydrogen is passed to the atmosphere. The heat for vaporization is supplied to the vapouriser electrically.

This meter system. and the specific gravity of the medium. The nitrogen available from a bottle is passed to a pressure reducer for expansion and admitted into the primary water tank via the N 2 supply line. 5. Removing the hydrogen gas above the water level in the primary water tank during shutdown of the primary water system Removing the hydrogen gas dissolved in the primary water during shutdown of the primary water system. thus eliminating the risk of corrosion attack. The gas inlet and gas outlet pipes of the gas dryer are connected at points of the generator with different static heads(differential fan pressure). The N 2 purge during shutdown prevents the formation of an explosive hydrogen-air mixture During operation hydrogen may enter into the primary water tank by diffusion at the insulating hoses. therefore. the speed of the generator fan.5 Gas Analysis In addition. functions only at rated speed. so that the gas is forced through the dryer by the differential pressure only. .1-7200-0500/2 0709 E The N 2 purge during initial operation ensures a complete removal of the oxygen from the primary water circuit. Removing the oxygen dissolved in the primary water during filling of the primary water system. 6.of the generator.4 Mechanical Purity Meter System The second purity meter system is a mechanical type and uses the physical relationships between the hydrogen pressure. facilities are provided for gas sampling for chemical analysis of the gas in the generator. Q Q Q Q Removing the air above the water level in the primary water tank during initial operation of the primary water system. nitrogen supply is required for: Nitrogen (N2 ) Supply On a water-cooled turbine generator an additional 2. Gas Dryer A small amount of the hydrogen circulating in the generator for cooling is passed through a gas drier. 5. 7.

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6 CR FL SHUT OFF CO2 SUPPLY TO EXHAUST F ROMTG GAS UNIT BHEL.5 CS FL SHUT OFF AT OUTLET FROM MKG 19/ AA002 GAS UNIT 17 MKG 25 AA 501 GLOBE VALVE 25 2.5 CS SC SHUT OFF AT OUTLET TO AF GAS UNIT 21 MKG 25 AA 511 GLOBE VALVE 8 25.REDUCER 25 2.5 CS SC H2.5 CR SC SHUT OFF AT OUTLET FROM MKG 11/ AA001 8 MKG 15 AA 502 GLOBE VALVE 25 2.REDUCER 8 25. DESIG TYPE OF VALVE NB mm NP MPA BODY mat END conn FUNCTION LOCATIOIN 1 MKG 11 AA 001 PR.REDUCER(STAGE-1) H2 DISTRIBUTER 2 MKG 11 AA 501 GLOBE VALVE 8 25.5 CR SC SHUT OFF AT OUTLET FROM MKG 12/ AA001 H2 DISTRIB 11 MKG 17 AA 504 GLOBE VALVE 25 2.0 CS SC H2 PR.REDUCER (STAGE-2) GAS UNIT 14 MKG 19 AA 002 PR.REDUCER 25 2.0 CS SC SHUTOFF AT H2 CYLINDER H2 CYLINDER 3 MKG 11 AA 531 MANIFOLD VLV 8 25.5 CS SC SHUT OFF AT INLET TO AF GAS UNIT 18 MKG 25 AA 502 GLOBE VALVE 50 2.5 CS FL SHUT OFF AT OUTLET FROM MKG 19/ AA001 GAS UNIT 16 MKG 19 AA 502 GLOBE VALVE 50 2.0 CR SC SHUT OFF AT INLET TO GAS ANALYSE R CABINET GAS UNIT 22 MKG 25 AA 512 GLOBE VALVE 8 25.5 CS SC FOR CONNECTING H2 DISTRIBUTER TO GAS UNIT 10 MKG 16 AA 501 GLOBE VALVE 25 2.REDUCER 8 0.0 CR SC SHUT OFF AT INLET TO KG12/ AA 001 7 MKG 15 AA 501 GLOBE VALVE 25 2.PR.5 CS SC SHUT OFF AT INLET TO MKG 19/ AA 002 GAS UNIT 13 MKG 19 AA 001 PR.0 CS SC H2 PR.5 CS SC H2 PR.5 CS SC FOR CONNECTING GAS UNIT TO STATI ONH2 PLANT GAS UNIT 12 MKG 17 AA 505 GLOBE VALVE 25 2.0 CR SC H2 DISTRIBUTER MANIFOLD H2 DISTRIBUTER 4 MKG 11 AA 561 GLOBE VALVE 8 25.0 CR SC FOR TAKING SAMPLE OF GAS FOR PUR ITY ANALYSIS GAS UNIT 23 MKG 25 AA 518 THREE WAY VLV 50 1.5 CS SC SHUT OFF AT INLET TO KG19/ AA 001 9 MKG 15 AA 504 GLOBE VALVE 25 2.REDUCER(STAGE-1) 6 MKG 12 AA 501 GLOBE VALVE 8 25.Turbogenerators List of Valves for Gas System Description SL VALVE NO.6 CR SC FOR CALIBRATION OF GAS ANALYSER GAS UNIT 20 MKG 25 AA 509 GLOBE VALVE 25 2.5 CS FL EXHAUST GAS UNIT 19 MKG 25 AA 507 3-WAY VALVE 12 1.REDUCER (STAGE-2) H2 UNIT 15 MKG 19 AA 501 GLOBE VALVE 50 2.1-7212-10545/1 0607 E . Haridwar MK H2 DISTRIBUTER H2 DISTRIBUTER M M H2 DISTRIBUTER H2 DISTRIB GAS UNIT GAS UNIT 2.0 CR SC SHUT OFF AT INLET TO G 11/ AA 001 5 MKG 12 AA 001 PR.

6 CS FL SHUT OFF AT INLET TO OIL TRAP IN GAS DRIER INL.0 CR SC INLET TO PRESSURE REGULATOR N2 DISTRIBTR 30 MKG 35 AA 501 GLOBE VALVE 8 25.6 CS FL SHUT OFF AT INLET TO REF.SL VALVE NO.0 CR SC N2 DISTRIBUTER MANIFOLD N2 DISTRIBTR 29 MKG 31 AA 503 GATE VALVE 8 25.6 CS SC INLET OF DEW POINT METER FROM C ASING GAS PIPE LINE 2.6 CS FL SHUT OFF AT OUTLET TO REF.6 CS FL SHUT OFF AT OUTLET TO REF.0 CR SC CO2 DISTRIBUTER MANIFOLD VALVES CO2 DISTRIBTR 35 MKG 51 AA 561 GLOBE VALVE 10 25.5 CS SC TO RELEASE EXCESS CO2 PR. GAS DR IER-2 PIPE LINE 41 MKG 69 AA 510 GAS VALVE 50 1.6 CS SC SHUT OFF IN OIL TRAP DRAIN PIPE LINE 44 MKG 69 AA 506 GLOBE VALVE 8 1.0 CS SC N2 PRESSURE REGULATION N2 DISTRIBTR 27 MKG 31 AA 501 GLOBE VALVE 8 CS SC SHUTOFF VALVE AT N2 CYLINDER N2 CYLINDER 28 MKG 31 AA 502 GLOBE VALVE 8 25.6 CS FL TO RELEASE EXCESS CO2 PR.5 CR SC SHUT OFF AT INLET TO CO2 VAPORI SER CO2 VAPOURSR 36 MKG 59 AA 001 SAFETY RELIEF VLV 32 0.1-7212-10545/2 0607 E PIPE LINE .6 CS FL SHUT OFF TO H2 SUPPLY TO GENERAT OR GAS UNIT 26 MKG31 AA001 PR REGULATOR 8 15.0 CR SC VALVE AT INLET OF GAC FROM GENER ATOR PIPELINE 25 MKG 25 AA 519 3-WAY VALVE 50 1. CO2 VAPOURSR 33 MKG 51 AA 501 GLOBE VALVE 8 CS SC SHUTOFF AT CO2 CYLINDER CO2 CYLINDER 34 MKG 51 AA 531 MANIFOLD VALVE 8 25. DESIG TYPE OF VALVE NB mm NP MPA BODY mat END conn FUNCTION LOCATIOIN 24 MKG25 AA021 GLOBE VALVE 8 25. ATCO2 VAP.6 CS SC INLET OF DEW POINT METER FROM GA S DRIER OUTLET PIPE LINE 45 MKG 69 AA 507 GLOBE VALVE 8 1. GAS DR IER-1 PIPE LINE 39 MKG 69 AA 503 GAS VALVE 50 1. AT INL TO CO2 VAP.6 CS FL SHUT OFF AT INLET TO REF. PIPE LINE 43 MKG 69 AA 502 GAS VALVE 15 1. OUTL CO2 DISTRIBTR 37 MKG59 AA507 GLOBE VALVE 50 CR SC OUTLET CO2 PRESSURE REGULATOR PIPELINE 38 MKG 69 AA 502 GAS VALVE 50 1.0 CS SC SHUTOFF AT INLET TO GAC FROM GEN ERATOR 32 MKG 51 AA 001 SAFETY RELIEF VLV 6 17.GAS DR IER-1 PIPE LINE 40 MKG 69 AA 509 GAS VALVE 50 1.0 CR SC OUTLET OF PRESSURE REGULATOR N2 DISTRIBTR 31 MKG 05 AA 501 GLOBE VALVE 8 25.0 CR SC VALVE AT INLET TO GAS ANALYSER C ABINET PIPELINE 25 MKG25 AA022 GLOBE VALVE 8 25.GAS D RIER-2 PIPE LINE 42 MKG 69 AA 505 GAS VALVE 50 1.

The pump shaft is supported in oil-lubricated anti-friction bearings. The oil level in the bearing housing can be checked at an oil sight glass. two full-capacity primary water pump sets are provided. Haridwar discharge is directed radially upwards. The pump suction is arranged axially.1-7320-0500/1 0709 E . The spiral casing is flanged to the bearing housing. The pump impeller is provided with relief holes close to the hub so that no axial thrust is carried by the bearings. Either pump can be in service with other acting as the stand-by. The pump is connected to the three-phase AC motor by a flexible coupling covered by a coupling guard.Turbogenerators Primary Water Pumps Description Design Features of Primary Water Pumps The primary water for cooling the stator winding. The cooling water is supplied to the sliding-ring gland through a bypass line from the pump discharge. 2. The primary water pumps are of a single-stage centrifugal type with spiral casing and overhung impeller. while the BHEL. The standby pump is ready for service and is automatically started without interrupting the primary water circulation if the operating pump fails. phase connectors and terminal bushings is circulated in a closed system. The point where the pump shaft passes through the pump casing is sealed by means of a water-cooler sliding-ring gland. To insure uninterrupted generator operation.

Turbogenerators CO 2 Vaporiser Description 1 General CO 2 is used to displace air from the generator before hydrogen filling and to displace hydrogen from the generator before filling the generator with air.1 3 11 1 2 3 4 5 6 outlet to the cooled copper pipe of the evaporator. Haridwar 2. For protection against excessive pressures in the CO 2 line. The heat transfer liquid is filled into the CO 2 vaporiser through the expansion vessel mounted on top of the housing. it must be expanded into a gas before use.1-7230-0500/1 0709 E . one relief valve is arranged before and after the CO 2 flash evaporator. Heating of the CO 2 in the copper pipe coil is sufficient to prevent icing of the expansion device at the prevailing flow velocities. Vent for heat transmitting liquid Copper pipe coil Insulation Expansion vessel Relief valve before CO 2 vaporiser Shutoff valve before CO 2 vaporiser 4 10 5 9 7 8 9 10 11 12 6 8 7 CO2 inlet CO2 outlet Housing Heating element Drain for heat transfer liquid Terminal box CO 2 Vaporiser BHEL. The opposite flange contains the inlet and 1 2 12 Fig. The CO 2 is expanded in a CO 2 vaporiser located on the gas valve rack. Since the CO 2 is available in the liquid state. The horizontally arranged housing is filled with heat transmitting liquid to ensure a better heat transfer to the copper pipe coil and thus to the CO 2 flowing through the pipe coil. The orifice at the CO 2 out let of the expansion vessel provides for an expansion of the CO 2 obtained from the bottles to a pressure of 25 to 7 psig. 2 Design features and mode of operation The CO 2 vaporiser consists of a tubular housing closed by flanges at both ends.To prevent icing of the vaporiser it is electrically heated. One flange carries electrical heating elements which are connected to terminals in the terminal box mounted external to the flange.

which can be observed through the glass window. the condensate gets collected in the condensate chamber. BHEL. Drain the condensate chamber once every 24 hours. This is done to ensure that no hydrogen leakage takes place from the generator system. For draining. Haridwar After the operation of the Refrigeration drier.Turbogenerators Gas Dryer (RefrigerationType) Description For hydrogen gas drying. Refrigeration gas driers are available. Either of these two can be selected for the gas drying operation. to bring in circuit either drier-1 or drier-2: MKG69 AA501 MKG69 AA504 At inlet of Refrigeration gas drier-1 At outlet of Refrigeration gas drier-1 MKG69 AA 506 MKG69 AA507 At inlet of Refrigeration gas drier-2 At outlet of Refrigeration gas drier-2 The Refrigeration gas drier is to be operated for a total period of 8 hours in 24 hours duration. refer O&M manual for the Refrigeration gas drier 2.1-7270-0553/1 0709 E . This can be suitably selected on the timer available on the drier. by suitably operating the following valves. For further details. 2 nos. first open the upper valve and let the condensate flow from the condensate chamber and collect in the pipe. Then close this upper valve and open the lower valve to drain the condensate.

were added to the water or condensate. it must have an electrical conductivity below a value of 2 µmho/cm. pressure and temperature transmitters. etc. The primary water is circulated by one of the two pumps on the primary water supply unit. Since the cooling water is the primary coolant to dissipate the losses. it is designated as primary water. The primary water supply unit combines the following components for primary water supply to the generator: Primary water pumps Primary water filters Conductivity transmitter Water treatment system Flow. hydrazine.1 7 2 10 Simplified schematic of the primary water system BHEL. 2 3 Primary Water Circuit Fig. mechanically clean -distilled water -fully de-mineralised water from boiler feed water treatment plant -condensate Since the primary water comes into direct contact with the high-voltage stator winding. terminal bushings and phase connectors are dissipated through direct water cooling.Turbogenerators Primary Water System Description 1 General The losses occurring in the stator windings. Haridwar Primary water circuit-General Coolant flow: Stator winding Coolant flow: Main bushings and phase connectors Water treatment Waste gas 2. Fully de-mineralised water from the boiler feed water treatment plant and condensate may only be used if no chemicals. The primary water system basically consists of the following components: -Primary water supply unit -Primary water coolers -Primary water valve rack -Primary water tank free. 1 shows a simplified schematic of the primary water system. Note that the diagram shows that the external portion of the system may be operated through a bypass line. Both primary water pumps are of full-capacity type. such as ammonia. The electric control Primary Water Quality The primary water system may be filled with oxygen- 12 1 2 3 9 11 8 12 1 2 3 4 5 6 7 8 9 10 4 5 11 12 Primary water tank Pressure regulator Waste gas to atmosphere Pump Cooler Filter Bypass line Cooling water for stator winding Ion exchanger Cooling water for main bushings and phase connector Teflon hose Cooling water manifold 6 11 Fig. phosphate. with no primary water flowing through the water-cooled generator components. The water in the primary water circuit is therefore treated in a water treatment system.1-7300-0500/1 0709 E .

The hydrogen gas in the primary water tank is vented to atmosphere via the primary water valve rack and a pressure regulator. a large water surface and sufficient retention time. The primary water is drawn from the primary water tank and passes to a primary water manifold (inlet) via coolers and filters and from there to the stator bars via teflon hoses. has a relatively high water temperature. The pressure regulator can be adjusted to set the gas pressure in the primary water tank. Additionally. a capacitance type measuring system is provide for activating an alarm at minimum and maximum water level. The primary water leaving the stator winding is passed through similar teflon hoses to another primary water manifold (outlet) and is then returned to the primary water tank. intensive de-gassing of the primary water is ensured. The purpose of primary water tank is to remove the hydrogen in the primary water after it 2. The water level in the primary water tank can be read at a water level gauge. Since the primary water tank is the lowest pressure point in the system. . A separate flow path from a point before the stator winding inlet cools the bushings and phase connectors. 4 Primary Water Tank The primary water tank is mounted on the stator frame on anti-vibration pads and is covered by the generator lagging.circuit of the pumps is arranged so that either pump may be selected for normal service.1-7300-0500/2 0709 E leaves the stator winding. The hydrogen occurs in the primary water due to diffusion through the teflon hoses which connect the stator winding to inlet and outlet manifolds.

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6 SS FL FEED VALVE AFTER DOSING PUMP ALK.5 SS SC PRIMARY WATER DRAIN VALVE FOR CO OLER-1 PIPE LINE 17 MKF 52 AA 522 NEEDLE VALVE 15 2. DESIG TYPE OF VALVE NB mm NP MPA BODY mat END conn FUNCTION LOCATIOIN 1 MKF 12 AA 001 N. Haridwar 2.5 SS FL PRIMARY WATER SHUT OFF VALVE BEF ORE COOLER-1 PIPE LINE 13 MKF 52 AA502 GLOBE VALVE 100 2.5 SS FL PRIMARY WATER SHUT OFF VALVE AFT ER COOLER-1 PIPE LINE 15 MKF 52 AA512 GLOBE VALVE 100 2.5 SS FL OUTLET OF STATOR WATER PUMP-1 P&F UNIT 5 MKF 22 AA001 N.6 SS FL SHUTOFF VALVE FOR ALKALISER UNIT PIPE LINE 11 MKF 36 AA 497 NEEDLE VALVE 15 2.5 SS FL INLET TO STATOR WATER PUMP-1 MKF 12/AP001 P&F UNIT 7 MKF 22 AA502 NEEDLE VALVE 10 2.5 SS FL PRIMARY WATER SHUT OFF VALVE AFT ER COOLER-2 PIPE LINE 16 MKF 52 AA521 NEEDLE VALVE 15 2.R VALVE 100 1.6 SS FL NON RETURN AT OUTLET OF STATOR WATER PUMP-1 P&F UNIT 2 MKF 12 AA 501 GLOBE VALVE 100 2.1-7312-10553/1 0709 E .5 SS SC PRIMARY WATER VENT VALVE FOR COO LER-1 PIPE LINE 19 MKF 52 AA 532 NEEDLE VALVE 10 2.5 SS SC PRIMARY WATER DRAIN VALVE (MANIF OLD) PIPE LINE 22 MKF 52 AA 545 NEEDLE VALVE 10 2.5 SS SC PRIMARY WATER VENT VALVE FOR COO LER-2 PIPE LINE 20 MKF 52 AA 541 NEEDLE VALVE 15 2.R VALVE 100 1.5 SS SC PRIMARY WATER VENT VALVE (MANIFO LD) PIPE LINE 23 MKF 52 AA 551 NEEDLE VALVE 15 2. UNIT 10 MKF 36 AA 495 GLOBE VALVE 25 1.6 SS FL NON RETURN AT OUTLET OF STATOR WATER PUMP-1 P&F UNIT 6 MKF 22 AA 501 GLOBE VALVE 100 2.5 SS SC PRIMARY WATER DRAIN VALVE FOR CO OLER-2 PIPE LINE 18 MKF 52 AA 531 NEEDLE VALVE 10 2.5 SS FL INLET TO STATOR WATER PUMP-1 MKF 12/AP001 P&F UNIT 3 MKF 12 AA502 NEEDLE VALVE 10 2.5 SS SC VENT VALVE AT ALKALISER UNIT PIPE LINE 12 MKF 52 AA501 GLOBE VALVE 100 2.5 SS SC COOLING WATER DRAIN VALVE AT COO LER-1 PIPE LINE BHEL.5 SS FL PRIMARY WATER SHUT OFF VALVE BEF ORE COOLER-2 PIPE LINE 14 MKF 52 AA511 GLOBE VALVE 100 2.5 SS SC PRIMARY WATER VENT VALVE BEFORE COOLERS PIPE LINE 21 MKF 52 AA544 NEEDLE VALVE 15 2.5 SS FL OUTLET OF STATOR WATER PUMP-1 P&F UNIT 9 MKF 36 AA 488 DOZING VALVE 25 1.5 SS SC DRAIN VALVE BEFORE PUMP-1 P&F UNIT 4 MKF 12 AA 504 GLOBE VALVE 100 2.Turbogenerators List of Valves for Primary Water System Description SL VALVE NO.5 SS SC DRAIN VALVE BEFORE PUMP-2 P&F UNIT 8 MKF 22 AA 504 GLOBE VALVE 100 2.

5 SS FL MAKE UP DRAIN VALVE PIPE LINE 40 MKF 60 AA 502 REG.5 SS FL RELIEF VALVE IN MAKE UP LINE P&F UNIT 37 MKF 60 AA 003 N.1-7312-10553/2 0709 E .5 SS SC DRAIN VALVE AT FINE FILTER P&F UNIT 46 MKF 60 AA 512 NEEDLE VALVE 10 2.5 SS SC COOLING WATER VENT VALVE AT COOL ER-2 PIPE LINE 27 MKF 52 AA 578 NEEDLE VALVE 15 2.5 SS SC DRAIN VALVE AT FILTER-1 P&F UNIT 30 MKF 52 AA 582 NEEDLE VALVE 10 2. VALVE 25 2.5 SS FL OUTLET FROM WATER FILTER-2 P&F UNIT 36 MKF 60 AA 001 RELIEF VALVE 25 2.5 SS SC VENT VALVE AFTER PW COOLERS PIPE LINE 28 MKF 52 AA 580 GLOBE VALVE 100 2.5 SS FL SHUT OFF VALVE AFTER FINE FILTER P&F UNIT 48 MKF 60 AA 517 NEEDLE VALVE 10 2.5 SS SC VENT VALVE AT FINE FILTER P&F UNIT 47 MKF 60 AA 513 GLOBE VALVE 25 2.SL VALVE NO.5 SS SC VENT VALVE AT FILTER-2 P&F UNIT 35 MKF 52 AA 593 GLOBE VALVE 100 2.5 SS SC VENT VALVE BEFORE ION-EXCHANGER P&F UNIT 42 MKF 60 AA 506 GLOBE VALVE 25 2.5 SS FL INLET TO WATER FILTER-1 P&F UNIT 29 MKF 52 AA 581 NEEDLE VALVE 15 2.5 SS FL MAKE UP INLET VALVE PIPE LINE 39 MKF 60 AA 201 GLOBE VALVE 25 2. VALVE 25 2. DESIG TYPE OF VALVE NB mm NP MPA BODY mat END conn FUNCTION LOCATIOIN 24 MKF 52 AA 552 NEEDLE VALVE 15 25.6 SS FL CHECK VALVE IN MAKE UP LINE P&F UNIT 38 MKF 60 AA 501 REG.5 SS SC DRAIN VALVE AT FILTER-2 P&F UNIT 34 MKF 52 AA 592 NEEDLE VALVE 10 2.5 SS SC VENT VALVE AT FILTER-1 P&F UNIT 31 MKF 52 AA 583 GLOBE VALVE 100 2.R VALVE 25 1.5 SS SC DRAIN VALVE AFTER ION-EXCHANGER P&F UNIT 45 MKF 60 AA 511 NEEDLE VALVE 10 2.5 SS SC DRAIN VALVE FOR WATER TREATMENT SYSTEM P&F UNIT 2.5 SS FL SHUT OFF VALVE IN MAKE UP LINE P&F UNIT 43 MKF 60 AA 509 GLOBE VALVE 25 2.5 SS FL CONTROL VALVE FOR WATER TREATMEN T SYSTEM P&F UNIT 41 MKF 60 AA 503 NEEDLE VALVE 10 2.5 SS FL OUTLET FROM WATER FILTER-1 P&F UNIT 32 MKF 52 AA 590 GLOBE VALVE 100 2.5 SS FL SHUT OFF VALVE AFTER ION-EXCHANG ER P&F UNIT 44 MKF 60 AA 510 NEEDLE VALVE 10 2.5 SS SC COOLING WATER VENT VALVE AT COOL ER-1 PIPE LINE 26 MKF 52 AA 562 NEEDLE VALVE 10 2.0 SS SC COOLING WATER DRAIN VALVE AT COO LER-2 PIPE LINE 25 MKF 52 AA 561 NEEDLE VALVE 10 2.5 SS FL INLET TO WATER FILTER-2 P&F UNIT 33 MKF 52 AA 591 NEEDLE VALVE 15 2.

TANK 64 MKF 82 AA 001 GLOBE VALVE 100 1.W.W.5 SS SC SHUT OFF VALVE FOR PRESS.6 SS FL SHUT OFF VALVE BEFORE LEVEL TRAN SMITTER.W.5 SS SC SHUT OFF VALVE AFTER FLOW TRANSM ITTER AT STATOR OUT PIPE LINE 69 MKF 82 AA 507 NEEDLE VALVE 15 2.W.6 SS FL VENT VALVE AT LEVEL TRANSMITTER P. VALVE 20 1.BOTTOM P.5 SS SC DRAIN VALVE BEFORE MKF82/AA501 PIPE LINE 68 MKF 82 AA 505 NEEDLE VALVE 15 2.W.6 SS FL SHUT OFF VALVE IN PRIMARY WATER OUTLET OF STATOR WDG P.TANK 56 MKF 01 AA 311 WATER VALVE 20 1.W.5 SS SC DRAIN PRIMARY WATER MAKE UP LINE P&F UNIT 52 MKF 80 AA 121 GLOBE VALVE 100 2.5 SS SC SHUT OFF VALVE BEFORE FLOW TRANS MITTER AT STATOR OUT PIPE LINE BHEL.5 SS FL SHUT OFF VALVE FOR GEN.6 SS FL SHUT OFF FOR OUTLET FROM LEVEL TRANSMITTER P.TANK 61 MKF 01 AA 306 WATER VALVE 20 1.6 SS FL SHUT OFF VALVE BEFORE LEVEL TRAN SMITTER.TANK 55 MKF 01 AA 321 WATER VALVE 20 1.5 SS FL SHUT OFF VALVE AFTER WATER TREAT MENT SYSTEM P&F UNIT 50 MKF 60 AA 520 GLOBE VALVE 25 2. MEAS BEFORE STATOR WDG PIPE LINE 71 MKF 82 AA 509 NEEDLE VALVE 15 2.TANK 53 MKF 80 AA 503 GLOBE VALVE 100 2.W.W.W.5 SS FL SHUT OFF AT INLET TO GEN.6 SS FL SHUT OFF VALVE FOR INLET TO LEVEL TRANSMITTER P.6 SS FL SHUT OFF VALVE BEFORE WATER LEVE L GAUGE.BOTTOM P.W.TOP P.6 SS FL SHUT OFF VALVE BEFORE WATER LEVE L GAUGE.5 SS FL SHUT OFF IN MAIN CIRCUIT DISCHAR GELINE P.1-7312-10553/3 0709 E .TANK 62 MKF 01 AA 301 WATER VALVE 20 1.6 SS FL REGULATING VALVE BEFORE STATOR WINDING PIPE LINE 66 MKF 82 AA 504 NEEDLE VALVE 15 2.TANK 60 MKF 01 AA 251 WATER VALVE 20 1.TANK 63 MKF 81 AA 502 REG.Turbogenerators List of Valves for Primary Water System Description SL VALVE NO.W.TOP P.TANK 58 MKF 01 AA 316 WATER VALVE 20 1.TANK 54 MKF 80 AA 504 GLOBE VALVE 100 2. P.5 SS FL BY PASS VALVE IN MAKE UP LINE P&F UNIT 51 MKF 60 AA 522 NEEDLE VALVE 10 2.5 SS SC SHUT OFF VALVE BEFORE FLOW TRANS MITTER AT STATOR OUT PIPE LINE 67 MKF 82 AA 502 NEEDLE VALVE 10 2.W.W.5 SS SC SHUT OFF VALVE AFTER FLOW TRANSM ITTER AT STATOR OUT PIPE LINE 70 MKF 82 AA 508 NEEDLE VALVE 15 2.6 SS FL FOR NITROGEN FILLING P.TANK 65 MKF 82 AA 501 REG. BY PASS P. VALVE 100 1.TANK 57 MKF 01 AA 326 WATER VALVE 20 1.5 SS SC DRAIN VALVE AT LEVEL TRANSMITTER P. DESIG TYPE OF VALVE NB mm NP MPA BODY mat END conn FUNCTION LOCATIOIN 49 MKF 60 AA 519 GLOBE VALVE 25 2. Haridwar 2.TANK 59 MKF 01 AA 210 GLOBE VALVE 10 2.

5 SS SC SHUT OFF VALVE AFTER FLOW TRANSM ITTER MKF83/CF001A PIPE LINE 79 MKF 83 AA 505 NEEDLE VALVE 15 2.6 SS FL REGULATING VALVE BEFORE BUSHING PIPE LINE 76 MKF 83 AA 502 GLOBE VALVE 40 1.SL VALVE NO.5 SS SC SHUTR OFF VALVE AFTER FLOW TRANS MITTER AT STATOR OUT 73 MKF 82 AA 512 NEEDLE VALVE 10 2.5 SS SC SHUT OFF VALVE BEFORE FLOW TRANS MITTER MKF83/CF001A PIPE LINE 94 MKF 83 AA 520 NEEDLE VALVE 15 2. 74 MKF 82 AA 513 NEEDLE VALVE 10 2.5 SS SC SHUT OFF VALVE AFTER FLOW TRANSM ITTER MKF83/CF001B PIPE LINE 85 MKF 83 AA 515 NEEDLE VALVE 15 2.5 SS SC SHUT OFF VALVE AFTER FLOW TRANSM ITTER MKF83/CF021B PIPE LINE 89 PGB 71 AA 501 GATE VALVE 250 1.6 CS FL COOLING WATER INLET OF COOLER-1 PIPE LINE 90 PGB 71 AA 502 GATE VALVE 250 1.P.5 SS SC SHUT OFF VALVE BEFORE FLOW TRANS MITTER MKF83/CF001B PIPE LINE 84 MKF 83 AA 514 NEEDLE VALVE 15 2. DESIG TYPE OF VALVE NB mm NP MPA BODY mat END conn FUNCTION LOCATIOIN 72 MKF 82 AA 510 NEEDLE VALVE 15 2.5 SS SC SHUT OFF VALVE BEFORE FLOW TRANS MITTER MKF83/CF021A PIPE LINE 82 MKF 83 AA 508 NEEDLE VALVE 15 2.5 SS SC SHUT OFF VALVE AFTER FLOW TRANSM ITTER MKF83/CF001A PIPE LINE 95 MKF83 AA521 NEEDLE VALVE 15 2.5 SS SC SHUT OFF VALVE BEFORE FLOW TRANS MITTER MKF83/CF011B PIPE LINE 86 MKF 83 AA 516 NEEDLE VALVE 15 2.5 SS SC SHUT OFF VALVE AFTER FLOW TRANSM ITTER MKF83/011A PIPE LINE 81 MKF 83 AA 507 NEEDLE VALVE 15 2.GAUGE GEN.5 SS SC SHUT OFF VALVE BEFORE FLOW TRANS MITTER MKF83/CF011A PIPE LINE 80 MKF 83 AA 506 NEEDLE VALVE 15 2.5 SS SC SHUT OFF VALVE AFTER FLOW TRANSM ITTER MKF83/011A PIPE LINE 2.6 CS FL COOLING WATER OUTLET OF COOLER-1 PIPE LINE 92 PGB 72 AA 502 GATE VALVE 250 1.5 SS SC ISOLATION VALVE FOR D.6 CS FL COLING WATER INLET OF COOLER-2 PIPE LINE 91 PGB 72 AA 501 GATE VALVE 250 1.5 SS SC SHUT OFF VALVE BEFORE FLOW TRANS MITTER MKF83/CF021B PIPE LINE 88 MKF 83 AA 518 NEEDLE VALVE 15 2.6 CS FL COOLING WATER OUTLET OF COOLER-2 PIPE LINE 93 MKF83 AA519 NEEDLE VALVE 15 2.1-7312-10553/4 0709 E PIPE LINE .5 SS SC SHUT OFF VALVE AFTER FLOW TRANSM ITTER MKF83/CF021A PIPE LINE 83 MKF 83 AA 513 NEEDLE VALVE 15 2.5 SS SC ISOLATION VALVE FOR D.6 SS FL SHUT OFF VALVE AFTER BUSHING PIPE LINE 77 MKF 83 AA 503 NEEDLE VALVE 15 2.P.5 SS SC SHUT OFF VALVE BEFORE FLOW TRANS MITTER MKF83/CF001A PIPE LINE 78 MKF 83 AA 504 NEEDLE VALVE 15 2. VALVE 40 1.GAUGE GEN. 75 MKF 83 AA 501 REG.5 SS SC SHUT OFF VALVE AFTER FLOW TRANSM ITTER MKF83/CF011B PIPE LINE 87 MKF 83 AA 517 NEEDLE VALVE 15 2.5 SS SC SHUT OFF VALVE BEFORE FLOW TRANS MITTER MKF83/CF011B PIPE LINE 96 MKF83 AA522 NEEDLE VALVE 15 2.

1-7312-10553/5 0709 E .5 SS SC ISOLATION VALVE FOR WDG.Turbogenerators List of Valves for Primary Water System Description SL VALVE NO.5 SS SC SHUT OFF VALVE BEFORE FLOW TRANS MITTER MKF83/CF021B PIPE LINE 98 MKF83 AA524 NEEDLE VALVE 15 2. Haridwar 2. DESIG TYPE OF VALVE NB mm NP MPA BODY mat END conn FUNCTION LOCATIOIN 97 MKF83 AA523 NEEDLE VALVE 15 2.TRANSMITTER PIPE LINE Legend FL SC CS CR GM = Flanged = Screwed = Carbon Steel = Cromium Steel = Gun Metal RT = Room Temperature BHEL. INLET PR.5 SS SC SHUT OFF VALVE AFTER FLOW TRANSM ITTER MKF83/CF021A PIPE LINE 99 MKF 82 AA 514 NEEDLE VALVE 10 2.

two full-capacity primary water pump sets are provided. The pump is connected to the three-phase AC motor by a flexible coupling covered by a coupling guard. 2. The cooling water is supplied to the sliding-ring gland through a bypass line from the pump discharge. while the BHEL. The primary water pumps are of a single-stage centrifugal type with spiral casing and overhung impeller.Turbogenerators Primary Water Pumps Description Design Features of Primary Water Pumps The primary water for cooling the stator winding. The oil level in the bearing housing can be checked at an oil sight glass. The spiral casing is flanged to the bearing housing. To insure uninterrupted generator operation. Either pump can be in service with other acting as the stand-by. Haridwar discharge is directed radially upwards. The point where the pump shaft passes through the pump casing is sealed by means of a water-cooler sliding-ring gland. The pump impeller is provided with relief holes close to the hub so that no axial thrust is carried by the bearings.1-7320-0500/1 0709 E . phase connectors and terminal bushings is circulated in a closed system. The pump suction is arranged axially. The pump shaft is supported in oil-lubricated anti-friction bearings. The standby pump is ready for service and is automatically started without interrupting the primary water circulation if the operating pump fails.

while the other tubesheet is a floating type. This achieves a more efficient heat exchange and protects the tubes from vibrations and bending. Tube bundle is free to move in response to temperature change.1-7330-10553/1 0709 E . Each cooler shell has vent and drain connection. Haridwar Primary water cooler 2. The pipe nozzles for the primary water inlet and outlet are welded to the shell.Turbogenerators Primary Water Cooler Description The primary water cooler is of a straight tube type. The primary water cooler sections are interconnected on their primary water sides via valves. Baffles installed on the tube bundle result in a transverse flow of cooling water across the tubes. the water channels are equipped with vent and drain connections. The larger tubesheet is mounted between the shell flange and the water channel. One tubesheet is stationary. Tube bundle. The tube bundle consists of round tubes expanded into the tubesheets. 1 BHEL. The floating tubesheet is sealed by O-Ring. cooler shell and water channels are bolted together. To vent and drain the tube side of the primary water coolers. Q Q The water channel at glands can be removed without draining the primary water. The cooler shell is stainless steel with welded flanges for connection to the flanges on the water channels. 1 2 1 2 3 4 5 6 7 Gasket Tube bundle Cooler shell O-ring Shell flange Tube plate Water chamber Note: Sketch may differ from actual equipment 3 4 5 6 7 Fig.

Turbogenerators

Primary Water Treatment System

Description
The water treatment system serves to maintain a
low electrical conductivity of the primary water. The water
treatment system is connected in parallel to main circuit
and contains a mixed-bed ion exchanger with series
connected fine filter, an integrating flow meter and a
conductivity transmitter.
1.

Mixed-Bed Ion Exchanger

The mixed-bed ion exchanger consists of a tank
filled with anion and cation exchanger tank prevent the
escape of the resins into the piping system. A fine filter
after the ion exchanger retains any resin particles. An
alarm is initiated when the filter is contaminated.
The water flow passing through the ion exchanger
is measured by means of an integrating flow meter after
the filter. After the ion exchanger part of the flow is
passed through a conductivity transmitter for checking
the resin activity.
2.

Ion Exchanger Resins

The ion exchangers consist of chemically and highly
active synthetic resins.
The base substances of the exchanger resins are
polymers. The polymer in the cation exchanger contains
highly acid groups, while the polymer in the anion
exchanger is composed of highly basic groups.

BHEL, Haridwar

The exchanger resins are thus capable of accepting
ions from the primary water while simultaneously
releasing equivalent amounts of other ions (hydrogen
ions from the cation exchanger and hydroxyl ions from
the exchanger) to the primary water. This process takes
place through the ion exchanger.
The combination of highly acid cation exchangers
and highly basic cation exchangers forms a multitude of
small demineralization units, resulting in a high-purity
deionate.
The capacity of the mixed- bed of the ion exchanger
is limited by the number of ion it can exchange. This
capacity is primarily determined by the type of exchanger
used, but also depends on the quantity of reactivating
agent, the rate of flow and the water temperature.
When the resins are exhausted, they must be
replaced by new resins.
After removal from the primary water treatment
system, the resins can be reactivated.
3. Adding Make-up Water to the Primary Water
Circuit
Any loss of primary water in the total circuit can be
compensated for by introducing make-up water upstream
of the mixed-bed ion exchanger. The quantity of make up water is totaled at a volumetric water meter and is
indicative of the tightness of the primary water system.

2.1-7340-0500/1
0709 E

Turbogenerators
Description
1

General

Even with the use of oxygen-poor water, copper
corrosion in the primary water circuit of water-cooled
windings cannot be completely avoided; in isolated
cases the corrosion product s reduce the crosssectional flow area of the water distribution system.
Besides, the formation of conductive deposits can
occur in the rotating water inlet and outlet hoses of
water-cooled rotor windings.
The severity of the corrosion attack can be largely
reduced by alkalizing the oxygen-poor water. Also, the
system becomes less susceptible to disturbances
resulting from air in-leakage.
Operating the generator with alkaline water at pH
8 to 9 improves its reliability land availability.
Operation at alkaline pH is ensured by a selfregulating alkalizer unit for feeding dilute sodium
hydroxide solution (NaOH).
2

Mode of Operation

Dilute sodium hydroxide solution is injected into
the low-conductivity primary water circuit where it
remains as dissolved, dissociated sodium hydroxide
solution. OH – ion concentration determines the pH
value.
The ion exchanger in the water treatment system,
i.e. mixed bed filters with H + cation exchangers and
OH – a n i o n e x c h a n g e r s , r e m a i n s i n s e r v i c e
continuously. It removes all copper, iron, chlorine,

Alkalizer Unit
for Primary Water Circuit

carbon dioxide ions, etc. from the water, However, it
also removes the Na + ions from the sodium hydroxide
solution. This elimination of sodium, which is
proportional both to the volumetric flow rate through
the ion exchanger and the NaOH concentration, must
be compensated by continuous feeding of dilute
sodium hydroxide solution.
The alkalizer unit is arranged in the treatment
circuit Sodium hydroxide solution is injected into the
treatment circuit where it is mixed with the water in
the treatment circuit and raises its conductivity. The
water has the highest purity at the feed point
downstream of the ion exchangers. The conductivity
of the mixed water is only determined by the
concentration of the sodium hydroxide solution and
provides a reference quantity for the pH valve. The
relationship between pH and conductivity under ideal
conditions is illustrated in Fig.1
Following the admission on alkaline water, the
conductivity in the treatment circuit is monitored.
Conductivity must be maintained constant as required
for obtaining the specified alkalinity. Conductivity in
primary water circuit likewise approaches a constant
value after several hours.
3

The hydraulic circuit of the alkalizer units is
illustrated in Fig.2
The diaphragm pump extracts the NaOH solution

1
2
3
Fig. 1 Conductivity as a function of pH in water at 18oC

BHEL, Haridwar

Hydraulic Circuit

Diaphragm pump
NaOH tank
Feed valve
(check valve)

Fig.2

4
5
6
7

Level detector
Soda lime filter in tank vent
Vent
Treatment circuit

Schematic Diagram of Alkalizer Unit
2.1-7341-0500/1
0709 E

from the NaOH tank and delivers it to the treatment circuit
via a spring-loaded feed valve. The treatment circuit and
especially the fine filter down steam of the treatment
circuit homogenize the concentration of the solution
injected into the circuit by shot feeding. The volume flow
meter in the treatment circuit stops the diaphragm pump
via a limit switch when the volumetric flow rate drops
below a predetermined limit value. A vent on the
diaphragm pump enables starting without back pressure

5
4
3
2

1

1.
2.
3.
4.
5.

NaOH tank
NaOH tank cap
Diaphragm pump
NaOH tank vent with lime filter
Feed valve (check valve)
Fig. 3

Alkalyser Unit

2.1-7341-0500/2
0709 E

and venting of the unit for activation. Low NaOH level in
the tank is sensed with a level detector to activate an
alarm. A soda lime filter in the tank vent binds the carbon
dioxide contained in the inlet air and prevents the
formation of carbonates in the NaOH solution.
The tank has a capacity to store the sodium hydroxide
solution required for a service period of several months.
4

Control and Monitoring
An interlock using the volumetric flow rate in the
treatment circuit as a criterion prevents starting of the
diaphragm pump and NaOH feeding into the treatment
circuit under no-flow or empty conditions. The feed rate
of the diaphragm pump is controlled by changing the
stroking rate dependent on the conductivity in the
treatment circuit using a controller and stroking rate
transducer.
The diaphragm pump is stopped as soon as the
conductivity in treatment circuit or conductivity in primary
water circuit exceeds a predetermined maximum valve,
or as soon as the conductivity in treatment circuit or
volumetric flow rate in treatment circuit drops below a
minimum valve.
This avoids over feeding due to faults or incorrect
operation of the alkalizer unit. After the pump has been
stopped the conductivity of the water is promptly
decreased by ion exchanger in the mixed-bed filter.
The alkalizer unit provides warning limits for
Q
low conductivity in primary water circuit
Q
low conductivity in leakage water circuit
Q
low level in NaOH tank.
which are displayed in the control cabinet.
Via potential-isolated contacts the following alarm
conditions can be signalled to the control room either as
single alarm or as group alarm:
Q
low conductivity in leakage water circuit
Q
low conductivity in primary water circuit
Q
low NaOH level in tank
Q
loss of supply voltage.

Turbogenerators

Primary Water Filters

Description
1

Main Filter

The primary water system includes a strainer-type
main filter with magnet bars. The filter screen of the
strainer has a mesh size of 75 mm (3 mils) and is
supported by a perforated sheet-metal cylinder. The
magnet bars consist of a magnet carrier and a number
of permanent magnets. The high-grade permanent
magnets have an unlimited useful service life. The
magnet bars are arranged so that a strong magnetic
field is set up between them. The primary water must
pass through this magnetic field so that all iron particles
come within the range of the magnetic bars, and are
thus attracted and retained. The magnet bar are
protected by stainless steel sleeves. On contamination
of the strainer-type filter, which is indicated by an alarm
initiated at excessive differential pressure, the filter
should be cleaned.

BHEL, Haridwar

2

Fine Filter

A fine filed with one-way filter element giving a degree
of filtration of 5 mm (0.2 mils) is installed after the mixedbed ion exchanger in the primary water treatment system.
The filter element consists of cellulose fibres bonded
with synthetic resin to achieve stability. The fibres are
distributed in the element in such a way that their porosity
is highest on the outer circumference of the element and
decreases continuously towards the filer interior.
Therefore, filtration takes place in depth, and the solid
matter is held in the entire volume of the element. The
coarser particles are removed at the highly porous outer
surface, while the smaller particles are arrested in the
element body at varying depth, depending on their size.
On contamination of the filter, which is indicated by an
alarm initiated at excessive differential pressure, the filter
element should be removed and replaced with new one.

2.1-7343-0500/1
0709 E

Turbogenerators

Primary Water Main Filter

Description

1
2
3
4

5
Primary
water
inlet

6

7

8

Primary
water
outlet

9

10
13

1
2
3
4
5
6
12

11

7
8
9
10
11
12
13

Connection for vent pipe
Filter cover
O-ring
Compression spring
Clamping bolt (adjustablea0
Connections for differential
pressure indicator
Supporting cylinder (inner)
Filter screen
Supporting cylinder (outer)
Filter housing
Connection for drain pipe
Tension bolt
Magnet bar

Note: Internal details shown here are typical and may vary
from actual supply.

BHEL, Haridwar

2.1-7344-0500/1
0709 E

Turbogenerators

Primary Water Fine Filter

Description
1
2

3
4
5
6
Primary
water outlet
4
7

8
1
2
3
4
5
6
7
8
9
10
11
12

Connection for vent pipe
Differential pressure indicator
Filter cover
O-ring
Impulse pipe for differential
pressure indicator
Support plate
Upper seating ring
Filter housing
Filter element
Clamping bolt
Bottom seating ring
Connections for drain pipe

9

10

11

Primary
water inlet

Note: Internal details shown here are typical and may vary
from actual supply.
12

BHEL, Haridwar

2.1-7345-0500/1
0709 E

Turbogenerators
Description

Primary water
outlet

Protective Screens at Primary Water Inlet
and Outlet

Primary water
inlet

Detail-X
Section A-B

Detail-Y

BHEL, Haridwar

2.1-7349-0500/1
0709 E

Turbogenerators

Coolant Temperature Control

Description
Due to load variations during operation and the resulting
thermal expansions and contractions, the generator is
subjected to stresses.
In order to reduce these stresses, the hydrogen cooling
circuit and the primary water cooling are each provided with
a temperature control system to control the cooling gas and
primary water temperatures so that the active generator
components are maintained at the proper temperature level.
The requirements for the temperature control systems are
described below :
ϑcold

=

ϑhot

=

ϑmean =
∆ϑ

=

Cold gas temperature or cold primary water
temperature
Hot gas temperature or hot primary water
temperature
Mean temperature of hot and cold gas or of
hot and cold primary water
ϑ - ϑcold with generator carrying full load.
hot

The temperature rise ∆ϑ at full load is the temperature
difference between the hot and cold hydrogen gas as given
in the hydrogen cooler design data or between the hot and
cold primary water as given in the design data of the primary
water cooler.
After start-up and run-up to rated speed, the cooling water
supply to the hydrogen coolers should be opened only when
the temperature of the hydrogen gas has reached the preset
cold gas reference. The temperature difference between cold
gas and hot gas is determined by the no-load losses.
The cooling water supply to the primary water coolers

should be opened only when the generator is carrying load,
since only then current-dependent heat losses will have to
be dissipated.
The temperature control systems are cold coolant
temperature control schemes with variable set point as a
function of the stator current. Set point adjustment is selectable
between I and I2 or with an exponent between one and two.
With rising stator current, the set point is reduced, so that the
mean value (ϑmean) of hot and cold coolant temperatures
assumes a nearly constant value, as shown in Fig. 1.
The difference between the setting values of the two set
points corresponds to half the temperature rise of the
hydrogen cooling gas at no-load, with 5-10 K (9-180F) to be
taken as a guiding value.
In order to maintain a low temperature level in the
generator, the reference should be set at the lowest possible
value, ensuring that the cold coolant temperature will not drop
below the minimum level of 10 0 C (50 0F) even when the
generator is carrying the full load.
Parallel shifting of the curves shown in Fig. 1 is possible
by adjustment of the cold gas reference. The temperature of
cold primary water must, however, always be higher than cold
hydrogen cooling gas over the entire load range of the
generator in order to avoid any condensation of moisture
contained in the gas on the generator components carrying
primary water.
The control valve must be absolutely tight when in the
closed position to ensure that the cooling gas temperature
will not drop while the generator is being shut down.

t
(0F)

Room
temperature

Generator load l/lN (%)
Fig. 1 Coolant temperature as a Function of Generator load

BHEL, Haridwar

2.1-8010-0500/1
0709 E

p. The bearing oil circuit and the seal oil circuit are separated from each other. the drain oil is returned to the turbine oil tank via the seal oil storage tank and a loop seal. the degassed oil is admitted to the turbine oil tank together with the bearing oil via a loop seal. If the exhauster fails. Particular precautions are taken with respect to a failure of the seal oil system. After remaining in this tank for a predetermined time. During normal operation. The seal oil storage tank is continuously vented via the vapor exhauster provided for the bearing compartments. During normal operation.1-8400 BHEL. practically no hydrogen will enter the turbine lube oil tank via the loop seal together with the seal oil drained from the shaft seals. Operation of the exhauster is monitored by a flow transmitter with limit switch. After remaining in this tank for a predetermined time. Also refer to the following section [1] 2. T h e s e a l o i l d r a i n e d f r o m t h e s e a l o i l t ank (hydrogen side circuit) passes into the seal oil storage tank. Long time experience has shown that no operational restrictions are required as long as the hydrogen losses do not 3 exceed 12 m (s. only two hydrogen bottles should be opened if the bottle supply is used. The safety and protective measures provided for the generator are described in detail in this section.Turbogenerators Safety Equipment Description for Hydrogen Operation The use of hydrogen as coolant in the generator calls for special safety equipment to ensure that hazardous operating conditions which might endanger personnel or the plant will not occur.1-8310-0500/1 0709 E . since the hydrogen is already extracted in the seal oil storage tank. leaks may develop which result in a continuous escape of hydrogen. To prevent the hydrogen which enters the bearing compartment from escaping via the oil drain pipes.) during any 24 hour period. The loop is designed to withstand momentary pressure surges. To avoid any danger to the unit to the hydrogen supply. The measures outlined above have the following effects: Q Q Q The bearing compartments and the oil drain pipes are ventilated continuously so that no explosive hazard will arise during normal operation. This loop seal is permanently filled with oil to prevent the escape of gas. This continuous ventilation of the seal oil storage tank prevents the formation of any explosive hydrogen-air-mixture. The exhauster creates a slight vacuum in the seal oil storage tank so that the oil saturated with hydrogen is degassed. Haridwar Measuring devices and supervisory equipment 2. The surroundings of the generator and the hydrogen supply system should not be endangered if engineering principles were followed in plant design and provision is made for ample ventilation of these areas so that the formation of localized hydrogen pockets or explosive hydrogen-air mixtures is precluded. The required measuring and alarm equipment is discussed elsewhere in this manual [1]. Any hydrogen collecting in the bearing compartment will be drawn off by the exhauster and vented.t. A special vapor exhauster creates a slight vacuum in the generator bearing compartments to prevent the escape of oil vapor from the bearing compartments along the shaft. the degassed oil is admitted to the turbine oil tank together with the bearing oil via a loop seal. the second exhauster on standby is automatically started. The isolating action of the loop seal prevents the hydrogen escaping due to small leakages from flowing into the turbine through the only partly filled oil drain pipe.

.

5 CS SC PW TANK GAS EXHAUST PIPE LINE 7 MKF91 AA513 GLOBE VALVE 20 2.EXHAUS TER-2 PIPE LINE 4 MKQ32 AA001 NON-RETURN 80 2.EXHAUST ER-1 PIPE LINE 3 MKQ31 AA001 NON-RETURN 80 2.5 CS SC PW TANK GAS EXHAUST PIPE LINE 8 MKF91 AA505 GLOBE VALVE 20 2.5 CS SC PW TANK GAS EXHAUST PIPE LINE Legend FL SC CS CR GM = Flanged = Screwed = Carbon Steel = Cromium Steel = Gun Metal RT = Room Temperature BHEL.5 CS SC SHUT OFF AT PW TANK EXHAUST PIPE LINE 6 MKF91 AA506 GLOBE VALVE 20 2.5 GM FL SHUT OFF AT INLET OF VAP. Haridwar 2.5 GM FL SHUT OFF AT INLET OF VAP.EXHAUS TER-2 PIPE LINE 5 MKF91 AA003 SAFETY VALVE 6 2.Turbogenerators List of Valves for Waste Gas System Description SL VALVE NO.5 CS FL SHUT OFF AT OUTLET OF VAP.1-8312-10553/1 0709 E . DESIG TYPE OF VALVE NB mm NP MPA BODY mat END conn FUNCTION LOCATIOIN 1 MKQ31 AA501 DIAPHRAGM VALVE 80 2.5 CS FL SHUT OFF AT OUTLET OF VAP.EXHAUST ER-1 PIPE LINE 2 MKQ32 AA501 DIAPHRAGM VALVE 80 2.

The fluid drained should be transferred to the waste oil tank of the power station for controlled waste disposal. In the waste fluid system. 1 Generator Waste Fluid System BHEL.Turbogenerators Generator Waste Fluid System Description The Waste fluid system serves for controlled discharge of fluid to be drained from the • • • seal oil system generator liquid level detection system waste gas system as a result of venting or minor leaks. In addition. Any waste fluid collected is discharged to the waste fluid system either directly or via collecting vessels that are integrated in the respective systems. the fluid is collected in a pipe section of large nominal size. the fluids to be drained for carrying out repair or maintenance work in the above areas are discharged to the waste fluid system. Fig.1-8315-10553/1 0709 E . Haridwar 2. This pipe section is fitted with a shutoff valve for fluid draining and a level detector for activating a high level alarm.

Primary water flows through the stator winding.1 Turbogenerators Generator Mechanical Equipment Description Protection Tripping Criteria Turbogenerators require comprehensive safety and supervisory devices to prevent damage and long forced outages. 2 Protection Circuits 2. The following criteria are sensed by the generator mechanical equipment protection and processed by the generator protection circuits: 1.7 Low Primary Water Flow Rate at Bushing Outlets Each of these criteria activates a turbine trip. enter into the water circuit. results in a reduction of oil viscosity. for instance.3 High Hot Air Temperature in Exciter Unit 1. 2. Secondary cooling water flows through the hydrogen coolers located in the stator end shields. As a result of the high hydrogen pressure. phase connectors and bushing in case of insufficient primary water supply. however.1-8320-0500/1 0709E .4 High Seal Oil Inlet Temperatures 1. 1.7 Protection of Water-Cooled Components Against Insufficient primary Water Supply The protection circuits covering criteria 1.7 prevent overheating and damage to the stator winding. 2. BHEL. The generator is disconnected from the system and deexcited through the two-channel reverse power relay. Haridwar 2.6 Low Primary Water Flow Rate at Sector Outlet 1. Due to the restricted volume of the compartment the liquid can rise quickly.2 Liquid in Generator Terminal Box terminal bushing and phase connectors. two level detectors are connected to the generator terminal box to activate the generator mechanical equipment protection before a critical level is reached. 2. Little water will emerge from a small leak. The hydrogen loss can be derived from the hydrogen consumption of the generator. Hydrogen will. High seal oil temperature.1 Generators Protection Against Overheating by High Cold Gas Temperature The protection circuit covering criterion 1. Operation of the generator will be seriously endangered in the event of a major ingress of water which will collect in the generator terminal box. resulting in a terminal short-circuit or ground fault.4 Shaft Seal protection Against High Seal Oil Inlet Temperature High seal oil inlet temperature endangers proper sealing performance of the shaft seals.3 Exciter Unit Protection Against Overheating The protection circuit covering criterion 1.1 High Cold Gas Temperature in Generator 1. Generator operation will only be endangered by these coolants in the event of large leakages.3 prevents overheating of the exciter in case of insufficient cooling (failure of exciter coolers).5 prevents insufficient cooling and thus overheating of the watercooled components in case of high primary water inlet temperature.1 prevents insufficient cooling and thus overheating of the hydrogencooled components in case of high cooling gas temperature.6/2.2 G enerator Protection Against Internal Ground Fault or Terminal Short-Circuit The generator may be damaged by leaks in components through which primary or secondary cooling water or seal oil flows inside the generator. 2. The protection relieves the operating personnel from making the necessary fast decisions. 2.5 Protecting of Water-Cooled Components Against Overheating The protection circuit covering criteria 1. as may. be experienced on failure of the seal oil coolers. The gas may penetrate the seal oil film at the shaft seal contact face and allow the hydrogen to enter the bearing compartment.5 High Primary Water Inlet Temperature 1. In order to prevent such a failure.6 to 1. The protective equipment detects dangerous operation conditions at an early stage and prevents them from developing into damaging conditions.

1-8321-0500/1 0709 E .Turbogenerators Tripping Scheme for Generator Description Mechanical Equipment Protection TT GCB FB A Liquid in generator terminal box High cold gas temperature High hot air temperature in main exciter High seal oil temperature downstream of cooler High primary water flow rate at stator outlet High primary water flow rate at stator outlet Low primary water flow rate at bushing outlet Tripout without reverse power protection (Short time initiation) TT GCB FB A = = = = Turbine trip Generator Circuit breaker Field breaker Alarm Alarm is initiated when the electrical generator protection system is tripped. BHEL. Haridwar 2. Individual alarms for each criterion are provided.

Turbogenerators Description Generator Mechanical Equipemtn Protection Two-out-of-Two Protection Circuit With Functional Test Plant enable CSA11 = non coincidence module CSF11 = functional test module CSV11 = logic module CSZ11 = pulse generator BHEL.1-8323-0500/1 0709 E . Haridwar GS = limit value monitor K1 = relay MU = transducer 2.

2 Stator Ground Fault Protection Breakdown of insulation between the stator winding and frame results in a stator ground fault. the rotor ground fault protection must always operate of avoid the hazard of sudden. Operating value: 0. If the loss of field cannot be detected directly (e. under-excitation and excessive thermal stresses. The protective equipment must be designed so that any serious fault will result in an immediate disconnection and de-excitation of the generator. If possible. Generator faults are then detected by two differential protection devices.g. the generator may also be included in the differential protection for the main transformer and station service feeder. exciters with rotating diodes).4/ N Relay time: < 60 ms In cert ain cases. 3 Under-excitation Protection Failure of the voltage regulator.2-0. The following protective equipment is recommended: Rapid fault detection is required for the following reasons: Q An interruption of the field circuit with arcing releases high amounts of energy in the form of heat which may cause severe burning. To minimize the consequential damage. Short-circuits or interruptions in the field circuit result in a complete loss of field and thus in instability of the generator. r o t o r o v e r v o l ta g e . Q A one-line-to-ground fault may develop to a double ground fault. A momentary excursion beyond the steady-state stability limit must not necessarily result in a loss of stability. enabling them to operate the unit outside the critical range or to take precautionary measures for shutdown. In addition to a suitable technical design and responsible mode of operation. extremely high vibrations due to magnetic unbalances. mal-operation of the generator or transformer control system and generator operation in a system with capacitive load may result in a reduction of the excitation required to ensure system stability below a predetermined minimum value. This protection must ensure a fast and selective detection of any faults in order to minimize their dangerous effects. ground faults. The fault is detected by a differential relay which initiates immediate isolation and de-excitation of the generator. This causes higher temperature rises in the rotor and core end portions. overvoltages. including the neutral point o f t h e g e n e r a t o r. the protected area should include the generator only. Relay time: <1 s The load resistance of a found transformer and any required boost to raise the neutral point potential should be selected so that ground current due to a fault will amount to less than 15 A. For this reason. Faults which do not cause any direct damage must be brought to the attention of the operating staff. it is recommended to introduce a second stator criterion covering the range of the permeance values 1/ xd and 1/ x ’d and to provide for instantaneous tripping when this criterion is exceeded. In the core of four-pole generators.1-8330-0500/1 0709 E . an over current protection should be provided which operates Rotor Ground Fault Protection BHEL. s y s t e m s w i m s a n d t o r s i o n a l vibrations of the shaft. the stator ground fault protection should cover the complete winding. provision must therefore be made for automatic protection facilities. Therefore it is advisable to design the underexcitation protection so that a warning will be given when the steady-state stability limit is reached. In order to obtain a high sensitivity. Relay time: approximately 1 s 4 1 Differential protection Breakdown of insulation between different stator phase windings results in an internal short-circuit. especially on four-pole generators. The protection must operate instantaneously if a loss of field occurs when the steady-state stability limit is reached. 5 Over current Protection System faults may result in inadmissible thermal stressing of the generator. Haridwar 2.Turbogenerators Generator Electrical Protection Description Generators are high-quality machines for securing the best possible continuity of power supply. it is recommended to provide two pole and four-pole generators with a protection circuit featuring a delayed response. Generators may be endangered by short-circuits. T h e p r o t e c t i o n i s t o i n i t i a t e immediate isolation and de-excitation of the generator. The generator will be shut down after a few seconds only. resulting in dangerous magnetic unbalances.

all one and two line-to-ground faults occurring in the system.2 × UN) operating value and delayed tripping. In case of large units. Specific faults in the turbine-generator interior initiate emergency tripping. the generator can be continuously operated at rated k VA up to 95% of rated frequency. however. the overcurrent protection serves as backup protection for the differential protection. When the continuously permissible load unbalance is reached. Mal-operation during manual voltage regulation of the generator may also result in inadmissible voltage stressing of these devices. advisable to provide surge diverters for the generator too. Since the turbine is then no longer supplied with cooling steam. With a view to a possible flashover from the highvoltage winding to the low-voltage winding in the unit transformer. Care should be taken to provide explosion-proof surge diverters or suitable constructional measures in order to avoid danger to persons or nearby components. e. A definite-time delay over current relay may be used for this purpose.1-8330-0500/2 0709E Since the frequency deviation due to a system disturbance is normally accompanied by a voltage deviation. phase breakages or circuit breaker failures are in fact load unbalances which may result in unduly high thermal stressing of the rotor. whereas a time-dependent isolation from the system occurs when this value is exceeded.3/N Relay time: 6-8 s maximum To avoid long relay times.e. 7 Rise-in-voltage Protection Rejection of partial or complete system loads causes a voltage rise. 9 Reverse Power Protection A rise in system frequency for any reason whatsoever result in closing of the control valves. and the turbine is driven by the motoring generator. followed by an increase in the prime mover speed. it is recommended to provide a protection with unbalanced load/time characteristic. If connected to the generator neutral point.g. VDE 0530. This relay is energized by over current and operates with long or short-time setting. with low (1. Normally. at least in the case of large units. Operating value and relay time should be matched to the load unbalanced/time characteristic applicable to the particular generator. To avoid excessive magnetic and thermal stressing. Due to the sudden voltage variations resulting from switching operations. the protection should be designed on the basis of the permissible load characteristic of the generator on frequency and voltage deviations.2-1. The relay must be provided with a time delay of approximately 20s to prevent undesired response to system swings (long time setting). However. UP = 2 UN + 1 kV) Impulse spark-over voltage <4 × UN . it is advisable. it is recommended to provide an under-frequency protection.: Q Q with high (1. which should be connected between the phases and ground. it is recommended to equip large generators with an inverse-time-delay (impedance relay. however. to provide a two-stage rise-in voltage protection.45 × UN) operating value and instantaneous tripping. i. its relay time should longer than that of the system protection. dependent on the location of the short-circuit. At rated voltage. This may result in the generator and the apparatus connected to it being endangered by unduly high voltages. an alarm is given. the surge diverters are installed in the direct vicinity of the unit transformer. The steam supply to the turbine is interrupted. It is recommended to provide a two-stage load unbalance protection. It is assumed that switching surges due to a load isolator or circuit breaker connected between the generator and transformer will not endanger the generator.4 × UN (allowing for power-frequency overvoltage on load rejection) Power-frequency spark-over voltage: approximately 2 × UN (<test voltage for stator winding. Operating value: about 50-80% of reverse power Relay time: longtime setting: approximately 20 s short-time setting: approximately 4s 10 Overvoltage Protection The use of surge inverters on the high-voltage side of the unit transformer is considered sufficient for protecting the generator against atmospheric over voltage and switching surges in the system. 6 Load Unbalance Protection Generators operating in an interconnected system are normally subjected to small load unbalances only. Operating value: 1. Design principle: Reseal voltage: approximately 1. it is. the unit must be disconnected from the system. A reliable criterion of perfectly tight closure of the emergency stop valves is the flow of power from the system back into the generator.on failure of the system protection. 8 Under-Frequency Protection Major disturbances in an interconnected system may result in operation of the generator at under-frequency. 2. Disconnection of the unit from the system by the generator circuit breaker with a time delay of 4s is only permissible after the reverse power has been drawn by the generator (short-time setting).

Haridwar 2. BHEL.Turbogenerators Tripping Scheme for Description Generator Electrical Protection Initiation of TT GCB FB Differential protection Stator ground fault protection Rotor ground fault protection Underexcitation protection without loss of field with loss of field Over current protection Unbalance load protection Rise-in-voltage protection Under-frequency protection Reverse power Long time short time (operates uonly at TT) TT has been activated TT = Turbine trip GCB = Generator circuit breaker FB = Field breaker Alarm is initiated when the electrical power protection system is tripped. Individual alarms for each criterion are provided.1-8331-0500/1 0709 E .

1 2 3 4 Fig. which ensures that at least one brush will make contact with the rotating shaft journal. Haridwar 3. The brush holders are arranged with 90 0 displacement.Turbogenerators Rotor Grounding System Description Grounding brushes are fitted to the turbine-end stator end shield to remove the static charges of the shafts. Stator end shield 2. Turbine bearing 2. Brush holder BHEL. Rotor shaft 4.1-8350-0500/1 0709 E .1 Arrangement of Brush Holders 1.

Haridwar 5 6 7 8 Insulation Roror shaft Labyrinth ring End shield 2.Turbogenerators Arrangement of Brush Holders for Description Rotor Grounding System 1 2 4 5 3 6 8 7 2 3 1 2 3 4 Brush holder Grounding brush (Design A) Grounding brush (Design B) Brush spindle BHEL.1-8351-0500/1 0709 E .

the alarm devices initiate visual or audible signals in the event of a controlled quantity falling below or exceeding the predetermined limit values. 2.1-8400-0500/1 0709 E .Turbogenerators Operation The supervisory equipment consists of alarms and measuring devices. automatic controls and protective devices which provide for a reduction of the manual supervisory work. Haridwar Measuring Devices and Supervisory Equipment Introduction measuring and alarm devices are combined to form one supervisory. The measuring devices give a visual indication of the system parameters. In many cases. Closely associated with the supervisory equipment are regulating systems. the BHEL.

1. Thermocouples are mainly employed where small time constants require fast temperature indication.Turbogenerators Operation 1 Temperature Tranducers Resistance Temperature Detectors and Thermocouples Resistance Temperature Detectors (RTD’s) RTD’s are used for temperature measurements on the generator. BHEL. the resistance of lead wires RL3 and RL4 from the RTD to the amplifier is negligible. When making measurements with RTD’s the resistance element is exposed to the temperature to be measured. 1.e. 2: Four-wire Connection Leads RL1 and RL2 form the pair of lead wires to the RTD Pt 100. The temperature coefficient amounts to α =3.1-8410-0500/1 0709 E .1. 2. Fig. e. 2 Thermocouples Thermocouples are used for temperature measurements on generator.1 Principle Temperature measurement with thermocouples is carried out as follows: Two conductors of dissimilar materials. to measure the slot temperatures and the cold gas and hot gas temperatures. Long leads are exposed to different temperatures.1 Circuit Connections The two-wire connections so far commonly used involves errors in case of leads. 1. automatic compensation for lead wire resistance including its changes can be achieved by resistance of the two leads forming the pair to the element are always the same. e. it amplifies only the voltage drop across the RTD to the required output voltage level.1 Three wire Connections If a third lead is connected to the element in addition to the two element leads. even if it would be substantially increased be the provision of a safety barrier (explosion protection).g. 1: Resistance Characteristics of Platinum RTD’s 100 Ω The standard reference resistance of the platinum resistance element is 100 ohms.e.2 Four-Wire Connection If the two element leads are not alike or if the threewire method of compensation would be too costly a fourwire circuit should be used. To use the thermoelectric emf for temperature measurement. Haridwar Due to the mostly very high input resistance of amplifier V. i.2 shows the circuit diagram of the four-wire method. the positive and the negative conductor (thermoelectric elements) are joined at one end (hot junction) so as to produce an electromotive force (emf). to measure the generator and exciter bearing temperatures. the free ends of the conductors are exposed to a constant temperature (cold junction temperature) and connected to a milli-voltmeter calibrated in 0C. while the other set of lead wires RL3 and RL4 from the RTD are connected to amplifier V. The magnitude of the emf is dependent upon the temperature difference between the temperature to be measured and that of the other two ends of the conductors. a thermoelectric emf (in mV). The RTD works on the change in electrical resistance of a conductor by the following formula: R = R0 (1+ α T) where R0 α T = reference resistance at 00C = temperature coefficient. i. 1. Being a normal differential amplifier.85×10-3 degC-1 this being the mean value for the range 0 -100 0C. 2.g. and = temperature in 0C Fig. and the lead resistances then reach values in the order of the resistance of the RTD element. Fig.

the large number of thermocouples used on the generator can be connected to a double pole measuring point selector switch enabling the respective thermocouple to be connected to a compensator for measurement. 40 30 20 Cu-CuNi Fe-CuNi NiCr-Ni 10 PtRh-Pt 0 Fig. The compensating leads used for the different thermocouples are identified by colors: Cu-CuNi brown Fe-CuNi blue NiCr-Ni green PtRh-Pt white NiCr-Constantan red The insulating sleeve of the positive lead is provided withe a red mark in addition to the color code. A cold junction at a temperature of 00C can be very easily produced by melting ice.4: Voltage-temperature function for standardised thermocouples 2. Note that in these cases certain corrections must be added to the calibration figure of the particular thermocouple which are referred to 00C. Thermoelectric voltage Utherm in mV 60 50 NiCr-Const.3 Cold Junction For measuring a temperature by means of a 2.NiCu Fe . To obtain a simpler circuit.6 mV/100 deg C ~6.: 5 Circuit arrangement for connection of several thermocouples The cold junction can.1 mV/100 deg C ~0. The electronic cold junction also avoids the temperature error due to the junction between the compensating leads and the copper leads.Pt Ni Cr. continuous oC 400 700 1000 1300 400 Cold junction correction Connecting cables Milli volt meter Compensating resister Fig.3 mV/100 deg C Colour codes Neg. also be implemented by using a Pt100 RTD for determination of the actual temperature.3 mV/100 deg C ~4. however. To do this.Thermocouple Cu . add the thermoelectric emf due to the cold junction temperature to the measured thermoelectric emf and read measuring point temperature to obtain the total thermoelectric emf .NiCu Ni Cr . When exposed to a temperature up to 200 0C they produce the same thermoelectric emf as the associated thermocouple. 2.1-8410-0500/2 0709 E 1 Compensator 2 Genenerator 3 Double pole double throw switch Fig. 3: Thermocouples Parameter ~4.Ni Pt Rh . See DIN 43710 for calibration data and limits of error of compensating leads. pole Pos. .3 mV/100 deg C ~5.pole Red Red Red Red Red Brown Blue Green White Purple Indicator Moving coil thermocouple. The temperature is referred to the calibration figure for 0 o C by electronic means.Constantan 1 Hot junction 2 Thermocouple 3 Compensating lead Temperature limits oC -200 -200 ± 0 ± 0 ± 0 4 5 6 7 - +600 +900 +1200 +1600 +1000 Max.2 Compensating Leads The compensating leads serve to extend the thermocouple up to the cold junction. The use of thermostats with reference junction temperature of 20 0 C and 500C is also possible. the cold junction temperature must be known.

These detectors are utilized as tripping criteria for the generator mechanical equipment protection. 1 Temperature Monitoring 1.3 Primary Water Temperatures The temperature of the hot primary water in the turbine-end water manifold of the stator winding is measured withe manifold of the stator winding is measured with resistance temperature detectors. resistance characteristic. 1 Stator slot resistance temperature detector 1.1-8420-0500/1 0709 E . Haridwar 2 3 4 1 2 3 4 Shutoff valve before level detector Level detector Sight glass Shut off valve after level detector Fig. 2 Level detector When pipes from several low-level points of the generator are connected to a common level detector. high mechanical strength and insensitivity to electrical and magnetic fields. Fig. The RTD’S are characterized by a constant temperature vs. 3 Combined arrangement of Level detectors in Seal oil valve rack 2. 1.2 Cold and Hot Gas Temperatures The temperature of the hot and cold gases are measured by RTD’S upstream and downstream of the hydrogen coolers. The RTD’S are embedded directly in the stator slots between the bottom and top bars at points where the highest temperature are expected. BHEL. 1 2 3 4 5 1 2 3 4 5 Top bar Resistance temperature detector Separator Bottom bar Stator core 2 Stator Liquid Detection Liquid (cooling water from hydrogen coolers.2 and 3. whereas all other detectors initiate only alarms. This platinum measuring wire is embedded in a molded plastic body which provides for insulation and pressure relief. 1 Fig. and the limit values are sensed downsteam of the coolers for use with the hydrogen temperature control system. sight glasses are provided in the inlet pipe to identify the source of the liquid. See Figs. The two pipes extend serval inches above the bottom of the generator terminal box and are interconnected so that both detectors will respond if the box should be in an inclined position.1 Stator Slot Monitoring The slot temperatures are measured with resistance temperature detectors (RTD’S). The generator terminal box has two leakage detection pipes acting on the generator protectors. Temperature detectors located in the generator interior are mounted in gas tight protective tubes welded to the stator frame.Supervision of Generator Turbogenerators Operation The most essential measuring and supervisory devices at the generator serve for: -temperature monitoring -detection of liquid in generator interior. The temperature detectors are mounted in the water manifold in thermowell exposed to the primary water. primary water or seal oil) entering the generator housing is sensed by level detectors assembled in gas tight housing located on the seal oil valve rack.

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The actual measuring point is located at the babbitt/sleeve interface. 1 Bearing temperature measurement 2. To permit a reliable assessment of the running condition. Measurement and recording of the temperatures are performed in conjunction with the turbine supervision. 2 4 Vibration Monitoring The generator and exciter rotors are manufactured with high precision and carefully balanced. result in vibrations during operation. which are transmitted to the stator frame and foundation via the bearings. BHEL. The overall turbine protection is tripped when the maximum permissible temperature is exceeded. vibration pickups are located at the bearings. however.1-8440-0500/1 0709E . The unavoidable residual unbalance will. Measurement and recording of the vibrations are performed in conjunction with the turbine supervision.Turbogenerators Supervision of Bearings Operation 1 Generator Bearing Temperatures 1 2 3 The generator bearing temperatures are measured with thermocouples located in the bearing lower halves. Haridwar 1 2 3 4 Rotor shaft Babbitt Thermocouple Bearing sleeve Fig. The overall turbine protection is tripped when a predetermined amplitude is exceeded.

a pressure switch activates air side seal oil pump-2. The alarm is initiated when the probe is no longer covered with oil. results in an alarm to be initiated when the probe is immersed in oil. The most essential measuring and supervisory devices in the seal oil are: Q Q Q Q 1 Level detectors Pressure and differential pressure gauges Temperature detectors Volume flow measuring devices Level Detectors Within the seal oil systemQ Q Q the oil levels in the TE and EE prechambers the oil levels in the seal oil tank the oil levels in the seal oil storage tank are supervised. set by means of the control orifice. In addition. due to an increase in the amount of seal oil on the hydrogen side of the shaft seal. Seal oil pump 3 is activated via a differential pressure transducer. air side oil pump 3 is automatically started. A low oil level in the seal oil storage tank-only feasible during the start-up phase. Q Seal oil pressure downstream of oil orifice At this pressure gauge the seal oil pressure. The reading is required for setting of the C valve and for visual examination. a pressure switch activates air side seal oil pump-1. Local indication is required for pressure setting of the A2 valve and for visual examination. A low oil level in the seal oil tank is monitored such that an alarm takes place when the probe is no longer covered with oil. Q Pressure downstream of air side seal oil pump 2 On failure of seal oil pump-2. A high oil level in the generator prechambers. Haridwar 2.Turbogenerators Supervision of Seal Oil System Operation The location of the transmitters of the measuring and supervisory equipment in the seal oil system is shown in the seal oil diagram [1]. Q TE and EE ring relief pressure The pressure gauges indicate the relief pressure sit by means of the manual control valves. can be observed. 2 Pressure and Differential Pressure Gauges The following pressure measuring points are provided: Q Pressure downstream of air side seal oil pump-1 On failure of seal oil pump-1.1-8450-0500/1 0709 E . If the later is not ready for operation. Q Pressure downstream of hydrogen side seal oil pump A pressure switch signals a failure of the oil supply. If the later is not ready for operation. Local indication is required for pressure setting of the A1 valve and for visual examination. which detects the pressure differential between the generator casing pressure and the air side seal oil. pressure transmitters are provided for further processing of the pressure signals. and a pressure switch when pressure falls below the preset set point value.results in an alarm for protection of the air side pumps. This prevents dry running of the hydrogen side seal oil pump. Q Pressure in hydrogen side seal oil circuit of shaft seal This pressure gauge serves for local observation of BHEL. Q Pressure downstream of air side seal oil pump 3 A pressure switch signals the takeover of the seal oil supply by seal oil pump 3. Q H2 casing pressure This pressure gauge reading is required for setting the pressure differential between the air side seal oil pressure and the H2 casing pressure. An additional pressure switch initiates miscellaneous alarms and is used for Off control of the hydrogen side seal oil pump. Q Pressure downstream of air side seal oil pumps Readings from this pressure gauge are required for pressure setting of the A1 and A2 valves. air side seal oil pump 3 is automatically started. Local indication is required for pressure setting of the A1 valve and for visual examination.

1-7111 Seal Oil Diagram . the following temperatures are measured by means of resistance temperature detectors for remote indication : Q Q Q 4. TE Also refer to the following section [1] 2. Cooling water temperature upstream and 2. Pressure differentials are sensed at the following points: Pressure differential between the air side seal oil before TE and EE shaft seals and the generator casing pressure is sensed by transducers which initiate an alarm on falling pressure differential. 3. Seal oil temperature upstream and downstream of hydrogen side seal oil coolers. Differential Pressure Indication at Air . Temperature Detectors The following temperatures are measured locally with thermometers : In addition. Seal oil temperature downstream of air side and hydrogen side seal oil coolers. Seal oil temperature upstream and downstream of air side and hydrogen side seal oil coolers. Q Q Seal oil temperature upstream and downstream of air side seal oil coolers.the set seal oil pressure at the shaft seal. EE hydrogen side seal oil. TE hydrogen side seal oil.1-8450-0500/2 0709 E Volume Flow Meter System The following volume flows are measured for comparison measurements : Q Q Q Seal oil temperature in hydrogen side seal oil drain. Q Q Q Q Volume Volume Volume Volume Volume Volume flow flow flow flow flow flow of of of of of of EE seal ring relief oil TE seal ring relief oil air side seal oil.Cooled Hydrogen Side Seal Oil Filters The indicators display the degree of filter contamination and activate an alarm at preset pressure differentials. Local indication is provide for manual adjustment of the pressure regulating valves and for visual examination. downstream of air side and hydrogen side seal oil coolers. TE and EE. EE air side seal oil.

temperature detectors are used for supervision of CO2 flash evaporator.1-7211 Gas Diagram [2] refer Operation and maintenance manual of the Gas analyser cabinet BHEL. on completion of the measurement. The H2 casing pressure can be read at a local pressure gauge. Q H2 pressure at pressure reducers. the pressure is sensed with a pressure transmitter. 4 Temperature detectors Within the gas system. Q H2 bottle pressure The bottle pressure can be read at the pressure gauge. The pressure switch activates a signal at low H2 pressure. Haridwar 2. Q H2 casing pressure The pressure is sensed by pressure transmitters. Q N2 bottle pressure The bottle pressure can be read at a local pressure gauge. The temperatures of the heat transfer liquid in CO2 flash evaporator is detected by means of RTD and used for control functions. refer Operation and maintenance manual of the Gas analyser cabinet [2]. and. the temperature of heat transfer liquid in the CO2 flash evaporator is indicated locally by a thermometer. The measuring gas volume flow can be read locally at the flow meter. For observation of the pressure settings. where the hydrogen is replaced with carbon dioxide and the carbon dioxide in turn with air. In addition. The gas purity meter system is also used when removing the hydrogen from the generator. Als refer to the following sections [1] 2. The signals of the remaining two transmitters are converted into alarm and control signals. In addition. The gas required for the measurement is taken from the generator or from the filling lines. 3 Pressure Gauges The following measuring points are provided : Q CO2 bottle pressure The bottle pressure during CO2 filling can be observed at a local pressure gauge. a precisely defined measuring gas flow must be admitted to the gas purity meter system. the electrical signal of one pressure transmitter being used for remote control and supervision. The gas purity meter system is equipped with a limit switch which provides a signal to initiate an alarm when the purity drops below a preset value. 2 Volume Flow System Q Measuring gas volume flow For comparison measurement. For details on the gas purity meter system. The essential measuring and supervisory devices in the gas system are : Q Q Q Q 1 Purity meter systems Volume flow meter system Pressure gauge Temperature detectors Gas Purity Meter System The gas purity meter system measures the purity of the hydrogen gas in the generator as well as the composition of the gas mixtures (CO2/ air and H2/ CO2) during filling of the generator.1-8460-0500/1 0709 E . the electrical signal being used for remote control and supervision.Turbogenerators Supervision of Gas System Operation The location of the transmitters of the measuring and supervisory equipment in the gas system is shown in the Gas Diagram [1]. respectively. is discharged to the atmosphere through a vent line.

If the flow falls below a minimum value. A local water level gauge is located in parallel to the electrical monitoring system. an alarm is activated. Pressure downstream of primary water pump 2 5 Temperature Detectors The following temperatures are measured locally by means of thermometers: Volume Flow Meter System Primary water temperature downstream of coolers Q Cooling water temperature upstream and downstream of coolers Q Primary water temperature downstream of bushings Q The primary water volume flows of the stator winding and bushings are measured and indicated by a differential pressure flow meter system.Turbogenerators Supervision of Primary Water System Operation The location of the transmitters of the measuring and supervisory equipment in the primary water system is shown in the Primary Water diagram [1]. The measuring point in the primary water inlet of the generator permits the conductivity of the entire cooling system to be assessed. Q 2 3 Gas pressure in primary water tank A pressure switch activates an alarm at rising gas pressure in the primary water tank. Haridwar 2. Resistance temperature detectors are used to measure the followings temperatures for further processing according to different methods: Primary water temperature upstream and downstream of coolers Q Primary water temperature downstream of stator winding Q Primary water temperature downstream of bushings Q Primary water temperature downstream of coolers Q 4 Pressure Gauges Pressure or pressure differentials are sensed at the following measuring point in the primary water cooling circuit: Q Pressure downstream of primary water pump 1 Also refer to the following section [1] 2. a pressure gauge is provided downstream of each pump for local observation of the pressure.1-8470-0500/1 0709 E . The amount of water added to the system during operation is determined by a water meter. If the flow continues to fall. The amount of primary water flowing though the ion exchanger is monitored by a local flow meter. The pressure gauge is provided for local observation. a high or low water level initiating an alarm. a pressure gauge is provided for local observation of the tank gas pressure. Both measuring devices are equipped for indication and alarm. Q Q Differential pressure across main filter Differential pressure across fine filter Differential pressure transmitters are provided across both these filters for indication of differential pressure and also for initiating alarm. Q The measuring point downstream of the ion exchanger checks the ion exchanger for proper performance. In addition.1-7311 Primary Water Diagram BHEL. The essential measuring and supervisory devices in the primary water system are: Q Q Q Q Q 1 Conductivity meter system Level monitoring system Volume flow meters Pressure gauges Temperature detectors Conductivity Meter System The conductivity of the primary water is monitored: Q Q Downstream of ion exchanger Upstream of primary water inlet of generator Q The two pressure measuring points are equipped with pressure switches and are required for automatic control of the two primary water pumps. The pressure switches initiate an alarm at rising primary water pressure. Level Monitoring System The water level in the primary water tank is sensed by capacitive method. the generator mechanical equipment protection is tripped. In addition. Pressure upstream of stator winding This pressure measuring point is equipped with pressure switches and a local pressure gauge.

One is connected to the star point of the three-phase winding of the main exciter and the other to the frame.Turbogenerators Supervision of Exciter Operation The most essential measuring and supervisory devices at the exciter are: Q Q Q Q 1 Temperature monitoring system Fuse monitoring system Ground fault detection system Excitation current measuring device Temperature Monitoring System The exciter is provided with devices for monitoring the temperatures of the cold air after the exciter cooler and the hot air leaving the rectifier wheels and hot air leaving the rectifier wheels and main exciter. 3 Ground Fault Detection System Two sliprings are installed on the shaft between the main exciter and bearing. 4 Excitation Current Measuring Device The excitation current is measured indirectly through a coil arranged between two poles of the main exciter. Haridwar wheels may be checked during operation with the builtin stroboscope. These sliprings permit ground fault detection. The voltage induced in this coil is proportional to the excitation current thus enabling a determination of the excitation current. 2 Fuse Monitoring System The indicator flags of the fuses on the rectifier BHEL. 2.1-8490-0500/1 0709 E .

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The three-phase AC generated by the permanent-magnet pilot exciter is rectified and controlled by the AVR to provide a variable DC current for exciting the main exciter. This contact system is also designed to compensate for length variations of the leads due to thermal expansion. This three-phase AC induced in the rotor of the main exciter is rectified by the rotating rectifier bridge and fed to the field winding of the generator rotor through the DC leads in the rotor shaft. The three-phase pilot exciter has a revolving field with BHEL. The arrangement of the diodes is such that this contact pressure is increased by the centrifugal force during rotation. Haridwar The exciter rotor shown in fig.1-9100-0500/1 0709 E . 3 shows additional components contained in the rectifier wheels. Two diodes each are mounted in each aluminum alloy heat sink and thus connected in parallel. Mechanical coupling of the two shaft assemblies results in simultaneous coupling of the dc leads in the central shaft bore through the Multicontact electrical contact system consisting of plug-in bolts and sockets. 1 Basic Arrangement of Brushless Excitation System With Rotating Diodes Fig. The exciter shaft is supported on a bearing between the main and pilot exciter. the rotor of the main exciter and the permanent-magnet rotor of the pilot exciter. 2 Rectifier Wheels The main-components of the rectifier wheels are the silicon diodes which are arranged in the rectifier wheels in a three-phase bridge circuit. 2. 5 4 3 2 1 3 4 1 5 6 1 2 3 4 5 7 Coupling Rectifier wheel Rotor of main exciter Fan Permanent magnet rotor Fig. The shaft is rigidly coupled to the generator rotor. A common shaft carries the rectifier wheels. 2 corresponds to the basic arrangement described above.Exciter Turbogenerators Description 1 Design Feature The exciter consists of -Rectifier wheels -Three-phase pilot exciter -Cooler -Metering and supervisory equipment 2 permanent magnet poles. The contact pressure for the silicon wafer is produced by a plate spring assembly. Fig. The three-phase AC is induced in the rotor of the main exciter. 1 shows the basic arrangement of the exciter. The generator and exciter rotors are thus supported on total of three bearings. 2 Exciter Rotor 8 9 10 1 Automatic voltage regulator 2 Permanent magnet pilot exciter 3 Sliprings for field ground fault detection 4 Quadrature-axis measuring coil 5 Three-phase main exciter 6 Diode rectifier set 7 Three-phase lead 8 Multicontact connector 9 Rotor winding of turbogenerator 10 Stator winding of tubogenerator Fig.

4. After full impregnation with synthetic resin and curing. Fuse 5 3. A journal bearing is arranged between main exciter and pilot exciter and has forced oil lubrication from the turbine oil supply. Exciter armature 6. 8. The winding conductors are transposed within the core length.1-9100-0500/2 7 3. which are combined in a single resinencapsulated unit. The two wheels are identical in their mechanical design and differ only in the forward directions of the diodes. This arrangement ensures good accessibility to all components and a minimum of circuit connections. the complete armature rotor is shrunk onto the shaft. The conductors are attached by means of banding clips and equipped with screw-on lugs for the internal diode connections. Diode Rectifier Wheel 6 3 2. Diode 3. 3 Rectifier Wheel Associated with each heat sink is a fuse which serves to switch off the two diodes if one diodes fails (loss of reverse blocking capability). The three-phase winding is inserted in the slots of the laminated armature rotor. The three-phase alternating currents is obtained via copper conductors arranged on the shaft circumference between the rectifier wheels and the three-phase main exciter. 4 Main Exciter compression rings. The direct current from the rectifier wheels is fed to DC leads arranged in the center bore of the shaft via radial bolts.1 2 1. The field winding is arranged on the laminated magnetic poles. The armature rotor consists of stacked laminations. Their ends being connected so as to form a damper winding Between two poles a quadrature-axis coil is fitted for inductive measurement of the exciter current. For suppression of the momentary voltage peaks arising from commutation. 4 Three-Phase Pilot Exciter The three-phase pilot exciter is a 16 pole revolving-field unit. The winding ends are run to a bus ring system to which the three-phase leads to the rectifier wheels are also connected. Exciter main stator Fig. The frame accommodates the . 7. The connections are made on the side facing the rectifier wheels. The insulated and shrunken rectifier wheels serve as DC buses for the negative and positive side of the rectifier bridge. each wheel is provided with six RC network consisting of a capacitor and a damping resistor each. which are compressed by through bolts over 2. and the end turns of the rotor winding are secured with steal bands. 8 3 4 Stator Amature Rotor Sliprings for ground fault detection Bearing housing Fig. 3 Three-Phase Main Exciter The three-phase main exciter is a six-pole revolvingarmature unit. At the pole shoe bars are provided. Wound armature 3 4 4. Diode Rectifier Wheel 5. Arranged in the stator frame are the poles with the field and damper winding.

While the generator is running. The cooling air is circulated BHEL. The exciter is air cooled. The magnets are braced between the hub and the external pole shoe with bolts.1-9100-0500/3 0709 E . 5 Cooling of Exciter Replacement of Air Inside Exciter Enclosure When the generator is filled with hydrogen (operation or standstill) an adequate replacement of the air inside the exciter enclosure must be ensured. The air volume inside the exciter enclosure requires an air change rate of 125 m3/h. the air dryer of the exciter unit discharges dry air inside the exciter enclosure. Each pole consists of 12 separate permanent magnets which are housed in a non-magnetic metallic enclosure. The magnet hub is shrunk onto the free shaft end. 5 Permanent-Magnet Pilot Exciter laminated core with the three-phase winding. The air leaves the exciter enclosure via the leakage air filter and the leakage air outlet at the shaft as well as via the bearing vapor exhaust system if this system is in service. Haridwar 2. The complete exciter is housed in an enclosure draw the cool air in at both ends and expel the warned air to the compartment beneath the base plate. The volume of air extracted from the cooling air circuit is replaced via the filters located at the top of the enclosure. 6 1 1 2 3 2 3 Stator Pilot exciter Stator winding Permanent magnet rotor Fig. The main exciter enclosure receives cool air from the fan after it passes over the pilot exciter. The air enters the main exciter from both ends and is passed into ducts below the rotor body and discharged through radial slots in the rotor core to the lower compartment. the air leaving the exciter enclosure via the bearing vapor exhaust system and the leakage air outlet in the foundation provides for a pull-through system. The rotor consists of a hub with mounted poles.Turbogenerators Exciter Description in a closed circuit and cooled in two cooler sections arranged alongside the exciter. The warm air is then returned to the main enclosure via the cooler sections. When the generator is at rest.

Turbogenerators Description Basic Arrangement of Brushless Excitation System 2 3 1 4 5 6 7 8 9 10 1 Automatic voltage regulator 6 Diode rectifier set 2 Permanent magnet pilot exciter 7 Three-phase lead 3 Sliprings for field ground fault detection 8 Multicontact connector 4 Quadrature-axis measuring coil 9 Rotor winding of turbogenerator 5 Three-phase main exciter 10 Stator winding of tubogenerator BHEL. Haridwar 2.1-9101-0500/1 0709 E .

Turbogenerators Rectifier Wheels Description 1 ~ 2 3 4 5 Current path 6 - 7 8 + 9 4 3 2 10 + 1 2 3 4 5 AC lead Fuse Heat sink Diode Rectifier wheel (+ve polarity) BHEL.1-9102-0500/1 0709 E . Haridwar 6 7 8 9 10 _ Hot air outlet Tension bolt Terminal bolt Rectifier wheel (-ve polarity) DC lead 2.

1-9103-0500/1 0709 E .Turbogenerators Rectifier Wheels and Coupling Description 1 2 3 4 5 6 7 Exciter coupling without Contact pin BHEL. Haridwar 1 2 3 4 5 6 7 8 Balancing Weight Fuse Rectifier wheels Diode Multi Contact band DC lead Coupling Contact pin 7 8 Exciter coupling with Contact pin 2.

Turbogenerators Permanent-Magnet Description Pilot Exciter Rotor and Fan 4 1 1 2 3 4 BHEL. Haridwar 5 2 3 4 Permanent magnet pole Fan Sliprings of field ground earth fault detection Rotor of main exciter 2.1-9104-0500/1 0709E .

Haridwar 2.1-9110-0500/1 0709 E .Turbogenerators Exciter Cross Section General 1 20 1 2 3 4 5 Coupling with connector Fuse Heat sink Rectifier wheels Diode 2 3 4 19 5 18 6 7 8 9 10 Magnetic pole of main exciter Main exciter rotor Main exciter stator Sliprings for ground fault detection Bearing 6 7 8 9 17 10 16 11 12 13 14 15 Radial flow fan Pilot exciter stator Pilot exciter rotor Exciter enclosure Foundation 16 17 18 19 20 11 12 13 14 15 Cooler Armature balancing ring Air housing Base frame DC lead BHEL.

During operation Hot air Cold air Section C-D Section A-B A to bearing vapour exhauster Description Leakage air and makeup air Exciter cooling Air circuit C Turbogenerators BHEL. Haridwar 2.1-9120-0500/1 0709 E .

The Observation period for one full revolution of the rectifier wheel (360 0) is approximately 25 seconds. If this period should not be sufficient for fuse checking. The capacitor and high-voltage transformer required to produce the firing pulses for the flash tubes are located on a printed circuit board which is accommodated in the handle of the flash lamp. At approximately 4500. The tubes. The stroboscope is located in the rectifier wheel and exciter enclosure so that the fuses may be observed from outside the exciter enclosure while controlling the stroboscope. The fuses on the rectifier wheels may be checked during operation with the stroboscope. The stroboscope contains four plug-in printed circuit boards which can be readily replaced in order to remedy any faults. a stationary image is obtained which ensures accurate checking of a single fuse. Haridwar 2. switching on the stroboscope for another two minutes without delay can be repeated for any desired number of times by depressing the On push-button. Fig. A separate flash tube is provided for each wheel (A and B). the two connectors for the flash lamps and the fuse are located on the back of the control unit. are permanently installed in the rectifier wheel enclosure. To synchronize the sequence of flashes with the generator rotation. The cables are run in flexible metal hoses for protection against mechanical damage. After approximately two minutes. and the observation can be repeated. A depressed push-button is indicated by an illuminated dot in the pushbutton head.Turbogenerators Stroboscope for Fuse Monitoring Description sequence of flashes can be interrupted at any time by actuating the Feed or Return push-button. Following this.1 2 3 4 5 67 8 5 Feed pushbutton 6 Pilot lamp for control voltage 7 Return pushbutton 9 10 8 On pushbutton 9 Off pushbutton 10 Flash tube 2 (B wheel) Components and Operating Elements of Stroboscope BHEL. The operating elements are located on the front panel of the control unit for ease of operation. All connectors have a mechanical lock and are protected against dust and splash water. The tubular lamps are connected to the control unit by cables. The continuous 1 1 Flash tube 1 (A wheel) 2 Control unit 3 Pushbutton for flash tube 1 4 Pushbutton for flash tube 2 Fig.1-9140-0500/1 0709 E . A double synchronous motor. the system frequency is utilized to activate the flashes. 1 shows the basic arrangement of a fully transistorized stroboscope The electronics required for control of the light signals are contained in the control unit and in the tubular lamps. the flash is reset to its initial rate. controlled through two push-button and connected to two potentiometers and IC's. This permits easy monitoring without any adjustment outside the exciter enclosure being required. the stroboscope is automatically switched off. causes the flash to be timed so that a slow-motion observation of the fuse becomes possible. The line connector. which are supplied through a common control unit.

3 Anti-condensation Heating System An Anti-condensation heating system to support the dryer is installed in the exciter base frame. The moisture absorbed by the dryer wheel is removed in a regeneration section by a stream of hot air directed through the wheel in the opposite direction of the inlet air and then discharged to the atmosphere.1-9150-0500/1 0709 E . lithium chloride. the wheel is provided with a system of tubular ducts. Continuous rotation of the dryer wheel ensures continuous dehumidification of the air within the exciter.1 Operating Principle of Adsorption Dryer The dehumidification takes place in a slowly rotating dryer wheel (approximately 7 revolutions per hour). the surfaces of which are impregnated with a highly hygroscopic material. The heaters are rated and arranged so that the temperature in the exciter interior. The tubular ducts are dimensioned so that a laminar flow with low pressure loss is obtained even at high air velocity.2 Regeneration Section In the regeneration section of the dryer wheel. i.Turbogenerators Exciter Drying System Description 1 General A dryer (dehumidifier) and an anti-condensation heating system are provided to avoid the formation of moisture condensate inside the exciter with the turbine-generator at rest or on turning gear. using separate air streams. 1 Schematic Diagram of Dryer removed as a result of the partial pressure drop existing between the air and the adsorbent material.e. 2. After regeneration.1 Adsorption Section The air to be dehumidified passes through the BHEL. 2. the accumulated moisture is removed from the dryer wheel by the heated regeneration air. The adsorption of moisture and regeneration of the dryer wheel material take place simultaneously. 2. 2 adsorption section of the dryer wheel. 2.1. The moisture is 1 2 3 4 5 Mode of Operation The dryer dehumidifies the air within the exciter enclosure. On its inlet side. the dryer wheel material is again capable of absorbing moisture. which ensures a continuous drying of the air. The inlet side of the dryer wheel is subdivided so that 1/4 is available for regeneration and 3/4 for the adsorption section.1. with part of the moisture contained in the air being removed by the adsorbent material. The honeycomb dryer wheel consists of a magnesium silica alloy containing crystalline lithium chloride. The dryer wheel is made of a nonflammable material. Haridwar 5 4 1 2 3 4 5 6 7 6 7 Regeneration air outlet Dryer wheel Heater Ventilator Filter Shutoff valve Dry air outlet Fig.

because a double fault causes magnetic unbalances with very high currents flowing through the faulted part. if possible. For this reason. 2.1-9180-0500/1 0709 E . It is very important for safe operation of a generator. If the field ground fault detection system detects a ground fault. If the insulation resistance between the exciter field circuit and ground either suddenly or slowly drops to RE < 5 kΩ the generator electrical protection is tripped (2nd stage). before the fault can fully develop. an alarm is activated at RE < 80 kΩ (1st stage). resulting in its destruction within a very short time.Turbogenerators Description The field ground fault detection system detects highresistance and low-resistance ground faults in the exciter field circuit. It is therefore an essential requirement that even simple ground faults should activate an alarm and protective measures be initiated. the field ground BHEL. Haridwar Ground Fault Detection System for Exciter Field Circuit fault detection system consists of two stages and operates continuously. The generator is thus automatically disconected from the system and de-excited.

Haridwar 2.Turbogenerators Arrangement of Bursh Holders for Description Ground Fault Detection System A B 1 2 3 4 7 5 1 2 3 4 5 6 7 6 Measuring sliprings Measuring brush Mounting plate Brush carrier segment Plug-in brush holder Measuring rod Measuring leads Section A-B BHEL.1-9181-0500/1 0709 E .

1-9182-0500/1 0709 E .Turbogenerators Brush Holders for Ground Fault Description Detection System 1 2 3 4 5 1 2 3 4 5 6 Handle Bayonet sleeve Brush contact pressure adjustment Compression spring Brush pigtail Measuring brush 6 BHEL. Haridwar 2.

Separate tables are provided for the various design groups of the generator and its auxiliaries.Turbogenerators Operating and Setting Values Operation General Strict observance of the operating and setting values is a prerequisite for reliable operation of the Turbogenerators. All operating and setting values refer to rated output of generator and maximum cooling water temperatures under steady-state conditions. such as static head in case of pressure measuring p o i n ts o r t h e r m a l c h a r a c t e r i s t i c s i n c a s e o f temperature measuring points. The Remark column contains additional information on controls.3-4000-0500/1 0709 E . They show the transmitters activating the controls and alarms as well as the transmitters acting on the generator protection circuits. Haridwar The operating and setting values initially specified in this manual are based on experience under due consideration of the specific site conditions. These settings require certain corrections to account for the actual conditions. 2. temperatures and pressures. The final settings obtained after startup and initial load operation are to be entered in the Operating Value column. BHEL. These calculated values are intended as guiding values for making the preliminary settings during initial commissioning of the unit.

) * It is assumed that generator is at rest during gas filling and removal.p.p.)/addition 100 m3 (s.p.t.) + consumption** V2 = p e.p.V Operation Recommended Stock Startup : Not permitted 3.V N2 Reduction of O2 content of Primary water: 50 m3 (s.013 bar BHEL.t.p.) 6 m3 (s.) : 100 .) s.t.p.5 m3/hr (s. Haridwar 2.t.) compressed air from air system must be ensured Not permitted in generator housing* : Air V1 = 3.t.300 dm3/hr (s. the purity deteriorates so that more gas is required for scavenging.p. V1 Replacement of CO2 in generator housing*: H2 V1 = 2. V1 During operation : 2. Due to the whirling motion between the medium to be displaced and medium admitted.) Reduction of H2 Reduction of O2 content of Primary content of Primary water introduced by water to be drained: makeup warer: 10 m3 (s.Turbogenerators Gas Quantities Operation Gas CO 2 Startup Shutdown Replacement of air in Generator housing*: Replacement of H2 in Generator housing*: V1 = 2.V Replacement of CO2 Not required Supply of 40-60 dm3 /s (s. = Standard temperature and pressure.t.t.p.( V1 + V2) 0.5 V Filling to operating pressure : Compensation for H2 losses : Not required 2.3-4010-0500/1 0709 E .t.t. Filling during turning gear operation will result in a higher gas consumption.t.V V1 = 2. ** Consumption: H2 purity measurement Primary water leakage monitoring system Primary water purging gas system : 20 dm3/hr (s.) : 120 dm3/hr (s.p.p. 0oC and 1.

t.t.2 It should be taken into consideration that the bottle contents cannot be completely used up.t.) CO2 bottle volume.p.p.t.p. This means approximately 3% of the bottle contents at a final pressure of 4 bar will remain following a fill to 3 bar. V = 4 .) V ----1 = V4 = 170 m 3 (s.) 3 .) = 10 m 3 (s. e.) V2 ---V3 = 340 m 3 (s. 85 m3 = 340 m3 (s.= ----------------. V = 3 .3-4010-0500/2 .t.) V1 ---V3 = 213 m3 (s. e. 85 m3 = 170 m3 (s. H2 and air required for filling.t.3 Bottle Volume H2 bottle 40 Liters at 150 bar H2 bottle 50 Liters at 200 bar = 6 m3 (s.g. V = 2 . 85 m3 = 255 m3 (s. 6 M3 (s.1 Filling Amount of H2 required to fill generator to operating pressure (operating pressure in bar x generator volume) V2 Z = = V1 Z = 2 .) Amount of compressed air required for removing CO2 (3 generator volumes) V1 = Amount of CO 2 required for removing air from generator (2 generator volumes) Pe .) -------------------. 85 m3 = 170 m3 (s.t.) Number of bottles required 1.t.t.5 . 15 M 3 (s.p. The values for other generator sizes.p.5 .In the following. e. 2.p. 1 Pe V V1 V2 V3 V4 Z Example = = = = = = = Operating pressure.p.) -------------------.p.) Z = 170 m3 (s.7 = 25.p.t.p.t.p.p. 85 m3 (s.p. a sufficient number of full CO 2 bottles must be available prior to starting with any generator filling operations.t.g.2 Purging Amount of CO 2 required for removing H 2 (2 generator volumes) V1 = 2 . e.~ 12 CO2 bottles V4 15 m3 (s. * For reasons of safety.) 1.t. 85 m3 Amount of gas to fill or purge generator Amount of gas to fill generator to operating pressure H2 bottle volume.) CO2 bottle : 40 Liters = 15 m 3 (s.) 1. operating pressures and gas bottle sizes will vary accordingly.t. an example is given to illustrate the calculation of the amounts of CO2. In the example one given generator volume and one given operating pressure are assumed.t.p.p.g.t.p.) V1 ---. For H2 bottles it is assumed that the contents can be expanded to a pressure of approximately 1 bar above the operation pressure. 4 bar Generator volume.t.g.) -------------------.5 generator volumes) V1 Z = = 2.) Amount of H 2 required for removing CO 2 from generator (2.t.p.p.~ 12 CO2 bottles 15 m 3 (s.~ 35 H2 bottles 6 m3 (s. V = 2.~ 57 H 2 bottles 6 m3 (s.) 45 = 17 66.

STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (TE) DEG.C CuCuNi MKY00GC111 - X MKA 11 CT011 TEMP.C CuCuNi MKY00GC111 GAMP - MKA 11 CT004 TEMP.LINE COMMON ANN.LINE COMMON ANN.(TE+EE) REV . WITH MKA07CL001 ATRS - - - - - X >MAX X <MAX LVL BELOW CASING C. PRESS. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (TE) DEG. PRESS. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (TE) DEG.(TE+EE) COMMON ANNUNCIATION FOR STATOR CORE TEMP. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (TE) DEG.C CuCuNi MKY00GC111 GAMP - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR X >MAX X <MAX LVL BELOW CASING C.C CuCuNi MKY00GC111 - X MKA 11 CT007 TEMP.(TE+EE) COMMON ANNUNCIATION FOR STATOR CORE TEMP. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (TE) DEG. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (TE) DEG.2. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (TE) DEG.C CuCuNi MKY00GC111 - X MKA 11 CT005 TEMP. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (TE) DEG.C CuCUNi MKY00GC111 - X MKA 11 CT003 TEMP. -50+50 dPG - - LOCAL 0-149-00-01185 (TE) mBAR - - - - MKA 07 CLOO1 OIL LEVEL IN - LS - CXW01B - PRECHAMBER (EE) - COC MKY01GC001A GAMP - MKA 07 CP501 SO DIFF.(TE+EE) COMMON ANNUNCIATION FOR STATOR CORE TEMP. -50+50 DPG - - LOCAL 0-149-00-01185 (EE) mBAR - - - - 0-149-00-01185 4 SERVICE MKA 11 CT001 TEMP. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (TE) DEG.(TE+EE) COMMON ANNUNCIATION FOR STATOR CORETEMP. WITH MKA06CL001 ATRS - - - - X >90 C - - - - - - X >90 C - - - - - - X >90 C - - - - - - X >90 C - - - - - - X >90 C - - - - - - X >90 C - - COMMON ANNUNCIATION FOR STATOR CORE TEMP.C CuCuNi MKY00GC111 GAMP - MKA 11 CT006 TEMP.C CuCuNi MKY00GC111 GAMP - MKA 11 CT008 TEMP.C CuCuNi MKY00GC111 GAMP - MKA 11 CT002 TEMP.C CuCuNi MKY00GC111 GAMP - MKA 11 CT010 TEMP.3-4030-10553/4 0709E SLNO 1 2 3 TAG PID_REF 5 6 7 8 9 10 11 12 13 14 15 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC MKA 06 CL001 OIL LEVEL IN - LS - CXW01B - 0-149-00-01185 PRECHAMBER (TE) - COC MKY01GC001A GAMP - MKA 06 CP501 SO DIFF.(TE+EE) COMMON ANNUNCIATION FOR STATOR CORE TEMP.C CuCuNi MKY00GC111 - X MKA 11 CT009 TEMP. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (TE) DEG. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (TE) DEG.

C CuCuNi MKY00GC111 - X MKA 12 CT001 TEMP.HIGH COMMON ANNUNCIATION FOR STATOR CORE TEMP. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -04 DEG.HIGH COMMON ANNUNCIATION FOR STATOR CORE TEMP.C Pt 100 - - X MKA 12 CT005 TEMP.C Pt 100 - - X MKA 12 CT003 TEMP.C Pt 100 - - X MKA 12 CT013 TEMP. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -25 DEG.HIGH COMMON ANNUNCIATION FOR STATOR CORE TEMP.C Pt 100 - GAMP - MKA 12 CT002 TEMP. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -09 DEG.HIGH COMMON ANNUNCIATION FOR STATOR CORE TEMP.C Pt 100 - GAMP - MKA 12 CT010 TEMP. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -20 DEG. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -12 DEG.C Pt 100 - GAMP - MKA 12 CT014 TEMP.HIGH COMMON ANNUNCIATION FOR STATOR CORE TEMP. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -12 DEG. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -01 DEG.HIGH COMMON ANNUNCIATION FOR STATOR CORE TEMP. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -25 DEG.C Pt 100 - GAMP - MKA 12 CT012 TEMP.HIGH REV .C Pt 100 - GAMP - MKA 12 CT004 TEMP.C Pt 100 - GAMP - MKA 12 CT006 TEMP. STATOR CORE (TE) RANGE UNIT 0-150 SENSOR TYPE TC JB1 JB2 MKA01GC021A CAB1 CAB2 IND REC - - DEG.C Pt 100 - - X MKA 12 CT009 TEMP.C Pt 100 - - X MKA 12 CT011 TEMP.SLNO 16 TAG PID_REF MKA 11 CT012 0-139-00-01223 17 18 19 20 21 22 23 24 25 26 27 28 2. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -20 DEG.C Pt 100 - GAMP - MKA 12 CT008 TEMP.3-4030-10553/5 0709E 29 30 SERVICE TEMP. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -17 DEG.C Pt 100 - - X ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - - - - X >80 C - - - - - - X >80 C - - - - - - X >80 C - - - - - - X >80 C - - - - - - X >80 C - - - - - - X >80 C - - - - - - X >80 C - - - - - - COMMON ANNUNCIATION FOR STATOR CORE TEMP. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -17 DEG. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -09 DEG. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -01 DEG. STATOR 0-100 RTD MKA01GC001B - - 0-139-00-01223 SLOT -04 DEG.C Pt 100 - - X MKA 12 CT007 TEMP.

C Pt 100 - GAMP - MKA 12 CT024 TEMP. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (EE) DEG. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -28 DEG.HIGH COMMON ANNUNCIATION FOR STATOR CORE TEMP.2. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -33 DEG.C CuCuNi MKY00GC112 GAMP - MKA 13 CT004 TEMP.C Pt 100 - GAMP - MKA 12 CT016 TEMP. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -44 DEG. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -28 DEG. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (EE) DEG.HIGH COMMON ANNUNCIATION FOR STATOR CORE TEMP.(TE+EE) REV .HIGH COMMON ANNUNCIATION FOR STATOR CORE TEMP.C CuCuNi MKY00GC112 GAMP - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR X >80 C - - - - - - X >80 C - - - - - - X >80 C - - - - - - X >80 C - - - - - - X >80 C - - - - - - X >90 C - - - - - - X >90 C - - - - - - X >90 C - - COMMON ANNUNCIATION FOR STATOR CORE TEMP.C CuCuNi MKY00GC112 - X MKA 13 CT005 TEMP. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (EE) DEG.HIGH COMMON ANNUNCIATION FOR STATOR CORE TEMP.C CuCuNi MKY00GC112 - X MKA 13 CT003 TEMP.C Pt 100 - - X MKA 12 CT021 TEMP.C Pt 100 - - X MKA 12 CT019 TEMP. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -41 DEG. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -41 DEG. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -44 DEG. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (EE) DEG. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -36 DEG. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -36 DEG.C Pt 100 - - X MKA 12 CT023 TEMP.3-4030-10553/6 0709E SLNO 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 TAG PID_REF SERVICE RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC MKA 12 CT015 TEMP.C Pt 100 - GAMP - MKA 12 CT022 TEMP. STATOR 0-100 RTD MKA01GC001C - - 0-139-00-01223 SLOT -33 DEG.C Pt 100 - GAMP - MKA 12 CT018 TEMP.(TE+EE) COMMON ANNUNCIATION FOR STATOR CORE TEMP. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (EE) DEG.C Pt 100 - - X MKA 13 CT001 TEMP.C CuCuNi MKY00GC112 GAMP - MKA 13 CT002 TEMP.HIGH COMMON ANNUNCIATION FOR STATOR CORE TEMP.C Pt 100 - - X MKA 12 CT017 TEMP.(TE+EE) COMMON ANNUNCIATION FOR STATOR CORE TEMP.C Pt 100 - GAMP - MKA 12 CT020 TEMP.

(TE+EE) COMMON ANNUNCIATION FOR STATOR CORE TEMP. & ATRS X >MAX X <MAX COMMON ANNUN. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (EE) DEG.(TE+EE) COMMON ANNUNCIATION FOR STATOR CORE TEMP.. LVL ABOVE BOTTOM OF CASING X >MAX X >MAX 2V3 (1) PROTN. STATOR CORE (EE) RANGE UNIT 0-150 SENSOR TYPE TC JB1 JB2 MKA01GC021A CAB1 CAB2 IND REC - - DEG.C CuCuNi MKY00GC112 GAMP - MKA 13 CT010 TEMP. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (EE) DEG.C CuCuNi MKY00GC112 - X MKA 13 CT009 TEMP. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (EE) DEG. LVL ABOVE BOTTOM OF CASING X >MAX X >MAX 2V3 (1) PROTN. COMMON ANN.C CuCuNi MKY00GC112 GAMP - MKA 13 CT012 TEMP..C CuCuNi MKY00GC112 GAMP - MKA 13 CT008 TEMP. COMMON ANN. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (EE) DEG.C CuCuNi MKY00GC112 - X MKA 13 CT007 TEMP.SLNO 46 TAG PID_REF MKA 13 CT006 0-139-00-01223 47 48 49 50 51 52 53 54 55 56 57 58 2.(TE+EE) REV .3-4030-10553/7 0709E 59 60 SERVICE TEMP.. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (EE) DEG. COMMON ANN.) KG/CM2 - - - - MKA 24 CL001 LIQUID AT MAIN - LS - CXW01B - 0-139-00-01223 LEADS TOP MM COC MKY01GB001A CJJ05 - MKA 24 CL011 LIQUID AT MAIN - LS - CXW01B - 0-139-00-01223 LEADS TOP MM COC MKY01GB001A CJJ05 - MKA 24 CL021 LIQUID AT MAIN - LS - CXW01B - 0-139-00-01223 LEADS TOP MM COC MKY01GB001A CJJ05 - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - - - - X >90 C - - - - - - X >90 C - - - - - - X >90 C - - - - - - X >MAX X <MAX COMMON ANNUN.C CuCuNi MKY00GC112 - X MKA 13 CT011 TEMP. - LS - CXW01B - 0-139-00-01223 (TE) MM COC MKY01GB001A GAMP - MKA 22 CL001 LIQUID IN GEN. STATOR 0-150 TC MKA01GC021A - - 0-139-00-01223 CORE (EE) DEG. LVL ABOVE BOTTOM OF CASING COMMON ANNUNCIATION FOR STATOR CORE TEMP. & ATRS X >MAX X <MAX COMMON ANNUN. - LS - CXW01B - 0-139-00-01223 (CENTRE) MM COC MKY01GB001A GAMP - MKA 23 CL001 LIQUID AT MAIN - LS - CXW01B - 0-139-00-01223 LEADS BOTTOM MM COC MKY01GB001A GAMP - MKA 23 CL011 LIQUID AT MAIN - LS - CXW01B - 0-139-00-01223 LEADS BOTTOM MM COC MKY01GB001A GAMP - MKA 23 CP501 GAS IMPULS TO 0-10 PG - - LOCAL 0-149-00-01185 DPR(H2 PRESS.C CuCuNi MKY00GC112 - X MKA 21 CL001 LIQUID IN GEN. & ATRS X >MAX X <MAX COMMON ANNUN. & ATRS - - - - - X >MAX X >MAX 2V3 (1) PROTN.

MKA61CT003A & MKF82CT001A - - - - SPARE X >80 C - - C. WITH MKA61CT001A.4A & MKA72CT002A.3A.C Pt 100 - - - MKA 61 CT003A TEMP. ANN WITH MKA71CT002A.4A & MKA72CT002A.3A. PW O/L 0-100 RTD MKA01GC001D - - 0-139-00-01223 MANIFOLD DEG.4A & C. ANN WITH MKA71CT002A. HOT GAS 0-100 RTD MKA01GC001E - HMI/L 0-139-00-01223 CLRS C & D DEG.C Pt 100 - - - MKA 71 CT004A TEMP.3A. HOT GAS 0-100 RTD MKA01GC001E - HMI/L 0-139-00-01223 CLRS A & B DEG. PW O/L 0-100 RTD MKA01GC001D - - 0-139-00-01223 MANIFOLD DEG. ANN WITH MKA71CT002A.C Pt 100 - GAMP - MKA 72 CT002B TEMP.4A & MKA72CT002A.4A & C. PW O/L 0-100 RTD MKA01GC001D - - 0-139-00-01223 MANIFOLD DEG. HOT GAS 0-100 RTD MKA01GC001E - - 0-139-00-01223 CLRS C & D DEG. ANN.C Pt 100 - - - MKA 72 CT003A TEMP.3A. PW O/L 0-100 RTD MKA01GC001D - - 0-139-00-01223 MANIFOLD DEG.C Pt 100 - - - MKA 71 CT002A TEMP.3A.3A. PW O/L 0-100 RTD MKA01GC001D - - 0-139-00-01223 MANIFOLD DEG.3-4030-10553/8 0709E SLNO 61 62 63 TAG PID_REF 65 66 67 68 69 70 71 72 73 74 75 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC MKA 61 CT001A TEMP. ANN WITH MKA71CT002A. IND OF CLR A&B AND FOR FAST F/B TO C.4A & MKA72CT002A.C Pt 100 - GAMP - MKA 61 CT002B TEMP.C Pt 100 - GAMP - MKA 71 CT003B TEMP.C Pt 100 - GAMP - MKA 71 CT002B TEMP.C Pt 100 - - - MKA 71 CT003A TEMP. ANN.C Pt 100 - GAMP - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR REV X >80 C - - C. ANN WITH MKA71CT002A. IND CLR C&D .4A & C. HOT GAS 0-100 RTD MKA01GC001E - HMI/L 0-139-00-01223 CLRS C & D DEG. HOT GAS 0-100 RTD MKA01GC001E - - 0-139-00-01223 CLRS A & B DEG.3A. IND OF CLR A&B - - - - SPARE X >80 C - - C.C Pt 100 - GAMP - MKA 61 CT001B TEMP.V - - - - SPARE X >80 C - - C.V - - - - SPARE X >80 C - - C. WITH MKA61CT001A. HOT GAS 0-100 RTD MKA01GC001E - HMI/L 0-139-00-01223 CLRS A & B DEG.4A & MKA72CT002A. PW O/L 0-100 RTD MKA01GC001D - - 0-139-00-01223 64 SERVICE MANIFOLD DEG.C Pt 100 - GAMP - MKA 71 CT004B TEMP.C Pt 100 - - - MKA 61 CT002A TEMP. HOT GAS 0-100 RTD MKA01GB001A - HMI/L 0-139-00-01223 CLRS A & B DEG. MKA61CT003A & MKF82CT001A - - - - SPARE X >80 C - - C.C Pt 100 - GAMP - MKA 61 CT003B TEMP.3A. MKA61CT002A & MKF82CT001A - - - - SPARE X >80 C - - C. IND OF CLR C&D AND FOR FAST F/B TO C.3A. IND OF CLR A&B - - - - SPARE X >80 C - - C.C Pt 100 - - - MKA 72 CT002A TEMP.4A & C. WITH MKA61CT002A.3A.ANN.2. HOT GAS 0-100 RTD MKA01GB001A - - 0-139-00-01223 CLRS A & B DEG. HOT GAS 0-100 RTD MKA01GC001E - - 0-139-00-01223 CLRS A & B DEG.4A & C.

IND CLR C&D - - - - SPARE X >55 C >60 C X >60 C <45 C 2V3 (2) & MEAN VALUE INDICATION WITH MKA75CT003A & 4A AND ATRS - X SPARE >55 C >60 C X >60 C - 2V3 (2) & MEAN VALUE INDICATION WITH MKA75CT002A & 4A SPARE X >55 C >60 C X >60 C 2V3 (2) & MEAN VALUE INDICATION WITH MKA75CT002A & 3A - - - - SPARE X >55 C X >55C DIFF TEMP PW/H2 "LOW & V.C Pt 100 - - - MKA 75 CT002A TEMP.3-4030-10553/9 0709 E 89 90 CLRS C & D RANGE UNIT 0-100 SENSOR TYPE RTD JB1 JB2 MKA01GC001E CAB1 CAB2 IND REC - - DEG. COLD GAS 0-100 RTD MKA01GC001E - - 0-139-00-01223 CLRS A & B DEG. COLD GAS 0-100 RTD MKA01GC001E - - 0-139-00-01223 CLRS A & B DEG.3A.C Pt 100 - CJJ05 - MKA 75 CT004B TEMP.3A.C Pt 100 - CJJ05 - MKA 75 CT002B TEMP.C Pt 100 - CJJ05 - MKA 78 CT002B TEMP. COLD GAS 0-100 RTD MKA01GC001E - HMI/L 0-139-00-01223 CLRS A & B DEG.C PT 100 - - - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR REV - - - - SPARE X >80 C - - C.C Pt 100 - - - MKA 75 CT003A TEMP.4A & MKA72CT002A. COLD GAS 0-100 RTD MKA01GB001A - - 0-139-00-01223 CLRS A & B DEG. HOT GAS 0-100 RTD MKA01GB001A - HMI/L 0-139-00-01223 CLRS C & D DEG.C Pt 100 - - - MKA 78 CT003A TEMP. COLD GAS 0-100 RTD MKA01GB001A - HMI/L 0-139-00-01223 CLRS A & B DEG.C Pt 100 - CJJ05 - MKA 78 CT003B TEMP. HOT GAS 0-139-00-01223 77 78 79 80 81 82 83 84 85 86 87 88 2.C Pt 100 - - - MKA 78 CT002A TEMP.C Pt 100 - CJJ05 - MKA 75 CT003B TEMP. LOW WITH MKF80CT003A - - - - SPARE X >55 C >60 C X >60 C <45 C 2V3 (3) & MEAN VALUE INDICATION WITH MKA78CT003A & 4A AND ATRS X - - - SPARE X >55 C >60 C X >60 C 2V3 3) & MEAN VALUE INDICATION WITH MKA78CT002A & 4A - - - - SPARE . COLD GAS 0-100 RTD MKA01GC001F - HMI/L 0-139-00-01223 CLRS C & D DEG. ANN WITH MKA71CT002A.C Pt 100 - GAMP - MKA 75 CT005B TEMP. COLD GAS 0-100 RTD MKA01GC001F - - 0-139-00-01223 CLRS C & D DEG. COLD GAS 0-100 RTD MKA01GC001F - HMI/L 0-139-00-01223 CLRS C & D DEG. COLD GAS 0-100 RTD MKA01GC021B - - 0-139-00-01223 (LEFT) DEG.C Pt 100 - GAMP - MKA 72 CT004B TEMP.4A & C. COLD GAS 0-100 RTD MKA01GC001F - - 0-139-00-01223 CLRS C & D DEG. COLD GAS 0-100 RTD MKA01GC021B - HMI 0-139-00-01223 (LEFT) DEG.C Pt 100 - - - MKA 72 CT004A TEMP. HOT GAS 0-100 RTD MKA01GB001A - - 0-139-00-01223 CLRS C & D DEG.C Pt 100 - - - MKA 75 CT004A TEMP. COLD GAS 0-100 RTD MKA01GC001E - HMI/L 0-139-00-01223 CLRS A & B DEG.SLNO 76 TAG PID_REF SERVICE MKA 72 CT003B TEMP.C Pt 100 - - - MKA 75 CT005A TEMP.

COLD AIR 0-100 RTD MKC01GC001B - - 2-145-00-01019 MAIN EXCITER DEG. AXIS 0-8000 COL MKC01GC001C - HMI 2-145-00-01019 MEAS. >80 C X >80 C 2V3 (4) & MEAN VALUE INDICATION WITH MKC82CT001A & 3A - - - - SPARE . COLD AIR 0-100 RTD MKC01GC001B - - 2-145-00-01019 MAIN EXCITER DEG. COLD GAS 0-100 RTD MKA01GC021B - HMI 0-139-00-01223 94 SERVICE (RIGHT) DEG. >80 C X >80 C 2V3 (4) & MEAN VALUE INDICATION WITH MKC82CT002A & 3A - - - - SPARE X >75 C.>50 SWITCHING ON/OFF EXCITER SHUNT DOWN HTR. COLD AIR 0-100 RTD MKC01GC001B - - 2-145-00-01019 MAIN EXCITER DEG.2.C Pt 100 - - - MKC 82 CT002A TEMP. LOW WITH MKF80CT004A - - - - SPARE - X >110 C - - ROTOR TEMP PROCESSING WITH NON LINAR CURVE(SEE NOTE 7) FIELD CURRENT MEAS. COIL-1 A VOLT - GAMP X MKC 21 CE002 QUAD. FOR - - - - - 2-145-00-01019 FUSE CHECKING - - - - - MKC 80 CT012A TEMP. COIL-2 A VOLT - - - MKC 41 CU001 STROBO.C Pt 100 - - - MKC 80 CT014A TEMP. COLD GAS 0-100 RTD MKA01GC021B - - 0-139-00-01223 (RIGHT) DEG.C Pt 100 - GAMP - MKC 80 CT014B TEMP.C PT 100 - - - MKA 78 CT005A TEMP. AXIS 0-8000 COL MKC01GC001C - - 2-145-00-01019 MEAS. BY EDN - - - - SPARE - - - - VISUAL CHECKING OF FUSES X >45C X <45C. COLD GAS 0-100 RTD MKA01GB001A - HMI/L 0-139-00-01223 CLRS C & D DEG. HOT AIR 0-140 RTD MKC01GB001A - HMI 2-145-00-01019 MAIN EXCITER DEG.3-4030-10553/10 0709 E SLNO 91 92 93 TAG PID_REF 95 96 97 98 99 100 101 102 103 104 105 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC MKA 78 CT004A TEMP.C Pt 100 - GAMP - MKC 80 CT012B TEMP.C Pt 100 - - - MKC 82 CT001A TEMP. HOT AIR 0-140 RTD MKC01GB001A - - 2-145-00-01019 MAIN EXCITER DEG. PROT.C Pt 100 - GAMP - MKA 78 CT005B TEMP. HOT AIR 0-100 RTD MKC01GC001B - - 2-145-00-01019 MAIN EXCITER DEG.ALSO - - - - SPARE X >75 C. COLD AIR 0-100 RTD MKC01GC001B - HMI 2-145-00-01019 MAIN EXCITER DEG. / AIR DRIER <43 ATRS - - - - SPARE X >45C X >90 SWITCHING ON/OFF EXCITER SHUNT DOWN HEATER/AIR DRIER.C Pt 100 - GAMP - MKC 21 CE001 QUAD. COLD GAS 0-100 RTD MKA01GB001A - - 0-139-00-01223 CLRS C & D DEG.C Pt 100 - CJJ05 - MKC 82 CT001B TEMP. HOT AIR 0-100 RTD MKC01GC001B - HMI 2-145-00-01019 MAIN EXCITER DEG.C Pt 100 - CJJ05 - MKC 82 CT002B TEMP.C Pt 100 - CJJ05 - MKA 78 CT004B TEMP.C Pt 100 - - - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR REV X >55 C >60 C X >60 C 2V3 3) & MEAN VALUE INDICATION WITH MKA78CT002A & 3A - - - - SPARE X >55 C X >55 C DIFF TEMP PW/H2 "LOW & V.

HOT AIR 0-100 RTD MKC01GC001B - - 2-145-00-01019 RECT.HOT AIR 0-100 RTD MKC01GC001B - - 2-145-00-01019 RECT. 14B &18B X >90 C >130C X >130 C 2V4 (5) TRIP AT 130 C WITH MKD11CT014A. 18A &18B X >90 C >130C X >130 C 2V4 (5) TRIP AT 130 C WITH MKD11CT014A. BEARING 0-150 TC MKD11GC001 - - 0-139-00-01223 METAL (TE) DEG.C Pt 100 - - - 2-145-00-01019 MAIN EXCITER MKC 82 CT003B 2-145-00-01019 MKC 84 CT002A TEMP.C NiCrNi MKY00GC113 CJJ05 - MKD 11 CT014C TEMP. 14B &18A . HOT AIR 0-140 RTD MKC01GB001A - - MAIN EXCITER DEG.C NiCrNi MKY00GC113 - - MKD 11 CT018A TEMP.C NiCrNi MKY00GC114 - - MKD 12 CT018A TEMP. 18A &18B - - - - SPARE X >90 C >130C X >130 C 2V4 (6) TRIP AT 130 C WITH MKD12CT014A. BEARING 0-150 TC MKD11GC001 - - 0-139-00-01223 METAL (TE) DEG.C Pt 100 - - - MKD 11 CT014A TEMP. BEARING 0-150 TC MKD11GC001 - - 0-139-00-01223 METAL (TE) DEG.C NiCrNi MKY00GC114 CJJ05 - MKD 12 CT014B TEMP. 14B &18A - - - - SPARE X >90 C >130C X >130 C 2V4 (6) TRIP AT 130 C WITH MKD12CT014B. 14B &18B X >90 C >130C X >130 C 2V4 (6) TRIP AT 130 C WITH MKD12CT014A. BEARING 0-150 TC MKD12GC001 - - 0-139-00-01223 METAL (EE) DEG. BEARING 0-150 TC MKD11GC001 - HMI 0-139-00-01223 METAL (TE) DEG. BEARING 0-150 TC MKD11GC001 - HMI 0-139-00-01223 METAL (TE) DEG.C NiCrNi MKY00GC114 CJJ05 - MKD 12 CT018B TEMP. >80 C X >80 C 2V3 (4) & MEAN VALUE INDICATION WITH MKC82CT001A & 2A - - - - SPARE X >75 C - - - - - - SPARE X >90 C >130C X >130 C 2V4 (5) TRIP AT 130 C WITH MKD11CT014B.C NiCrNi MKY00GC113 CJJ05 - MKD 11 CT018B TEMP. BEARING 0-150 TC MKD12GC001 - - 0-139-00-01223 METAL (EE) DEG. BEARING 0-150 TC MKD11GC001 - - 0-139-00-01223 METAL (TE) DEG.3-4030-10553/11 0709 E 119 120 TAG PID_REF MKC 82 CT003A SERVICE TEMP.C NiCrNi MKY00GC113 CJJ05 - MKD 11 CT018C TEMP.C NiCrNi MKY00GC113 CJJ05 - MKD 11 CT014B TEMP.WHEEL DEG. BEARING 0-150 TC MKD12GC001 - HMI 0-139-00-01223 METAL (EE) DEG.C Pt 100 - GAMP - MKC 84 CT002B TEMP. 18A &18B X >90 C >130C X >130 C 2V4 (6) TRIP AT 130 C WITH MKD12CT014A.SLNO 106 107 108 109 110 111 112 113 114 115 116 117 118 2.WHEEL DEG. HOT AIR RANGE UNIT 0-140 SENSOR TYPE RTD JB1 JB2 MKC01GB001A CAB1 CAB2 IND REC - HMI DEG.C NiCrNi MKY00GC114 CJJ05 - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR REV X >75 C.C Pt 100 - CJJ05 - TEMP. BEARING 0-150 TC MKD12GC001 - HMI 0-139-00-01223 METAL (EE) DEG. BEARING 0-150 TC MKD12GC001 - - 0-139-00-01223 METAL (EE) DEG.C NiCrNi MKY00GC114 CJJ05 - MKD 12 CT014C TEMP. 18A &18B - - - - SPARE X >90 C >130C X >130 C 2V4 (5) TRIP AT 130 C WITH MKD11CT014A.C NiCrNi MKY00GC113 - - MKD 12 CT014A TEMP.

6 DPT MKF02GB001B - HMI/L 0-153-00-01063 MAIN FILTER 1 Kg/CM2 4-20mA - GAMP - REV . <5 COMMON ANN.C NiCrNi MKY00GC115 MKF 01 CL001 LEVEL PW TANK 0-470 LT - CXW01B HMI/L MM 4-20mA MKY01GB001A GAMP - 0-470 LG - - LOCAL MM - - - - MKF 01 CL501 LEVEL PW TANK ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - - - - SPARE X >90 C >130C X >130 C 2V4 (7) TRIP AT 130 C WITH MKD15CT014B. WITH MKF12CP001 & ATRS - - - - - - - X < MIN STOP OF DOSING PUMP ON LOW LEVEL ( INBUILT IN PUMP CKT. AFTER 0. <195. EXCITER 0-150 TC MKC01GC001C - HMI DEG. WITH MKF22CP001 & ATRS - - - - - X <5 X >5. 0-1.C NiCrNi MKY00GC115 CJJ05 - - - MKD 15 CT018C TEMP. 14B &18B X >90 C >130C X >130 C 2V4 (7) TRIP AT 130 C WITH MKD15CT014A.C NiCrNi MKY00GC115 - - MKD 15 CT018A TEMP. WITH MKF52CP002 - MKF 12 CP001 PRESS. AFTER 0.9 - - COMMON ANN. <5 COMMON ANN.<100 X >155 LVL ABOVE BOTTOM PERMISSIVE FOR SWITCHING ON OF SLC & ATRS - - - - - X <5 X >5. AFTER 0. EXCITER 0-150 TC MKC01GC001C - HMI 2-145-00-01019 BEARING DEG. EXCITER 0-150 TC MKC01GC001C - - BEARING DEG.5-16 PG - - LOCAL 0-153-00-01063 PUMP 1 Kg/CM2 - - - - MKF 22 CP001 PRESS. 14B &18A - - - - SPARE X >255.C NiCrNi MKY00GC115 CJJ05 - MKD 15 CT014B TEMP. 18A &18B - - - - SPARE X >90 C >130C X >130 C 2V4 (7) TRIP AT 130 C WITH MKD15CT014A. EXCITER 0-150 TC MKC01GC001C - - 2-145-00-01019 BEARING DEG.5-16 PS MKF02GB001A - - 0-153-00-01063 PUMP 2 Kg/CM2 COC - GAMP - MKF 22 CP501 PRESS.5-16 PS MKF02GB001A - - 0-153-00-01063 PUMP 1 Kg/CM2 COC - GAMP - MKF 12 CP501 PRESS. EXCITER 0-150 TC MKC01GC001C - - 2-145-00-01019 BEARING DEG. BEARING 0-150 TC 0-139-00-01223 METAL (EE) DEG.) X >0. 18A &18B X >90 C >130C X >130 C 2V4 (7) TRIP AT 130 C WITH MKD15CT014A. EXCITER 0-150 TC MKC01GC001C 2-145-00-01019 BEARING DEG.2.3-4030-10553/12 0709 E SLNO 121 122 123 TAG PID_REF SERVICE MKD 12 CT018C TEMP. AFTER 0.5-16 PG - - LOCAL 0-153-00-01063 PUMP 2 Kg/CM2 - - - - MKF 36 CL001 NaOH TANK LEVEL - LS MKF36GC001A - - - COC - - - 0-153-00-01063 135 CAB1 CAB2 BEARING 0-153-00-01063 130 JB1 JB2 MKD 15 CT014A 0-153-00-01063 129 SENSOR TYPE 2-145-00-01019 2-145-00-01019 124 RANGE UNIT MKF 52 CP001 DIFF PRESS.C 125 126 127 128 131 132 133 134 IND REC MKD12GC001 - - NiCrNi MKY00GC114 - - TEMP.C NiCrNi MKY00GC115 CJJ05 - MKD 15 CT018B TEMP.C NiCrNi MKY00GC115 CJJ05 - MKD 15 CT014C TEMP.

0 X <1.SLNO 136 TAG PID_REF MKF 52 CP002 0-153-00-01063 137 138 139 140 141 142 143 144 145 146 147 148 2. - - X >55. OF PW 0-100 RTD MKF02GC001A - - 0-153-00-01063 AT INLET DEG.0. >3.>60C X >60C <50C.C Pt 100 - - - MKF 80 CT004A TEMP. ON COND>4.0 SWITCHING 'ON' & 'OFF' OF DOSING PUMP. WITH MKF80CT003A&4A.6 DPT MKF02GB001B - HMI/L 0-153-00-01063 MESH FILTER Kg/CM2 4-20mA - GAMP - MKF 60 CQ001 COND.V.V. AFTER 0-5 CC MKF02GC001A - HMI 0-153-00-01063 MAIN FILTER uS/CM 4-20mA - GAMP - MKF 80 CT002A TEMP.C - - - - MKF 60 CF002 FLOW OF TREATED 6-60 FM MKF02GB001A - LOCAL 0-153-00-01063 WATER LPM - - GAMP - MKF 60 CF501 FLOW OF TOP 0-7 FG - - LOCAL 0-153-00-01063 UP WATER M3/HR - - - - MKF 60 CP001 DIFF PRESS FINE 0-1.0 X >2. MAIN FILTER 2 RANGE UNIT 0-1.9 - - - X <1.5 >4.C Pt 100 - CJJ05 - MKF 80 CT003B TEMP. PW TMP CONT VLV & PW/H2 DT ANN WITH MKA75CT005A SPARE X >60C >3 K 2V3 (8) & M.C Pt 100 - CJJ05 - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR X >0. AFTER 0-100 RTD MKF02GB001B - - 0-153-00-01063 PUMP 1&2 DEG.C Pt 100 - - - MKF 80 CT003A TEMP.0 >4.>60C <3K. IND WITH MKF80CT 002A& 3A.<1K - - X >55. IND. >MIN CONTROL OF DOSING PUMP FLOW METER USED WITH CNTCT - - - - - X >0. OF PW 0-100 RTD MKF02GC001A - HMI/L 0-153-00-01063 AT INLET DEG. AFTER 0-5 CC MKF02GC001A - HMI 0-153-00-01063 ION EXCHANGER uS/CM 4-20mA - GAMP - MKF 80 CQ001 COND. AFTER 0-100 RTD MKF02GB001B - - 0-153-00-01063 PUMP 1&2 DEG.C - - - - MKF 52 CT506 TEMP. OF PW 0-100 RTD MKF02GC001A - HMI/L 0-153-00-01063 AT INLET DEG.9 - - COMMON ANN.<1K REV SPARE X >60C >3 K 2V3 (8) & M. IND WITH MKF80CT 002A& 4A. PW TMP CONT VLV & PW/H2 DT ANN WITH MKA78CT005A .0us/cm FLUSHING OF DM WATER RECOM. 2V3 (8) & MEAN VAL. X >3.C Pt 100 MKY01GB001A GAMP - MKF 52 CT001B TEMP.0 >3. X >55. AFTER 0-100 TG - - LOCAL 0-153-00-01063 PUMP 1&2 DEG. AFTER 0-100 TG - - LOCAL 0-153-00-01063 PW CLR DEG. WITH MKF52CP001 X >80 C - - - - - - - SPARE - - - - - - - - - - X < MIN X <MIN.C Pt 100 - CJJ05 - MKF 80 CT002B TEMP.>60C <3K.3-4030-10553/13 0709 E 149 150 SERVICE DIFF PRESS.6 SENSOR TYPE DPT JB1 JB2 MKF02GB001B CAB1 CAB2 IND REC - HMI/L Kg/CM2 4-20mA - GAMP - MKF 52 CT001A TEMP. OF PW 0-100 RTD MKF02GC001A - HMI/L 0-153-00-01063 AT INLET DEG. PW TMP CONT VLV & ATRS.0 SWITCHING 'OFF' OF DOSING PMP. OF PW 0-100 RTD MKF02GC001A - - 0-153-00-01063 AT INLET DEG.C Pt 100 MKY01GB001A - - MKF 52 CT501 TEMP.

VAL IND WITH MKF82CF001B & 01C.3A.C Pt 100 - GAMP - - ORIFICE FOR FLOW 0-72M3/HR - 0-153-00-01063 REV X <54.<48 X <48 2V3 (9) DELAY OF 1MIN & M. X <54..VAL IND WITH MKF82CF001A & 01C. ORIFICE PLT.<48 X <48. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG.. TEMP MTG IN BAR (NOTE 10).0 - - - X >80 C - - C. FOR FAST FEED BACK PW TEMP CV - - - - SPARE - * - - ON LINE W.. AS PER SITE COND - * - - ON LINE W. OF 0-250 mbar.C Pt 100 MKY01GB001A GAMP - MKF 82 CT001B TEMP. ATRS ORIFICE PLT.0 >3.. X <54. OF PW 0-100 TG - - LOCAL 0-153-00-01063 AFTER CLR DEG. AS PER SITE COND - * - - ON LINE W.*. STATOR 0-100 RTD - - - 0-153-00-01063 WINDING O/L DEG.C Pt 100 - GAMP - MKF 82 CT003 TEMP. OF 0-250 mbar. AS PER SITE COND 01 . UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. 2A.*.3-4030-10553/14 0709 E SLNO 151 152 153 TAG PID_REF 155 156 157 158 159 160 161 162 163 164 165 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC MKF 80 CT004B TEMP.2.ANN. TEMP MTG IN BAR (NOTE 10).VAL IND WITH MKF82CF001A & 01B.C Pt 100 - GAMP - MKF 82 CT004 TEMP.5 DPT - - HMI/L 0-153-00-01063 STATOR WINDING Kg/Cm2 4-20mA MKY01GC001G GAMP - MKF 82 CP501 PRESS.WITH MKA61CT001A.. STATOR 0-10 PT - - HMI/L 0-153-00-01063 WINDING I/L Kg/Cm2 4-20mA MKY01GC001G GAMP - MKF 82 CP005 DIFF PRESS 0-2.8 - - - X >MAX - - - - - - - - X >3.C - - - - MKF 82 CF001 FLOW STATOR 0-250 DP - - - 0-153-00-01063 154 SERVICE WINDING O/L mBar - - ANN SETPTS ACTRL - - - - - - BIN SETPTS REMARKS CTR SPARE - - MKF 82 CF001A FLOW STATOR 0-72 DPT - - HMI/L WINDING O/L m3/hr 4-20mA MKY01GC001G CJJ05 X MKF 82 CF001B FLOW STATOR 0-72 DPT - - HMI/L 0-153-00-01063 WINDING O/L m3/hr 4-20mA MKY01GC001G CJJ05 - MKF 82 CF001C FLOW STATOR 0-72 DPT - - HMI/L 0-153-00-01063 WINDING O/L m3/hr 4-20mA MKY01GC001G CJJ05 - MKF 82 CP003 PRESS.<48 X <48 2V3 (9) DELAY OF 1MIN & M.*. OF 0-250 mbar.. >54 2V3 (9) DELAY OF 1MIN & M. STATOR 0-100 RTD - - HMI/L 0-153-00-01063 WINDING O/L DEG. ORIFICE PLT. TEMP MTG IN BAR (NOTE 10). X <3.C Pt 100 MKY01GB001A - - MKF 82 CT002 TEMP.C Pt 100 - - - MKF 80 CT501 TEMP. OF PW 0-100 RTD MKF02GC001A - - 0-153-00-01063 AT INLET DEG. STATOR 0-10 PG - - LOCAL 0-153-00-01063 WINDING I/L Kg/Cm2 - - - - MKF 82 CQ001 PW CONDCTIVITY 0-5 CC MKF02GC001A - HMI 0-153-00-01063 AT GEN O/L us/cm2 4-20mA - GAMP - MKF 82 CT001A TEMP.

UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG.. TEMP MTG IN BAR (NOTE 10)..*.C Pt 100 - GAMP - MKF 82 CT007 TEMP. LOWER BAR PW O/L RANGE UNIT 0-100 SENSOR TYPE RTD JB1 JB2 MKA01GF003 CAB1 CAB2 IND REC - - DEG.. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT017 TEMP..*.3-4030-10553/15 0709 E 179 180 SERVICE TEMP.*. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT014 TEMP.. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG..C Pt 100 - GAMP - MKF 82 CT008 TEMP. TEMP MTG IN BAR (NOTE 10).*. AS PER SITE COND - * - - ON LINE W...*.. AS PER SITE COND - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT012 TEMP.. TEMP MTG IN BAR (NOTE 10).. TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10).*. AS PER SITE COND - * - - ON LINE W. TEMP MTG IN BAR (NOTE 10).*.. AS PER SITE COND - * - - ON LINE W....C Pt 100 - GAMP - MKF 82 CT006 TEMP. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT016 TEMP..C Pt 100 - GAMP - MKF 82 CT015 TEMP...C Pt 100 - GAMP - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT009 TEMP. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT010 TEMP.SLNO 166 TAG PID_REF MKF 82 CT005 0-139-00-01223 167 168 169 170 171 172 173 174 175 176 177 178 2.. TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W. AS PER SITE COND - * - - ON LINE W.*. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.*.*.C Pt 100 - GAMP - MKF 82 CT019 TEMP. AS PER SITE COND - * - - ON LINE W. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT011 TEMP. TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W..C Pt 100 - GAMP - MKF 82 CT013 TEMP. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W..C Pt 100 - GAMP - MKF 82 CT018 TEMP. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG.. TEMP MTG IN BAR (NOTE 10). AS PER SITE COND REV ..*.*. TEMP MTG IN BAR (NOTE 10)... AS PER SITE COND - * - - ON LINE W.*. TEMP MTG IN BAR (NOTE 10).. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG.. TEMP MTG IN BAR (NOTE 10)..*. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.*... AS PER SITE COND - * - - ON LINE W. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. TEMP MTG IN BAR (NOTE 10).

UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W. TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W. AS PER SITE COND - * - - ON LINE W... LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG..*.C Pt 100 - GAMP - MKF 82 CT025 TEMP.C Pt 100 - GAMP - MKF 82 CT028 TEMP. AS PER SITE COND REV .*.C Pt 100 - GAMP - MKF 82 CT029 TEMP.. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT031 TEMP.C Pt 100 - GAMP - MKF 82 CT021 TEMP. TEMP MTG IN BAR (NOTE 10). LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG.. TEMP MTG IN BAR (NOTE 10).*.. TEMP MTG IN BAR (NOTE 10).2... UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 184 SERVICE PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT024 TEMP..C Pt 100 - GAMP - MKF 82 CT034 TEMP. AS PER SITE COND - * - - ON LINE W...C Pt 100 - GAMP - MKF 82 CT030 TEMP.. AS PER SITE COND - * - - ON LINE W.. TEMP MTG IN BAR (NOTE 10). UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG... UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG.*. AS PER SITE COND - * - - ON LINE W. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG.*..C Pt 100 - GAMP - MKF 82 CT027 TEMP...*.*..C Pt 100 - GAMP - MKF 82 CT032 TEMP. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT023 TEMP. TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W... AS PER SITE COND - * - - ON LINE W..*. AS PER SITE COND - * - - ON LINE W. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. TEMP MTG IN BAR (NOTE 10).*.*.C Pt 100 - GAMP - MKF 82 CT033 TEMP.3-4030-10553/16 0709 E SLNO 181 182 183 TAG PID_REF 185 186 187 188 189 190 191 192 193 194 195 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC MKF 82 CT020 TEMP. TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W..*.*. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG.. TEMP MTG IN BAR (NOTE 10). UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG.*. AS PER SITE COND - * - - ON LINE W. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT022 TEMP. AS PER SITE COND - * - - ON LINE W.*. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG... AS PER SITE COND - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT026 TEMP. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG.. TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10)... AS PER SITE COND - * - - ON LINE W. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - * - - ON LINE W.*..

. TEMP MTG IN BAR (NOTE 10). LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W..C Pt 100 - GAMP - MKF 82 CT048 TEMP.*. TEMP MTG IN BAR (NOTE 10).. TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.*. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT040 TEMP. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT039 TEMP. TEMP MTG IN BAR (NOTE 10).*.C Pt 100 - GAMP - MKF 82 CT042 TEMP..C Pt 100 - GAMP - MKF 82 CT041 TEMP...C Pt 100 - GAMP - MKF 82 CT043 TEMP.C Pt 100 - GAMP - MKF 82 CT046 TEMP.. AS PER SITE COND - * - - ON LINE W.. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG..C Pt 100 - GAMP - MKF 82 CT038 TEMP..*.*.3-4030-10553/17 0709 E 209 210 SERVICE TEMP. AS PER SITE COND - * - - ON LINE W.... TEMP MTG IN BAR (NOTE 10).*.. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT036 TEMP. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG..*.*. AS PER SITE COND REV .C Pt 100 - GAMP - MKF 82 CT044 TEMP.C Pt 100 - GAMP - MKF 82 CT045 TEMP.. AS PER SITE COND - * - - ON LINE W...*. TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10).. TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG...*. AS PER SITE COND - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT037 TEMP. TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG.*. AS PER SITE COND - * - - ON LINE W.. AS PER SITE COND - * - - ON LINE W... TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT047 TEMP. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. LOWER BAR PW O/L RANGE UNIT 0-100 SENSOR TYPE RTD JB1 JB2 MKA01GF003 CAB1 CAB2 IND REC - - DEG.C Pt 100 - GAMP - MKF 82 CT049 TEMP.SLNO 196 TAG PID_REF MKF 82 CT035 0-139-00-01223 197 198 199 200 201 202 203 204 205 206 207 208 2.*. TEMP MTG IN BAR (NOTE 10). UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.. AS PER SITE COND - * - - ON LINE W... LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.*.*.. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG.*...

AS PER SITE COND - * - - ON LINE W.*... UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG...2. AS PER SITE COND - * - - ON LINE W... TEMP MTG IN BAR (NOTE 10). UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG... AS PER SITE COND - * - - ON LINE W. TEMP MTG IN BAR (NOTE 10).. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT061 TEMP. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND REV .. AS PER SITE COND - * - - ON LINE W. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.*.C Pt 100 - GAMP - MKF 82 CT062 TEMP.*. TEMP MTG IN BAR (NOTE 10). LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG.*.*. AS PER SITE COND - * - - ON LINE W.. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG.. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.... TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10). LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG...*. AS PER SITE COND - * - - ON LINE W... TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W.*.C Pt 100 - GAMP - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT055 TEMP. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT058 TEMP.C Pt 100 - GAMP - MKF 82 CT051 TEMP.. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG.3-4030-10553/18 0709 E SLNO 211 212 213 TAG PID_REF 215 216 217 218 219 220 221 222 223 224 225 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC MKF 82 CT050 TEMP. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG.*. AS PER SITE COND - * - - ON LINE W.*.*. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT064 TEMP.. AS PER SITE COND - * - - ON LINE W. TEMP MTG IN BAR (NOTE 10)..C Pt 100 - GAMP - MKF 82 CT060 TEMP. AS PER SITE COND - * - - ON LINE W. TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 214 SERVICE PW O/L DEG..C Pt 100 - GAMP - MKF 82 CT053 TEMP.C Pt 100 - GAMP - MKF 82 CT063 TEMP.*.C Pt 100 - GAMP - MKF 82 CT057 TEMP....*. AS PER SITE COND - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT056 TEMP.*.. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT054 TEMP... TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT052 TEMP. TEMP MTG IN BAR (NOTE 10).*.. TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT059 TEMP.*. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG.

TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10).*.. TEMP MTG IN BAR (NOTE 10)..*.*.. TEMP MTG IN BAR (NOTE 10).. AS PER SITE COND - * - - ON LINE W. AS PER SITE COND - * - - ON LINE W..C Pt 100 - GAMP - MKF 82 CT069 TEMP.C Pt 100 - GAMP - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - * - - ON LINE W. TEMP MTG IN BAR (NOTE 10)...*.... UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG.*.C Pt 100 - GAMP - MKF 82 CT066 TEMP.C Pt 100 - GAMP - MKF 82 CT073 TEMP. AS PER SITE COND - * - - ON LINE W.. TEMP MTG IN BAR (NOTE 10). LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10). LOWER BAR PW O/L RANGE UNIT 0-100 SENSOR TYPE RTD JB1 JB2 MKA01GF008 CAB1 CAB2 IND REC - - DEG... AS PER SITE COND - * - - ON LINE W.*..*.*.C Pt 100 - GAMP - MKF 82 CT078 TEMP. TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W.*. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. TEMP MTG IN BAR (NOTE 10).*....C Pt 100 - GAMP - MKF 82 CT072 TEMP. TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W.*. AS PER SITE COND - * - - ON LINE W. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT071 TEMP. AS PER SITE COND - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT075 TEMP.... AS PER SITE COND - * - - ON LINE W. TEMP MTG IN BAR (NOTE 10).*.C Pt 100 - GAMP - MKF 82 CT067 TEMP. AS PER SITE COND - * - - ON LINE W. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT077 TEMP.C Pt 100 - GAMP - MKF 82 CT076 TEMP.. TEMP MTG IN BAR (NOTE 10).*..SLNO 226 TAG PID_REF MKF 82 CT065 0-139-00-01223 227 228 229 230 231 232 233 234 235 236 237 238 2. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG.. AS PER SITE COND - * - - ON LINE W..3-4030-10553/19 0709 E 239 240 SERVICE TEMP.*. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG.. AS PER SITE COND - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT079 TEMP.. AS PER SITE COND REV .C Pt 100 - GAMP - MKF 82 CT068 TEMP. TEMP MTG IN BAR (NOTE 10).*. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT074 TEMP. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT070 TEMP... UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG..

.C Pt 100 - GAMP - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - * - - ON LINE W. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT086 TEMP. TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10).. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG..*. TEMP MTG IN BAR (NOTE 10).*. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W. AS PER SITE COND - * - - ON LINE W. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT084 TEMP...C Pt 100 - GAMP - MKF 82 CT087 TEMP.. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.... AS PER SITE COND - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT088 TEMP. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG.*..C Pt 100 - GAMP - MKF 82 CT092 TEMP.*..*. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT094 TEMP.. AS PER SITE COND - * - - ON LINE W. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG.C Pt 100 - GAMP - MKF 82 CT090 TEMP.. TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT081 TEMP... TEMP MTG IN BAR (NOTE 10). AS PER SITE COND - * - - ON LINE W.....C Pt 100 - GAMP - MKF 82 CT093 TEMP...*.C Pt 100 - GAMP - MKF 82 CT082 TEMP. AS PER SITE COND - * - - ON LINE W.*. TEMP MTG IN BAR (NOTE 10).... TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10)...C Pt 100 - GAMP - MKF 82 CT089 TEMP.*.*..*.*. LOWER BAR 0-100 RTD MKA01GF008 - - 0-139-00-01223 PW O/L DEG. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.2.*.*.C Pt 100 - GAMP - MKF 82 CT085 TEMP. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 PW O/L DEG. AS PER SITE COND - * - - ON LINE W.*.3-4030-10553/20 0709 E SLNO 241 242 243 TAG PID_REF 245 246 247 248 249 250 251 252 253 254 255 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC MKF 82 CT080 TEMP. AS PER SITE COND - * - - ON LINE W. AS PER SITE COND REV ..*.. AS PER SITE COND - * - - ON LINE W. AS PER SITE COND - * - - ON LINE W.C Pt 100 - GAMP - MKF 82 CT091 TEMP. AS PER SITE COND - * - - ON LINE W. UPPER BAR 0-100 RTD MKA01GF007 - - 0-139-00-01223 244 SERVICE PW O/L DEG. TEMP MTG IN BAR (NOTE 10). TEMP MTG IN BAR (NOTE 10).C Pt 100 - GAMP - MKF 82 CT083 TEMP. AS PER SITE COND - * - - ON LINE W. TEMP MTG IN BAR (NOTE 10)..

- ORIFICE FOR FLOW 0-1.<1. AS PER SITE COND - - - - - - X <1.<1.4. TEMP MTG IN BAR (NOTE 10).8 DPT - - HMI/L BUSHING 'R' m3/hr 4-20mA MKY01GC001H CJJ05 - MKF 83 CF001C FLOW MAIN 0-1.4.8 DPT - - HMI/L 0-153-00-01063 BUSHING 'T' m3/hr 4-20mA MKY01GC001H CJJ05 - REV ORIFICE FOR FLOW 0-1.33 X <1.33 X <1.C Pt 100 - GAMP - MKF 82 CT096 TEMP.C - - - - - - MKF 83 CF001 FLOW MAIN 0-250 DP - 0-153-00-01063 BUSHING 'R' mBar - - MKF 83 CF001A FLOW MAIN 0-1.<1. >1.SLNO 256 TAG PID_REF MKF 82 CT095 0-139-00-01223 257 258 259 260 261 262 263 264 265 266 267 268 2.33.VAL IN WITH MKF83CF021A& 21C.8 DPT - - HMI/L 0-153-00-01063 BUSHING 'T' m3/hr 4-20mA MKY01GC001H CJJ05 - MKF 83 CF021B FLOW MAIN 0-1. OF 0-250 mbar.*.33 2V3 (12) DELAY OF 5SEC & M. ORIFICE PLT. X <1.3-4030-10553/21 0709 E 269 270 SERVICE TEMP.4. TEMP MTG IN BAR (NOTE 10)..VAL IN WITH MKF83CF011B & 11C.33 X <1.VAL IN WITH MKF83CF001B & 01C.VAL IN WITH MKF83CF001A & 01C.4.33.<1.33 X <1. OF 0-250 mbar. ORIFICE PLT.4.C Pt 100 - GAMP - MKF 82 CT097 TEMP. ATRS ORIFICE PLT.4.33 2V3 (11) DELAY OF 5SEC & M. LOWER BAR PW O/L RANGE UNIT 0-100 SENSOR TYPE RTD JB1 JB2 MKA01GF003 CAB1 CAB2 IND REC - - DEG.VAL IN WITH MKF83CF021B& 21C.33 X <1.C Pt 100 - GAMP - MKF 82 CT501 TEMP.8 DPT - - HMI/L 0-153-00-01063 BUSHING 'S' m3/hr 4-20mA MKY01GC001H CJJ05 - MKF 83 CF011B FLOW MAIN 0-1. STATOR 0-100 TG - - LOCAL 0-153-00-01063 WINDING O/L DEG.VAL IN WITH MKF83CF001A & 01B. AS PER SITE COND - * - - ON LINE W. UPPER BAR 0-100 RTD MKA01GF002 - - 0-139-00-01223 PW O/L DEG. ORIFICE PLT.4 2V3 (11) DELAY OF 5SEC & M.8 DPT - - HMI/L 0-153-00-01063 BUSHING 'S' m3/hr 4-20mA MKY01GC001H CJJ05 - MKF 83 CF021 FLOW MAIN 0-250 DP - - - 0-153-00-01063 BUSHING 'T' mBar - - X <1. X <1.<1.*.8M3/HR - MKF 83 CF011A FLOW MAIN 0-1.33 X <1. OF 0-250 mbar.8 DPT - - HMI/L 0-153-00-01063 BUSHING 'R' m3/hr 4-20mA MKY01GC001H CJJ05 - MKF 83 CF001B FLOW MAIN 0-1. TEMP MTG IN BAR (NOTE 10). OF 0-250 mbar.<1. ORIFICE PLT.. X <1. OF 0-250 mbar. ATRS ORIFICE PLT. AS PER SITE COND - * - - ON LINE W. ..33 2V3 (10) DELAY OF 5SEC & M.VAL IN WITH MKF83CF011A & 11C.<1. LOWER BAR 0-100 RTD MKA01GF003 - - 0-139-00-01223 PW O/L DEG. OF 0-250 mbar. ATRS ORIFICE PLT. OF 0-250 mbar.4.33 X <1.8 DPT - - HMI/L 0-153-00-01063 BUSHING 'R' m3/hr 4-20mA MKY01GC001H CJJ05 - - - MKF 83 CF011 FLOW MAIN 0-250 DP - BUSHING 'S' mBar - - BIN SETPTS REMARKS CTR - * - - ON LINE W.4.4 2V3 (10) DELAY OF 5SEC & M. ORIFICE PLT.8M3/HR - 0-153-00-01063 0-153-00-01063 ANN SETPTS ACTRL X <1.33.8 DPT - - HMI/L 0-153-00-01063 BUSHING 'S' m3/hr 4-20mA MKY01GC001H CJJ05 - MKF 83 CF011C FLOW MAIN 0-1. OF 0-250 mbar.. >1.33 2V3 (10) DELAY OF 5SEC & M.VAL IN WITH MKF83CF011A & 11B.<1.*. X <1.8M3/HR - MKF 83 CF021A FLOW MAIN 0-1..33 2V3 (11) DELAY OF 5SEC & M.. >1.4 2V3 (12) DELAY OF 5SEC & M.33 X <1. - ORIFICE FOR FLOW 0-1. X <1.

AFTER 0-100 RTD - - - 0-153-00-01063 274 SERVICE MAIN BUSHING DEG. H2 0-250 PG - - LOCAL 0-149-00-01186 CYLINDER Kg/Cm2 - - - - MKG 25 CP001 PR. <90% X >95% 3 RANGE GAS ANALYSER. - - - - - X <15 - - - - - - - - - X DP>1.2. H2 0-250 PT - - HMI/L 0-149-00-01186 CYLINDER Kg/Cm2 4-20mA MKY01GC001F GAMP - MKG 11 CP501 PRESS. H2-STATOR 0-10 PT MKG25GC001 - HMI/L/U 0-149-00-01186 (FOR SO/H2 DP) Kg/Cm2 4-20mA - GAMP - MKG 25 CP003 PRESS. OF 0-250 mbar. - - - - - - - - - - 01 . AFTER 0-100 TG - - LOCAL 0-153-00-01063 MAIN BUSHING DEG.2 DP FOR ATRS WITH MKW71CP011 X >3.3 - - LEAKAGE OF H2 IN PW CKT.C - - - - MKF 91 CP001 GAS PRESS.C Pt 100 MKY01GC001H GAMP - MKF 83 CT001B TEMP.VAL IN WITH MKF83CF021A& 21B. <3. AFTER 0-100 RTD - - - 0-153-00-01063 MAIN BUSHING DEG. 0-1 PS - - - 2-149-00-01068 PW TANK Kg/Cm2 COC MKY01GB001A GAMP - MKF 91 CP501 GAS PRESS.<1.3-4030-10553/22 0709 E SLNO 271 272 273 TAG PID_REF 275 276 277 278 279 280 281 282 283 284 285 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC MKF 83 CF021C FLOW MAIN 0-1. H2-STATOR 0-6 PG - - LOCAL 0-149-00-01186 FRAME Kg/Cm2 - - - - MKG 25 CQ001 PURITY H2 GEN 100-90% GA - CXW01C HMI/L/U 0-149-00-01186 CASING % - - GAMP X MKG 31 CP502 PRESS. 0-1 PG - - LOCAL 2-149-00-01068 PW TANK Kg/Cm2 - - - - MKG 11 CP001 PRESS. BELOW 90%H2 PURITY IN AIR. CO2 0-160 PG - - LOCAL 0-149-00-01186 CYLINDER Kg/Cm2 - - - - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR REV X <1.33 X <1. ATRS & M/C OPERATION NOT RECOMM.7.33 2V3 (12) DELAY OF 5SEC & M. N2 BEHIND 0-250 PG - - LOCAL 0-149-00-01186 FLASH Kg/Cm2 - - - - MKG 51 CP501 PRESS. X >70 C - - - - - - - SPARE - - - - - X >0.3 X DP>1. H2-STATOR 0-6 PT MKG25GC001 - HMI/L 0-149-00-01186 FRAME Kg/Cm2 4-20mA - GAMP X MKG 25 CP503 PRESS. ORIFICE PLT.8 DPT - - HMI/L 0-153-00-01063 BUSHING 'T' m3/hr 4-20mA MKY01GC001H CJJ05 - MKF 83 CT001A TEMP.0 ATRS - - - - - X <95%.C Pt 100 MKY01GC001H - - MKF 83 CT501 TEMP.4.2 DP FOR ATRS WITH MKW71CP021 - - X >3. H2-STATOR 0-10 PT MKG25GC001 - HMI/L/U 0-149-00-01186 (FOR SO/H2 DP) Kg/Cm2 4-20mA - GAMP - MKG 25 CP002 PR.

CO2 FLASH EVAP.C Pt 100 - - - MKW 03 CT002A TEMP H2 SIDE 0-100 RTD MKA01GC021B - - 0-149-00-01185 SO DRAIN (EE) DEG. RANGE UNIT 0-250 SENSOR TYPE RTD JB1 JB2 - CAB1 CAB2 IND REC - - DEG. OIL 0-2.C Pt 100 - GAMP - X >70 C - - COMM ANN. - - - - SPARE - - - - - X >MAX X >MAX - - 4-20mA OUT PUT TO GAMP FROM DEW POINT EQPT.O. DEG.C Pt 100 - GAMP - X >70 C - - COMM ANN. WITH MKW01CL002 X < MIN - - - - - - X <MIN X <MIN SWITCHING OFF H2 -SIDE S. PUMP MKW 03 CL002 OIL LEVEL IN - LS MKW01GC001B CXW01B SO TANK - COC - GAMP - - X <MIN - - - MKW 03 CL501 OIL LEVEL IN 0-470 LG - - LOCAL 0-149-00-01185 SO TANK MM - - - - - - - - - MKW 03 CT001A TEMP H2 SIDE 0-100 RTD MKA01GC001F - - 0-149-00-01185 SO DRAIN (TE) DEG.C - - - - MKG 69 CL001 LEVEL IN OIL LS - - 0-149-00-01186 TRAP DRIER I/L COC MKY01GC001B - MKG 69 CM001 DEW POINT AT GAS -60+20C MS - UCR HMI 0-149-00-01186 DRIER I/L OR O/L - - - GAMP - MKW 01 CL001 OIL LEVEL IN - LS - CXW01B - 0-149-00-01185 SOS TANK - COC MKY01GC001A GAMP - MKW 01 CL002 OIL LEVEL IN - LS - CXW01B - 0-149-00-01185 SOS TANK - COC MKY01GC001A GAMP - MKW 01 CP501 PRESS.C Pt 100 - - - - - - - SPARE 01 01 01 - 0-149-00-01185 REV COMM ANN. WITH MKW01CL001 . WITH MKW03CT002A MKW 03 CT001B TEMP H2 SIDE 0-100 RTD MKA01GC001F - - - - - - SPARE 0-149-00-01185 SO DRAIN (TE) DEG.C 4-20mA MKY01GC001B GAMP - MKG 51 CT001B TEMP.SLNO 286 TAG PID_REF MKG 51 CT001A 0-149-00-01186 287 288 289 290 291 292 293 294 295 296 297 298 2.C 4-20mA MKY01GC001B - - MKG 51 CT501 TEMP. DEG.CO2 0-250 TG - - LOCAL 0-149-00-01186 FLASH EVAP. X < MIN X >MIN SO PUMPS INTERLOCK COMM ANN.5 PG - - LOCAL 0-149-00-01185 INLET HEADER KG/CM2 - - - - MKW 03 CL001 OIL LEVEL IN - LS MKW01GC001B CXW01B 0-149-00-01185 SO TANK - COC - GAMP - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR X >150 C X <145.CO2 0-250 RTD - - - 0-149-00-01186 FLASH EVAP.3-4030-10553/23 0709 E 299 300 SERVICE TEMP. WITH MKW03CT001A MKW 03 CT002B TEMP H2 SIDE 0-100 RTD MKA01GC021B - - 0-149-00-01185 SO DRAIN (EE) DEG. >150 FOR SWITCHING ON/OFF CO2 FLASH EVAP.

OIL TEMP BEF 0-100 RTD MKW01GC001B - 0-149-00-01185 SO CLR (H2-S) DEG. S. AFT SO 0-16 PG - - LOCAL 0-149-00-01185 PUMP 3 A-S Kg/Cm2 - - - - MKW 51 CP001 DIFF.0. AFT SO 0-16 PG - - LOCAL 0-149-00-01185 PUMP 2 A-S Kg/Cm2 - - - - 0-149-00-01185 304 SERVICE MKW 31 CP001 PR. AFT SO 0-16 PG - - LOCAL 0-149-00-01185 PUMP 4 H2-S Kg/Cm2 - - - - MKW 21 CP001 PR.5-16 PS MKW01GB001A - - 0-149-00-01185 PUMP 2 A-S Kg/CM2 COC - GAMP - MKW 21 CP501 PR.0 ATRS - - - - - X <5.OIL TEMP BEF 0-100 RTD MKW01GC001B - 0-149-00-01185 SO CLR (A-S) DEG.0 COMMON ANN. <5. AFT SO 0. <5. AFT SO 0.0 X >5. AFT SO 0. AFT SO 0-16 PG - - LOCAL 0-149-00-01185 PUMP 1 (AIR-S) Kg/Cm2 - - - - MKW 13 CP001 PR.9 - - - - - - - - X >70 C - - - - - - - SPARE - - - - - X >0.OIL TEMP BEF 0-100 TG - - LOCAL 0-149-00-01185 SO CLR (A-S) DEG.C Pt 100 - GAMP HMI/L MKW 51 CT001B S.2.5 - - - - - - - - X >0.C Pt 100 - GAMP GAMP BIN SETPTS REMARKS CTR X <5.OIL 0-1.PR.3-4030-10553/24 0709 E SLNO 301 302 303 TAG PID_REF 305 306 307 308 309 310 311 312 313 314 315 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC MKW 11 CP001 SO PR.6 DPT MKW01GB001A - FILTER H2-S Kg/CM2 4-20mA - MKW 53 CT001A S.5-16 PS MKW01GB001A - 0-149-00-01185 PUMP 1 (AIR-S) Kg/Cm2 COC - GAMP - - MKW 11 CP501 SO PR.9 - - - X >70 C - - - - 0-149-00-01185 0-149-00-01185 ANN SETPTS ACTRL HMI/L - REV . WITH MKW21CP001 - - - - - X <7.5-16 PS MKW01GB001A - 0-149-00-01185 PUMP 3 A-S Kg/Cm2 COC - GAMP - MKW 31 CP501 PR.5-16 PS MKW01GB001A - - PUMP 4 H2-S Kg/Cm2 COC - GAMP - MKW 13 CP501 PR.OIL 0-1. WITH MKW11CP001 - - - - - X <8.6 DPT MKW01GB001A - 0-149-00-01185 FILTER A-S Kg/Cm2 4-20mA - GAMP - MKW 51 CP502 SO PR.0 COMMON ANN.0. S. BFR 0-16 PG - - LOCAL 0-149-00-01185 SO CLR (A-S) Kg/Cm2 - - - - MKW 51 CT001A S.OIL TEMP BEF 0-100 RTD MKW01GC001B - - SO CLR (A-S) DEG. AFT SO 0.0 X >5.C Pt 100 - - - MKW 51 CT501 S.C - - - - MKW 53 CP001 DIFF PR.0 X >7.

C.OIL TEMP BEF 0-100 TG - - LOCAL 0-149-00-01185 SO CLR (H2-S) DEG. 0.2.OIL TEMP BEF 0-149-00-01185 317 318 319 320 321 322 323 324 325 326 327 328 2. (EE) 0-10 PG - - LOCAL AIR SIDE Kg/CM2 - - - - MKW 71 CT001A SO TEMP AFT SO 0-140 RTD MKW01GB001A - 0-149-00-01185 CLRS (AIR SIDE) DEG.C - - - - MKW 71 CF511 SO FLOW (TE) 10-100 FM - - LOCAL 0-149-00-01185 AIR SIDE LPM - - - - MKW 71 CF521 SO FLOW (EE) 10-100 FM - - LOCAL 0-149-00-01185 AIR SIDE LPM - - - - MKW 71 CP001 SO PRESS.9.ANN WITH MKW71CP011.9 X DP<10mbar >4.5 TO SWITCH OFF H2-S SO PUMP & ATRS - - X <4. X <4. >4.9.C Pt 100 - CJJ05 - SPARE - - - - - - - - - - - - - - - X <4.C Pt 100 - HMI/L MKW 71 CT001B SO TEMP AFT SO 0-100 RTD MKW01GC001A - - CLRS (AIR SIDE) DEG. 0-10 PG - - LOCAL 0-149-00-01185 AIR SIDE Kg/CM2 - - - - MKW 71 CP511 SO PRESS. (TE) 0-10 PG - - LOCAL 0-149-00-01185 AIR SIDE Kg/CM2 - - - - GAMP GAMP GAMP HMI/L - HMI/L/U SO PRESS.5 DIRECT SWITCH 'ON' OF DC SEAL OIL PUMP.UCB IND DP FOR ATRS WITH MKG25CP001 & DP WITH MKW73CP001 FOR ANN X <4. (TE) 0-10 PT MKW01GC001B - 0-149-00-01185 AIR SIDE Kg/CM2 4-20mA - MKW 71 CP021 SO PRESS.5. DP>1.9 X DP<10mbar >4.SLNO 316 TAG PID_REF SERVICE MKW 53 CT001B S. DP>1.2.3-4030-10553/25 0709 E 329 330 SO CLR (H2-S) RANGE UNIT 0-100 SENSOR TYPE RTD JB1 JB2 CAB1 CAB2 IND REC MKW01GC001B - - - - DEG.C Pt 100 - MKW 53 CT501 S. 0-10 PT MKW01GC001B - 0-149-00-01185 AIR SIDE Kg/CM2 4-20mA - MKW 71 CP002 SO PRESS.ANN WITH MKW71CP021. >0. 0.5-10 PS MKW01GC001B - 0-149-00-01185 AIR SIDE Kg/CM2 COC - MKW 71 CP003 SO PRESS. C. (EE) 0-10 PT MKW01GC001B - 0-149-00-01185 AIR SIDE Kg/CM2 4-20mA - GAMP - MKW 71 CP501 SO PRESS.5-10 PS MKW01GC001B - - 0-149-00-01185 AIR SIDE Kg/CM2 COC - - - MKW 71 CP011 SO PRESS. >55C X >55 C 2V3 (13) & MEAN VALUE INDICATIO WITH MKW71CT002A&3A - - SPARE X >55 C 2V3 (13) & MEAN VALUE INDICATIO WITH MKW71CT001A&3A - 0-149-00-01185 MKW 71 CT002A - HMI/L/U HMI/L - REV - - MKW 71 CP521 0-149-00-01185 BIN SETPTS REMARKS CTR - - 0-149-00-01185 CJJ05 ANN SETPTS ACTRL - X >50 C >55C .UCB IND DP FOR ATRS WITH MKG25CP002 & DP WITH MKW73CP011 FOR ANN - - - - - - - - - - - - - - - X >50C.5.C Pt 100 - - - SO TEMP AFT SO 0-140 RTD MKW01GB001A - CLRS (AIR SIDE) DEG.6 - - - - - X <4.

- - - - - - - - - - X >50 C - - C.C Pt 100 - GAMP HMI/L MKW 73 CT001B TEMP.C Pt 100 - - - MKW 73 CT002A TEMP. X <MIN DP>10mbar - COM ANN. (TE) 0-10 PT - - HMI/L 0-149-00-01185 H2 SIDE Kg/CM2 4-20mA MKY01GC001A GAMP - MKW 73 CP011 SO PRESS.C Pt 100 - - - MKW 73 CT501 TEMP.ALARM WITH MKW73CT002A - - - - SPARE X >50 C - - C.2. (EE) 0-10 PG - - LOCAL 0-149-00-01185 H2 SIDE Kg/CM2 - - - - MKW 73 CT001A TEMP. WITH MKW73CP011 DP WITH MKW71CP011. SO AFT 0-100 RTD MKW01GC001A - - 0-149-00-01185 CLR H2 SIDE DEG.C Pt 100 - - MKW 71 CT501 SO TEMP AFT SO 0-100 TG - - LOCAL 0-149-00-01185 CLRS (AIR SIDE) DEG. WITH MKW73CP001 DP WITH MKW71CP021. SO AFT 0-100 RTD MKW01GC001A - - CLR H2 SIDE DEG. SO AFT 0-100 RTD MKW01GC001A - CLR H2 SIDE DEG. SO AFT 0-100 TG - - LOCAL 0-149-00-01185 CLR H2 SIDE DEG.C - - - - REV . (EE) 0-10 PT - - HMI/L 0-149-00-01185 H2 SIDE Kg/CM2 4-20mA MKY01GC001A GAMP - MKW 73 CP511 SO PRESS.C - - - - MKW 73 CF511 SO FLOW TURBINE 10-100 FM - - LOCAL 0-149-00-01185 END H2 SIDE LMP - - - - MKW 73 CF521 SO FLOW EXCITER 10-100 FM - - LOCAL 0-149-00-01185 END H2 SIDE LMP - - - - MKW 73 CP001 SO PRESS.C Pt 100 - MKW 71 CT003B SO TEMP AFT SO 0-100 RTD MKW01GC001A - - 0-149-00-01185 334 SERVICE CLRS (AIR SIDE) CJJ05 HMI/L DEG.C Pt 100 - GAMP X >50 C >55C - BIN SETPTS REMARKS CTR - - SPARE X >55 C 2V3 (13) & MEAN VALUE INDICATIO WITH MKW71CT001A&2A - - SPARE - - - - - - - - - - - - - - - X <MIN DP>10mbar - COM ANN. SO AFT 0-100 RTD MKW01GB001A - CLR H2 SIDE DEG. (TE) 0-10 PG - - LOCAL 0-149-00-01185 H2 SIDE Kg/CM2 - - - - MKW 73 CP521 SO PRESS.3-4030-10553/26 0709 E SLNO 331 332 333 TAG PID_REF 335 336 337 338 339 340 341 342 343 344 345 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC MKW 71 CT002B SO TEMP AFT SO 0-100 RTD MKW01GC001A - - 0-149-00-01185 CLRS (AIR SIDE) DEG.ALARM WITH MKW73CT001A - - - - SPARE - - - - - - 0-149-00-01185 0-149-00-01185 - - - 0-149-00-01185 ANN SETPTS ACTRL - MKW 73 CT002B TEMP.C Pt 100 - - - MKW 71 CT003A SO TEMP AFT SO 0-140 RTD MKW01GB001A - 0-149-00-01185 CLRS (AIR SIDE) DEG.

3-4030-10553/27 0709 E 359 360 SEAL FLOW RING RANGE UNIT 2. - 2-145-00-01019 ROTOR E/F RELAY K.BRUSH FOR 100 REF MKC01GC001A GEN PRO.ANN OF PGB31CT001A & 2A REV .5-10 PT - - - 0-139-00-01223 WATER I/L KG/CM2 4-20mA MKY01GC001E GAMP - PGB 30 CT501 WATER TEMP BFR 0-100 TG - - LOCAL 0-139-00-01223 H2 CLRS DEG.C Pt 100 MKY01GC001E GAMP - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - - - - - - - - - - X <MIN - - C.Ohm - CER GAMP - PGB 30 CP001 PRESS.66-26.<5 - - 2 STAGE ALARMS AT <80K AND E. H2 CLRS 0. AT THE I/L 0-10 PG - - LOCAL 0-139-00-01223 OF H2 CLR D KG/CM2 - - - - PGB 31 CT001A WATER TEMP BFR 0-100 RTD - - - 0-139-00-01223 H2 CLRS DEG. RING 0-10 PG - - LOCAL 0-149-00-01185 RELIEF OIL-(TE) Kg/CM2 - - - - MKW 76 CP521 PRESS.C - - - - PGB 31 CP501 PRESS. AT THE I/L 0-10 PG - - LOCAL 0-139-00-01223 OF H2 CLR A KG/CM2 - - - - PGB 31 CP502 PRESS. RING 0-10 PG - - LOCAL 0-149-00-01185 RELIEF OIL-(EE) Kg/CM2 - - - - MKX 81 CL011 WASTE FLUID LVL - LS - - - 3-149-00-010197 IN DRAIN TANK - COC MKY01GC001A GAMP - MKY 01 CE001 MESU.ALARM WITH MKW76CP001 - - - - - - - - - - X >MAX - - - X <80.66-26. AT THE I/L 0-10 PG - - LOCAL 0-139-00-01223 OF H2 CLR B KG/CM2 - - - - PGB 31 CP503 PRESS.6 FM - - LOCAL 0-149-00-01185 RELIEF OIL(EE) LPM - - - - MKW 76 CP001 PRESS. AT THE I/L 0-10 PG - - LOCAL 0-139-00-01223 OF H2 CLR C KG/CM2 - - - - PGB 31 CP504 PRESS. RING 0-10 PT - - HMI/L 0-149-00-01185 RELIEF OIL-(EE) Kg/CM2 4-20mA MKY01GC001A GAMP - 0-149-00-01185 347 SERVICE MKW 76 CP511 PRESS. RING 0-10 PT - - HMI/L 0-149-00-01185 RELIEF OIL-(TE) Kg/CM2 4-20mA MKY01GC001A GAMP - MKW 76 CP011 PRESS. ALARM AT <5K.SLNO 346 TAG PID_REF MKW 76 CF511 348 349 350 351 352 353 354 355 356 357 358 2. MANUAL TRIPPING ON MACHINE X >MAX - - - - - - - - - - - - - - - - - - - - - - - - - - - - X >38 C - - C.ALARM WITH MKW76CP011 X <MIN - - C.6 SENSOR TYPE FM JB1 JB2 - CAB1 CAB2 IND REC - LOCAL RELIEF OIL(TE) LPM - - - - MKW 76 CF521 SEAL FLOW RING 2.

AT O/L 0-10 PG - - LOCAL 0-139-00-01223 OF H2 CLR B KG/CM2 - - - - PGB 32 CP503 PRESS. AT O/L 0-10 PG - - LOCAL 0-139-00-01223 OF H2 CLR A KG/CM2 - - - - PGB 32 CP502 PRESS.ANN OF PGB31CT001A & 2A - - - - SPARE - - - - - - - - - - - - - - - - - - - - X >67 C - - C.C Pt 100 MKY01GC001C - - PGB 32 CT002A WATER TEMP AFT 0-100 RTD - - HMI 0-139-00-01223 H2 CLR B DEG.ANN OF PGB31CT001A. AT O/L 0-10 PG - - LOCAL 0-139-00-01223 OF H2 CLR C KG/CM2 - - - - PGB 32 CP504 PRESS. 3A & 4A - - - - SPARE X >67 C - - C.2A.C Pt 100 MKY01GC001D - - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - - - - SPARE X >38 C - - C. 3A & 4A - - - - SPARE REV . AT O/L 0-10 PG - - LOCAL 0-139-00-01223 OF H2 CLR D KG/CM2 - - - - PGB 32 CT001A WATER TEMP AFT 0-100 RTD - - HMI 0-139-00-01223 H2 CLR A DEG.C Pt 100 MKY01GC001C GAMP - PGB 32 CT001B WATER TEMP AFT 0-100 RTD - - - 0-139-00-01223 H2 CLR A DEG.3-4030-10553/28 0709 E SLNO 361 362 363 TAG PID_REF 365 366 367 368 369 370 371 372 373 374 375 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC PGB 31 CT001B WATER TEMP BFR 0-100 RTD - - - 0-139-00-01223 H2 CLRS DEG.2A.2A.C Pt 100 MKY01GC001E - - PGB 31 CT002A WATER TEMP BFR 0-100 RTD - - - 0-139-00-01223 H2 CLRS DEG. 3A & 4A - - - - SPARE X >67 C - - C.C Pt 100 MKY01GC001C GAMP - PGB 32 CT003B WATER TEMP AFT 0-100 RTD - - - 0-139-00-01223 H2 CLR C DEG.C Pt 100 MKY01GC001C GAMP - PGB 32 CT002B WATER TEMP AFT 0-100 RTD - - - 0-139-00-01223 H2 CLR B DEG.C Pt 100 MKY01GC001C - - PGB 32 CT003A WATER TEMP AFT 0-100 RTD - - HMI 0-139-00-01223 H2 CLR C DEG.2.ANN OF PGB31CT001A.C Pt 100 MKY01GC001F - - PGB 32 CP501 PRESS.2A.C Pt 100 MKY01GC001B GAMP - PGB 31 CT002B WATER TEMP BFR 0-100 RTD - - - 0-139-00-01223 364 SERVICE H2 CLRS DEG.C Pt 100 MKY01GC001D GAMP - PGB 32 CT004B WATER TEMP AFT 0-100 RTD - - - 0-139-00-01223 H2 CLR D DEG.ANN OF PGB31CT001A.C Pt 100 MKY01GC001C - - PGB 32 CT004A WATER TEMP AFT 0-100 RTD - - HMI 0-139-00-01223 H2 CLR D DEG. 3A & 4A - - - - SPARE X >67 C - - C.ANN OF PGB31CT001A.

C - - - - PGB 42 CP503 WATER PRESS AT 0-10 PG - - LOCAL 2-145-00-01019 I/L OF AIR CLR E Kg/CM2 - - - - PGB 42 CP504 WATER PRESS AT 0-10 PG - - LOCAL 2-145-00-01019 I/L OF AIR CLR F Kg/CM2 - - - - PGB 42 CP505 WATER PRESS AT 0-10 PG - - LOCAL 2-145-00-01019 O/L OF AIR CLR E Kg/CM2 - - - - PGB 42 CP506 WATER PRESS AT 0-10 PG - - LOCAL 2-145-00-01019 O/L OF AIR CLR F Kg/CM2 - - - - PGB 42 CT001A WATER TEMP AFT 0-100 RTD - - - 2-145-00-01019 EXCITER CLR E DEG.C Pt 100 MKY01GC001E GAMP - - - - SPARE - - - - - - - - - - - - - - - - - - - - - - - - - X >42 C - - COMM ANN WITH PGB42CT002A - - - - SPARE X >42 C - - COMM ANN WITH PGB42CT001A PGB 33 CT001B WATER TEMP AFT 0-100 RTD - - - 0-139-00-01223 H2 CLR DEG.3-4030-10553/29 0709E 389 390 SERVICE TEMP.C - - - - PGB 32 CT504 TEMP.C - - - - PGB 32 CT503 TEMP.C Pt 100 MKY01GC001E GAMP - REV . AT O/L OF 0-100 TG - - LOCAL 0-139-00-01223 H2 CLR D DEG.C Pt 100 MKY01GC001E - - PGB 42 CT002A WATER TEMP AFT 0-100 RTD - - - 2-145-00-01019 EXCITER CLR F DEG.SLNO 376 TAG PID_REF PGB 32 CT501 0-139-00-01223 377 378 379 380 381 382 383 384 385 386 387 388 2. AT O/L OF 0-100 TG - - LOCAL 0-139-00-01223 H2 CLR B DEG. ON CRT PGB 33 CG001A COLD GAS TEMP 0-100 POS - - HMI - 0-139-00-01223 CONTROL VALVE % 4-20mA MKY01GC001E GAMP - X PGB 33 CT001A WATER TEMP AFT 0-100 RTD - - - X >67 C - - - 0-139-00-01223 H2 CLR DEG. AT O/L OF 0-100 TG - - LOCAL 0-139-00-01223 H2 CLR C DEG.C - - CAB1 CAB2 IND REC - LOCAL - - PGB 32 CT502 TEMP.C Pt 100 MKY01GC001E - - PGB 33 CT501 WATER TEMP AFT 0-100 TG - - LOCAL 0-139-00-01223 H2 CLR DEG.C Pt 100 MKY01GC001E GAMP - PGB 42 CT001B WATER TEMP AFT 0-100 RTD - - - 2-145-00-01019 EXCITER CLR E DEG. AT O/L OF H2 CLR A RANGE UNIT 0-100 SENSOR TYPE TG JB1 JB2 - DEG.C - - - - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - - - - - - - - - - - - - - - - - - - - - - - ANALOG CONTROL WITH MOTORISED ACTUATOR. IND.

AFT SO CLR 1 0-10 PG - - LOCAL 0-149-00-01185 (H2-S) KG/CM2 - - - - PGB 52 CP502 PR. BEFOR SO 0-10 PG - - LOCAL 0-149-00-01185 CLR 1 (AIR-S) KG/CM2 - - - - PGB 61 CP502 PR. BEFOR SO 0-10 PG - - LOCAL 0-149-00-01185 CLR 2 (AIR-S) KG/CM2 - - - - PGB 62 CP501 PR.3-4030-10553/30 0709 E SLNO 391 392 393 TAG PID_REF 395 396 397 398 399 400 401 402 403 404 405 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC PGB 42 CT002B WATER TEMP AFT 0-100 RTD - - - 2-145-00-01019 EXCITER CLR F DEG.C Pt100 MKY01GC001G GAMP - X - - - - SPARE - - - - - - - - - - - - - - - - - - - - - - - - - PGB 52 CT001B TEMP-OUTLET 0-100 RTD - - - 0-149-00-01185 H2-S SO CLRS DEG.C - - - - PGB 51 CP501 PR. BEF SO CLR 2 0-10 PG - - LOCAL 0-149-00-01185 (H2-S) KG/CM2 - - - - PGB 52 CP501 PR.C Pt 100 MKY01GC001E - - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - - - - - - - PGB 50 CT001A CW TEMP AT I/L 0-100 RTD - - - - TO SO CLRS DEG.C Pt100 MKY01GC001E - - PGB 50 CT501 CW TEMP AT I/L 0-100 TG - - LOCAL 0-149-00-01185 TO SO CLRS DEG.C - - - - PGB 52 CT502 TEMP AFT SO 0-100 TG - - LOCAL 0-149-00-01185 CLR 2 (H2-S) DEG.C Pt100 MKY01GC001E GAMP - X PGB 50 CT001B CW TEMP AT I/L 0-100 RTD - - - - - - - SPARE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - TO SO CLRS DEG.2. AFTER SO 0-10 PG - - LOCAL 0-149-00-01185 CLR 1 (A-S) KG/CM2 - - - - REV SPARE 0-149-00-01185 0-149-00-01185 394 SERVICE 01 . BEF SO CLR 1 0-10 PG - - LOCAL 0-149-00-01185 (H2-S) KG/CM2 - - - - PGB 51 CP502 PR.C - - - - PGB 61 CP501 PR.C Pt100 MKY01GC001G - - PGB 52 CT501 TEMP AFT SO 0-100 TG - - LOCAL 0-149-00-01185 CLR 1 (H2-S) DEG. AFT SO CLR 2 0-10 PG - - LOCAL 0-149-00-01185 (H2-S) KG/CM2 - - - - 01 PGB 52 CT001A TEMP-OUTLET 0-100 RTD - - - - 0-149-00-01185 H2-S SO CLRS DEG.

3-4030-10553/31 0709 E 419 420 SERVICE PR. AFTER SO CLR 2 (A-S) RANGE UNIT 0-10 SENSOR TYPE PG JB1 JB2 - KG/CM2 - - CAB1 CAB2 IND REC - LOCAL - - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - - - - - - - - - PGB 62 CT001A TEMP.C Pt100 MKY01GC001F - - PGB 70 CT501 TEMP AT INLET 0-100 TG - - LOCAL 0-153-00-01063 PW CLRS DEG.C Pt100 MKY01GC001F GAMP - X - - - - - - - PGB 72 CT001B TEMP.SLNO 406 TAG PID_REF PGB 62 CP502 0-149-00-01185 407 408 409 410 411 412 413 414 415 416 417 418 2.O/L A-S 0-100 RTD - - - - 0-149-00-01185 SO CLRS DEG.O/L A-S 0-100 RTD - - - 0-149-00-01185 SO CLRS DEG.O/L 0-100 RTD - - - 0-153-00-01063 OF PW CLR-1 DEG.C Pt100 MKY01GC001G - - PGB 62 CT501 TEMP AFT SO 0-100 TG - - LOCAL 0-149-00-01185 CLR 1 (A-S) DEG.C - - - - PGB 71 CP501 CW PR.C Pt100 MKY01GC001F - - PGB 72 CT002A TEMP. AT O/L 0-10 PG - - LOCAL 0-153-00-01063 OF PW CLR-2 KG/CM2 - - - - PGB 72 CT001A TEMP.C Pt100 MKY01GC001F GAMP - X - - - - SPARE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SPARE PGB 70 CT001B TEMP AT INLET 0-100 RTD - - - 0-153-00-01063 PW CLRS DEG.C - - - - PGB 70 CT001A TEMP AT INLET 0-100 RTD - - - - 0-153-00-01063 PW CLRS DEG.AT INLET 0-10 PG - - LOCAL 0-153-00-01063 PW CLR-1 KG/CM2 Pt100 - - - PGB 71 CP502 CW PR. AT O/L 0-10 PG - - LOCAL 0-153-00-01063 OF PW CLR-1 KG/CM2 - - - - PGB 72 CP502 PR.O/L 0-100 RTD - - - - 0-153-00-01063 OF PW CLR-1 DEG.C - - - - PGB 62 CT502 TEMP AFT SO 0-100 TG - - LOCAL 0-149-00-01185 CLR 2 (A-S) DEG.C Pt100 MKY01GC001F GAMP - X REV 01 01 01 01 .C Pt100 MKY01GC001G GAMP - X - - - - SPARE - - - - - - - - - - - - - - PGB 62 CT001B TEMP.AT INLET 0-10 PG - - LOCAL 0-153-00-01063 PW CLR-2 KG/CM2 Pt100 - - - PGB 72 CP501 PR.O/L 0-100 RTD - - - - 0-153-00-01063 OF PW CLR-2 DEG.

C - - PGB 72 CT502 TEMP.C Pt100 MKY01GC001F - - PGB 72 CT501 TEMP.2.CNTRL 0-100 POS - - HMI - 0-153-00-01063 VALVE % 4-20mA MKY01GC001G GAMP - X REV .O/L 0-100 RTD - - - 0-153-00-01063 OF PW CLR-2 DEG.3-4030-10553/32 0709 E SLNO 421 422 TAG PID_REF 424 RANGE UNIT SENSOR TYPE JB1 JB2 CAB1 CAB2 IND REC PGB 72 CT002B TEMP.C - - - - ANN SETPTS ACTRL BIN SETPTS REMARKS CTR - - - - SPARE - - - - - - - - - - - - - ANALOG CONTROL WITH MOTORISED ACTUATOR. IND.AFTER 0-100 TG - - LOCAL - - 0-153-00-01063 423 SERVICE PW CLR-1 DEG. ON CRT CONSOLE PGB 73 CG001 PW TEMP.AFTER 0-100 TG - - LOCAL 0-153-00-01063 PW CLR-2 DEG.

The important requirement is that all checks and readings be made at certain predetermined intervals and preferably at the same load point. This table will.3-4100-0500/1 0709 E . 2. The observations and readings should be recorded. of course.Turbogenerators Running Routine Operation General 1. Any special conditions regarding the operation of the hydrogen-cooled BHEL. auxiliaries and all instruments and controls should be monitored to assure continuous reliable operation. Operating Log During initial startup and during normal operation. A generator at standstill is considered to have been taken into service and must be continuously monitored after one supply system was placed in operation. Normal and Special Operating Conditions The Generator should be continuously monitored from startup to shutdown. have to be adapted to the particular conditions of the plant. Haridwar turbogenerators should be noted separately. all checks should be made at frequent intervals. Such notes may be useful in determining the cause of any subsequent trouble and speeding up corrections. 2. the hydrogen-cooled Turbogenerators. A typical operating log is contained in these operating instructions. Hourly readings may be taken after completion of the initial period. During initial startup.

. Sl.........3-4120-0500/1 0709 E .................... Remark ...... Haridwar 2................... BHEL. Operating values* Unit Tag Number Active power MW Reactive power MVAR Stator current kA Stator voltage kV Rotor current A Speed s Generator gas pressure kg/cm -1 Slot 1 2 Slot temperature 3 4 5 6 0 0 0 0 0 0 0 C C C C C C Measuring point 1 outlet temperature Measuring point 2 0 C measuring point 3 0 C Measuring point 1 0 C TE Measuring point 2 0 C Stator core Measuring point 3 0 C temperature Measuring point 1 TE water manifold EE Measuring point 2 Measuring point 3 Gas temperature Coolers a/b cold Coolers c/d cold Coolers a/b hot Coolers c/d hot 0 0 0 0 0 0 C C C C C C 0 C EE After coolers a/b 0 C EE After coolers c/d 0 C 0 C TE 0 C EE 0 C Inlet Bearing oil temperature Outlet Generator bearing TE temperatures EE Shaft lift oil pressure Generator bearing vibration 0 0 2 C Primary water * Date C C TE kg/cm EE kg/cm TE ahv mm EE ahv mm 2 2 Data should be recorded during steady-state conditions after constant operation for several hours.....Turbogenerators Operating Log Operation Generator Supervision Job name ................................................... No......................................... ..

. Remark ............... Haridwar 2..... Inlet hydrogen side seal oil cooler Hydrogen side seal Outlet TE 0 0 0 2 2 2 C C Inlet 0 C Outlet 0 C Inlet 0 C Outlet. Sl. No.... ....................................... H2 side cooler 2 0 C Outlet........3-4150-0500/1 0709 E ....Turbogenerators Operating Log Operation Seal Oil System Job name ................... Operating values* Unit Air side pressure after seal oil pumps kg/cm 2 Hydrogen side pressure after seal oil pump kg/cm 2 Air side seal oil pressure after orifice kg/cm 2 TE kg/cm 2 EE kg/cm TE kg/cm EE kg/cm TE mbar EE mbar TE kg/cm EE kg/cm TE kg/s EE kg/s TE kg/s EE kg/s TE kg/s Air side seal oil pressure Hydrogen side seal oil pressure Seal oil differential pressure Ring relief oil pressure Air side seal oil volume flow Hydrogen side seal oil volume flow Ring relief oil volume flow EE Seal oil temperatures.......... Outlet............. BHEL....... air side cooler 2 2 C EE Cooling water temperatures Date kg/s 0 oil drain temperature air side seal oil coolers Tag Number 0 C Data should be recorded during steady-state conditions after constant operation for several hours...... H2 side cooler 1 0 C Outlet.................. air side cooler 1 0 C * 2 C Seal oil temperatures..........

.. Operating values* Unit H2 boottle pressure kg/cm2 CO2 boottle pressure kg/cm2 N2 boottle pressure kg/cm2 H2 purity (elec........................ purity meter system) % H2 H2 purity (mech......... purity meter system)** % H2 Gas flow for measuring H2 purity I/h H2 casing pressure kg/cm2 Temperature before gas dryer 0 Pressure before gas dryer kg/cm2 Tag......... Remark .......... BHEL..................3-4160-0500/1 0709 E ............ ............ Haridwar Date 2........ Sl.....Turbogenerators Operating Log Operation Gas System Job name ... Number C * Data should be recorded during steady-state conditions after constant operation several hours.................................. ** To be recordced only on failure of electrical purity meter system. No............

.............................Turbogenerators Operating Log Operation Primary Water System Job name ............................... No.....3-4170-0500/1 0709 E ........ Operating values* Unit Generator inlet 0 C Prinary water Stator winding outlet 0 C Temperature Bushing outlet 0 C Before coolers 0 C After collers 0 C Stator winding oulet dm 3/s Bushing outlet U dm 3/s Bushing outlet V dm 3/s Bushing outlet W dm 3/s Treated water dm 3/s Primary water Stator winding inlet kg/cm2 pressure After PW pumps 1/2 kg/cm2 Primary water conductivity After main filter µS/cm After ion exchanges µS/cm Prinary water flow Primary water level in primary water tank % Gas pressure in primary water tank kg/cm2 BHEL. ........................ Sl... Remark ........ Number Date 2........................... Haridwar Tag...................

.... No............... BHEL.. ...Turbogenerators Operating Log Operation Exciter Supervision Job name ..... Remark ......... Sl...................................... Haridwar 2......................................3-4190-0500/1 0709 E ................. Operating values* Cooling air temperature Main exciter Unit Cold air Hot air Rectifier wheels Hot air Coolers e/f Cooling water temperature Cooler e Cooler f Exciter bearing temperature 0 0 0 C C Inlet C Outlet 0 C Outlet Measuring Point 1 Measuring point 2 Bearing oil outlet temperature 0 C C 0 C 0 C Exciter shaft vibration Relative µm Exciter bearing vibration Absolute µm Shaft lift oil pressure * Date C 0 0 Tag Number kg Data should be recorded during steady-state conditions after constant operation several hours........................

3 Primary Water Supply The water quantity to be provided for filling the entire primary water circuit should amount to approximately two times the primary water filling quantity. the operating media required to fill the auxiliary systems should be made available. it should be ascertained that the following auxiliaries are in operation and will continue to remain in service. 1.4 Cooling Water Supply The coolers to be placed in operation should be filled with water. all connections should be rechecked.2.1 . 2. To do this. the cooler vents should be opened. 1.e.2. for filling the generator to operating pressure and to compensate for the H2 losses during operation [4]. the operating staff should ensure that a sufficient cooling water supply is available. 1. Before startup. The vents should be kept open until the air on the water side of the coolers has been completely expelled.2 Hydrogen (H2) The hydrogen gas quantity to be provided should suffice for displacing the CO2. The quantity of turbine oil required to fill the seal oil circuits should be taken into consideration when filling the turbine oil tank.Turbogenerators Preparations for Starting Operation Introduction It is a prerequisite for startup of the turbine generator that continuous contracts be maintained between all plant sections directly or indirectly involved in the starting procedure. This applies to piping as well as to cabling.1885 Primary Water Specification [3] 2. Q Q Q Q Q Turbine oil Carbon dioxide (CO2) Hydrogen (H2) Nitrogen (N2) Primary water Note : Continuous vents should remain open.1 . must conform to the specifications [1] and [2]. i. for displacement of the air prior to hydrogen filling and for Checking the Transmitters Also refer to the following information : [1] 2.4010 Gas Quantities BHEL. When doubts exist regarding the electrical temperature measurement.1 Seal Oil System The seal oil circuits should be filled with turbine oil. 1.1883 Gas Specification [2] 2. Unless temperature rises were brought about by other preparatory work at the measuring points.3 Nitrogen (N2) For primary water purging [4].1 Carbon Dioxide (CO2) The carbon dioxide quantity to be provided should suffice for two complete generator fillings [3]. temperatures of approximately ambient or room temperature should be indicated.2 Gas System 1. This allows for the water quantity required for rinsing the primary water circuit. All temperature measuring points should also be checked.2. 1. Haridwar 2. The operating media used. All alarm systems should be checked. 1. This applies to the local as well as the remote reading thermometers. 1. Q Q Q Q Seal oil system Gas system Primary water system Secondary cooling water system If auxiliaries were taken out of operation. calibration and line compensation should be repeated.e. When checking the cabling special attention should be paid to testing the metering and signal cables.3-5000-0500/1 0709 E . Prior to startup. Prior to startup. i. Operating Media immediate removal of the hydrogen from the generator.3 .

Stainless Steel Cooler Tubes Cooler tubes of stainless steel are susceptible to pitting and crevice corrosion under deposits.1 Copper or Copper Alloy Cooler Tubes Influences on the cooling water side can cause damage to the copper or copper alloy tubes of the coolers. 2. Admiralty brass (CuZn28Sn) is primarily used for fresh-water applications. The formation and the preservation of the protective film are essentially dependent on the conditions during initial commissioning and subsequent service. adverse influences should be minimized by suitable treatment procedures (e. 4 Initial Operation of Coolers Prior to placing the coolers in operation for the first time the cooling water system should be thoroughly cleaned by flushing to remove impurities and foreign matter. dispersant dosing.e. such as ammonia. Depending on the material used. standby coolers through which no cooling water flows for some period of time are subjected to all corrosive influences that can occur during an outage. 2. When using water directly obtained from natural water sources. possibly in conjunction with deposits. The corrosion rate decreases with increasing cooling water velocity.Turbogenerators Hints for Cooler Operation Operation 1 General The heat exchangers of the generator and its auxiliaries have copper. the growth of mussels must be prevented. The growth of micro organisms and. excessive cooling water velocity resulting from tube blockage by foreign bodies. in case of seawater installations. 3 Cooling Water Properties The cooling water used for the coolers must meet the following requirements : The cooling water must be free from coarse impurities Q BHEL. Copper and copper alloy tubes must from a protective film on the cooling water side to ensure adequate resistance to corrosion attack. this may lead to corrosion and/or stress corrosion cracking.2 insufficient protective film formation excessive cooling water velocity localized. cooling water must be continuously passed through coolers with copper alloy materials for the longest possible period of time (four to eight weeks) to ensure the formation of an effective protective film on the cooler tubes. Haridwar Q Q The amount of suspended material must be as small as possible. filtration. Details of the cooler tube materials are specified in the Technical Data section of this manual [1]. produce a corrosive influence. Corrosion damage can only be safely prevented if the standby coolers are drained on their water sides. Cooling water obtained from a closed secondary cooling water circuit mostly meets these requirements provided that the necessary care is exercised during initial operation.g. for example. bypass arrangements must ensure that the flushing procedure can be carried out without passing water through the coolers. chlorination and similar methods as specified in the literature). the coolers should not be in service on their cooling water sides.water service. especially when the cooling water has a high salt content and primarily when no cooling water is passed through the (standby) coolers for some time. while aluminium brass (CuZn20Al) is selected for sea. During this flushing procedure. by flushing the system without passing water through the coolers. copper alloy or stainless steel tubes. i. 5 Preventing Standstill Corrosion Depending on the cooler material and the kind and properties of the cooling water. Using cooler tubes of stainless steel with cooling water having a high salt content involves the risk of pitting and crevice corrosion when residual amounts of cooling water. Following the flushing procedure.3-5003-0500/1 0709 E . copper alloy or stainless steel tubes. 2 Cooler Tube Materials The coolers of the unit described have copper. deposits on tubes caused by suspended material and/or remnants of microorganisms which impair the formation of a protective film and promote corrosion. primarily in the form of erosion/corrosion and corrosion attack due to Q Q Q Q 2. especially in (standby) coolers having no cooling water flow for some time. This involves the risk that the microorganisms on the tube walls will die due to the lack of oxygen resulting from the loss of fresh water supply and form decay products during decomposition.

For drying the medium to be cooled can be passed through the coolers via the filler and vent pipes. it is recommended to perform a cooler changeover once every week so that the normal-service cooler and the standby cooler will be alternately in operation. If the temperature of the medium to be cooled is controlled by varying the cooling water volume flow. 8. this measure cannot be always implemented in practice. respectively improper cooler changeover would then result in heating and excessive expansion of the cooling water volume. Note : Standby coolers should be maintained ready for operation in dry condition in preference to wet preservation. For wet preservation always open a cooler vent on the water side or a shutoff valve by a small amount making sure to avoid a low-velocity water flow that would promote the entry of suspended material. For cleaning.1830 Cooler data 2. vented.g. 6.1 .1 Criteria for Cooler Changeover A cooler changeover is necessary when. 7. After cooler changeover. Also refer to the following information : [1] 2. Then open the shutoff valve on the outlet side by a small amount to avoid the effects of a water expansion due to water heating. Special Measures for Wet Preservation If a cooler has to be maintained ready for service in filled condition. leading to damage to the cooler gaskets or piping due to excessive pressure. If frequent manual cleaning is necessary on account of poor cooling water conditions. However. leakage). since the cooling water system is mostly designed only for supply of the cooling water flow through the normal-service cooler(s). especially in the case of brief outages and because of the need to maintain the cooler ready for operation. Preventing Deposits in Cooler Tubes Deposits in the cooler tubes are best prevented by supplying the normal-service coolers with the full cooling water volume flow. with the valves in the cooling water circuit fully open. In addition. the water volume in the cooler must not be hermetically sealed from the cooling water system or from the surrounding atmosphere. To do this. If a cooler has to maintained ready for service in filed condition. completely dried. < 100 mg/1 for stainless steel tubes). During occasional outages of sufficient duration or during an overhaul. and maintained in a dry condition.3-5003-0500/2 .cleaned. the installation of a high-velocity water cleaning system or of a cleaning system using sponge rubber balls should be considered. 8. the coolers may be flushed with water having a low salt content (Cl content < 500 mg/l for copper alloy tubes. it should than be checked whether in-service flushing is sufficient or whether manual cleaning is required. close shutoff valves upstream and downstream of the standby cooler. Fully open shutoff valves. Cooler Changeover Make sure to fill and vent standby coolers on their water sides prior to changing over the coolers. perform all measures required for preservation of the cooler removed from normal service and now on standby. the temperature of the medium to be cooled is rising above the normal level or when required on account of abnormal events (e. which must be performed by experienced personnel. it is recommended to supply the normal-service cooler with the full cooling water volume for a brief period twice every week in order to flush away any deposits formed on the tubes due to insufficient cooling water velocity. it should be flushed with the full cooling water volume flow for a brief period twice every week.

oil inlet) (after float valve. EE) (hydrogen side oil signal. Direction of pump rotation and oil level in seal oil pumps must have been checked. Note: All operating procedures should be performed in sequence specified. EE) MKW01 AA503 MKW11 AA504 MKW11 AA505 MKW31 AA504 MKW33 AA 505 MKW11 AA501 MKW21 AA501 MKW31 AA501 MKW11 AA003 MKW21 AA002 MKW31 AA003 MKW31 AA004 MKW11 AA004 MKW03 AA502 MKW03 AA501 MKW03 AA505 (at seal oil storage tank) (before A1 valve) (after A1 valve) (before A2 valve) (After A2 Valve) (before seal oil pump 1) (before seal oil pump 2) (before stand by seal oil pump 3) (after seal oil pump 1) (after seal oil pump 2) (after standby seal oil pump 3) (after standby seal oil pump 3) (after seal oil pumps) (before float valve. Seal oil storage tank must be filled with oil. TE) (hydrogen side oil signal.1 Open all pressure gauge shutoff valves 2. oil drain) (for oil level gauge) 2.Turbogenerators Filling and Initial Operation Operation of Air Side Seal Oil Circuit Prerequisites for filling of air side seal oil circuit 1 Preparatory work for start-up Q Q Q Q Q Seal oil circuit must have been cleaned and flushed.2 Open shutoff valves in signal pipes 2.3-5110-0500/1 0709 E . TE) (air side oil signal. Haridwar MKW11 AA506 MKW31 AA506 MKA23 AA503 MKA23 AA504 MKW71 AA513 MKW73 AA513 MKW71 AA523 MKW73 AA523 (air side oil signal to A1 valve) (air side oil signal to A2 valve) (gas signal to A1 valve) (gas signal to A2 valve) (air side oil signal. 2 Fill air side seal oil circuit 2. All relief valves must be set.3 Open shutoff and gate valves in air side seal oil circuit BHEL. All level detectors in seal oil system must be calibrated and activated.

TE) (seal ring relief oil. With the valve. When the coolers are filled with seal oil. Ensure that second exhauster is ready for start-up. Note : After filling. turn rotary transfer valve assembly to right-hand or left-hand stop. the shutoff valve for cooling water after the cooler should be closed. TE) (air side seal oil pressure. Place one exhauster in operation electrically. air in the piping must be slowly displaced with oil.4 Place seal oil coolers in operation 2. With seal oil storage tank MKW01 BB001 filled and shutoff valve MKW01 AA503 open.7 Start air side seal oil pump MKW11 AP001 (for oil level gauge) (adjustable orifice) (after volume flow indicator MKW71 CF511) (after volume flow indicator MKW71CF521) (after volume flow indicator MKW76 CF511) (after volume flow indicator MKW76 CF521) (seal ring relief oil. The pump should then remain in continuous operation. EE) indicate a constant pressure. one filter is in service and one filter on standby. De-energize seal oil pump immediately when the 2. With the valve assembly in this position. turn rotary transfer valve assembly to right-hand or left-hand stop.e. When the filters are filled with seal oil. The seal oil cooler placed in operation on the oil side should also be filled and vented on its water side. Start and immediately stop main seal oil pump several times until the pressure gauges at the generator. EE) Place both seal oil coolers in operation on oil side with rotary transfer valve assembly in its center position. Start seal oil pump 1. filters in operation with rotary transfer valve assembly in its center position.3-5110-0500/2 . assembly in this position. i.5 Place seal oil filters in operation 2.6 Place bearing vapor exhausters in operation 2.MKW03 AA506 MKW71 BP501 MKW71 AA512 MKW71 AA522 MKW76 AA512 MKW76 AA522 MKW76 AA513 MKW76 AA523 2. MKW71 CP511 MKW73 CP521 (air side seal oil pressure. Note : To avoid a temporary excessive pressure built up in the piping system. one cooler is in service and one cooler on standby. seal oil is available at seal oil pump 1 after a short time. Place both seal oil.

3-5110-0500/3 0709 E . and the flow of oil from the air side circuit into the seal oil tank is interrupted. the seal oil tank is simultaneously filled with seal oil via float valve MKW03 AA002. Start with filling of hydrogen side seal oil circuit.Turbogenerators Operation level detector system in the seal oil storage tank signals a low oil level. resulting in a rise of the oil level above the sight glass.8 Observe oil level in seal oil tank MKW03 BB001 During filling of the air side circuit. Haridwar 2. This is caused by the lack of pressure in the generator. 2. Restarting the seal oil pump is only permissible after the seal oil storage tank has been filled to the required level. However. The float valve closes when the oil level reaches a predetermined level. 2. oil will continue to flow from the hydrogen side of the shaft seal into the seal oil tank. BHEL.9 Set three-way valves before volume flow indicators to position for normal operation 3 Air side seal oil circuit is filled Set three-way valves MKW71 AA511 (before volume flow indicator MKW71 CF511) MKW71 AA521 (before volume flow indicator MKW71 CF521) MKW76 AA511 (before volume flow indicator MKW76 CF511) MKW76 AA521 (before volume flow indicator MKW76 CF521) to position where no oil passes through the volume flow indicators.

3-5120-0500/1 0709 E .1 Open shutoff and signal pipes 2.2 Open shutoff and gate valves Q Air side seal oil circuit was filled and is in operation. The seal oil cooler placed in operation on the oil side should also be filled and vented on its water side. turn rotary transfer valve assembly to right-hand or left-hand stop. turn rotary transfer valve assembly to right-hand or left-hand stop. BHEL. Haridwar Pace both seal oil filters in operation with rotary transfer valve assembly in its center position. MKW13 AA507 MKW13 AA505 MKA13 AA506 (signal equalization. When the filters are filled with seal oil. one filter is in service and one filter on standby. C valve) (air side oil signal.3 Place seal oil coolers in operation Place both seal oil coolers in operation on oil side with rotary transfer valve assembly in its center position. With the valve assembly in this position.4 Place seal oil filters in operation. the shutoff valve for cooling water after the cooler should be closed. C valve) MKA13 AA501 MKW13 AA003 MKW13 AA510 MKW73 AA512 (before hydrogen side seal oil pump) (after hydrogen side seal oil pump) (after C valve) (after volume flow indicator MKW73 CF511) (after volume flow indicator MKW73 CF512) (before seal oil cooler) MKW73 AA522 MKW13 AA503 2. 2. 2.Turbogenerators Filling and Initial Operation Operation of Hydrogen Side Seal Oil Circuit Prerequisites for filling of hydrogen side seal oil circuit : 1 Preparatory work for start-up 2 Fill hydrogen side seal oil circuit 2. Note: All operating procedures should be performed in sequence specified. C valve) (hydrogen side oil signal. Note : After filling. When the coolers are filled with seal oil. one cooler is in service and one cooler on standby. With the valve assembly in this position.

.3-5120-0500/2 Start with venting of seal oil circuits.7 Set three-way valves before volume flow indicators to position for normal operation Set three-way valves : MKW73 AA511 (before volume flow indicator MKW73 CF511) MKW73 AA521 (before volume flow indicator MKW73 CF521) to position where no oil passes through the volume flow indicators. 3 Hydrogen side seal oil circuit is filled. 2. Start and immediately stop pump several times until the air has been displaced from the piping. The pump should then remain in continuous operation.5 Place and keep hydrogen side seal oil pump MKW13 AP001 in operation Place hydrogen side seal oil pump in operation electrically.2.6 Close signal equalizing valve MKW13 AA507 at C valve 2. 2.

1.1 Vent signal pipes and main bellows of differential pressure regulating valves (A1.3 Vent seal oil filters Vent seal oil filters in air side and hydrogen side circuits through venting screws on filter housings. Vent seal oil coolers in air side and hydrogen side seal oil circuits by means of vent valves : MKW51 MKW51 MKW53 MKW53 AA511 AA510 AA511 AA510 (air side seal oil cooler 1) (air side seal oil cooler 2) *hydrogen side seal oil cooler 1) (hydrogen side seal oil cooler 2) Close vent valves when oil emerges without bubbles. Close valves when oil emerges without bubbles.2 Vent seal oil coolers Keep vent valves at differential pressure regulating valves open until oil emerges without bubbles. Haridwar Open vent valves MKW73 AA514 (in hydrogen side signal pipe) MKW71 AA514 (in air side signal pipe) for venting the signal pipes up to the pressure equalizing valve.5 Vent signal pipes and main bellows of pressure equalizing value MKW73 AA011 Venting should be performed as follows : Q Q BHEL. Close shutoff valve MKW71 AA513 (for air side oil signal) 2.Turbogenerators Venting of Seal Oil Circuits Operation 1 Vent seal oil circuit 1.4 Vent all signal pipes to the pressure measuring devices through the venting screw of the respective pressure gauge shutoff vale. Then loosen venting screws and vent main bellows of differential pressure regulating valves. 1. 1.3-5130-0500/1 0709 E . A2 and C valves) 1.

2.and open vent valve MKW71 AA514 to vent the main bellows of the pressure equalizing valve close vent valve when oil emerges without bubbles.3-5130-0500/2 to vent the main bellows of the pressure equalizing valve close vent valve when oil emerges with bubbles. Close shutoff valve MKW71 AA523 (for air side oil signal) and open vent valve MKW71 AA524 to vent the main bellows of the pressure equalizing valve. . Shutoff valve MKW71 AA523 should then be reopened. Q Close shutoff valve MKW73 AA523 (for hydrogen side oil signal) and open vent valve MKW73 AA524 2 Venting of all circuits and components of the seal oil system is cimpleteed. 1. Close valves when oil emerges without bubbles. Shutoff valve MKW73 AA523 should then be reopened. Close vent valve when oil emerges without bubbles. Shutoff valve MKW71 AA513 should then be reopened.6 Vent signal pipes and main bellows of pressure equalizing valve MKW73 AA021 Venting should be performed as follows : Q Q Open vent valves: MKW71 AA524 (in hydrogen side signal pipe) MKW71 AA524 *in air side signal pipe) for venting the signal pipes up to the pressure equalizing valve.

2 Set seal oil pressure for seal ring relief 1.3-5150-0500/1 0709 E . Adjust orifice MKW71 BP501 and A valve MKW11 AA002 so that the seal oil pressure for seal ring relief will be higher than the seal oil pressure at the shaft seals by approximately 1 bar. make sure to observe the static head of the respective units and instruments. Final adjustment can only be made when the generator is filled to rated pressure and operated at rated speed. Hydrogen side seal oil pressure is decreased by turning threaded stem clockwise and increased by turning counterclockwise. Check that temperatures of air side and hydrogen side seal oil are approximately equal.Turbogenerators Setting of Seal Oil Pressures Operation 1 Set seal oil pressures 1. Haridwar Note : Values indicated below apply to the generator at standstill and seal oil temperatures after coolers of 20 to 300C. When making the final adjustment. Loosen lock nut at valve stem. also check the running condition of the turbine-generator. This higher pressure is required to enable the pressure equalizing valves to maintain a constant seal oil pressure. When setting the pressures. Counterclockwise tuning of adjusting nut decreases seal oil pressure at shaft seals. since an incorrectly set seal oil pressure may impair the running condition of the generator. Use C valve to adjust oil pressure after hydrogen side seal oil pump.5 bar above the gas pressure in the generator is established at shaft seals.4 Adjust pressure equalizing valves MKW73 AA011 and MKW73 AA021 for hydrogen side circuit BHEL.1 Adjust A1 valve MKW11 AA002 1. The seal oil pressure after the hydrogen side seal oil pump must be higher than the seal oil pressure at the shaft seals.3 Adjust C valve MKW13 AA002 1. Turn adjusting nut to set A11 valve so that a seal oil pressure of approximately 1. pressure differences between air side and hydrogen side seal oil pressures are indicated by differential pressure gauges MKA06 CP501 and MKA07 CP501. Remove lower cap and loosen lock nut. Setting should be made in the same way as for the A valve by turning the adjusting nut. Note : Adjustment is preliminary only since shaft seals are not yet subjected to generator casing pressure. Note : Clockwise turning of adjusting nut increases seal oil pressure at shaft seals. 2.

Under normal condition. Make sure that position of upper threaded stem has not been changed. 2. the seal oil pressure must be the same as when operating with A1 valve. 1. During operation with A2 valve. tighten lock nut and replace cap. Stop operation of seal oil pumps 1 and 2. if required.After completion of the adjustment. A1 valve is the controlling valve.5 Adjust A2 valve MKW31 AA002 Note : The operating values for the A1 and C valves should be measured so they can be used as target values before starting with adjustment of A2 valve. 2 Setting of seal oil pressures is completed Set alarm and changeover contacts.3-5150-0500/2 . Standby seal oil pump 3 will start automatically. Make adjustment in the same manner as was done for A1 valve. Recheck and . correct setting when the generators is in operation.

Haridwar 2. If necessary. Remove hex plug from stator end shield located near the level detector. The oil level will drop. The alarm is activated as soon as the oil level reaches the level detector. The oil level in the generator pre-chambers will rise. Shutoff valve MKW03 AA501 should then be opened immediately and secured to prevent closing. Separate functional testing is required for each level detector. Alarm contacts at differential pressure indicators are set so that alarm will be initiated when filters are contaminated. correct pressure switch setting to match actual pressure conditions. This check is only permissible when the generator is filled with air at 0 bar. Take seal oil pump MKW13 AP001 out of service. Cancel the alarm. Close shutoff valve MKW03 AA501.1 Turbogenerators Setting of Operating Values Operation for Seal Oil system Set operating values for seal oil system 2 Alarm contacts at twin filters in air side and hydrogen side circuits 3 Check function of pressure switches 4 Check function of level detectors MKA06CL001 and MKA07 CL001 in installed condition Check function of complete control and supervisory equipment. 1 Level Detector BHEL.3-5160-0500/1 0709 E . 1 2 3 1 Stator end Shield 2 Hex Plug 3 Level Detector Fig. Check function of all pressure switches in installed condition.

replace hex plug. Set limit cards for temperature monitoring to operating 2. making sure that a gas tight seal is obtained.3-5160-0500/2 .5 Set limit cards for temperature monitoring 6 checking and setting of supervisory equipment is completed If seal oil flows from the threaded hole without an alarm being give. the cause of the level detector malfunction should be investigated. After completion of a successful test. shutoff valve MKW03 AA501 should then also be opened immediately. in such a case.

EE) Adjust three-way valves MKW76 AA511 and MKW76 AA521 so that relief oil flows via volume flow meters. TE) MKW76 AA522 (for seal ring relief. MKW71 AA512 (before TE shaft seal) MKW71 AA522 (before EE shaft seal) Adjust three-way valves MKW71 AA511 and MKW71 AA521 so that seal oil flow via volume flow meters. 4 Open shutoff valves for ring relief oil volume flow measurement MKW76 AA 512 (for seal ring relief. Haridwar 2. BHEL. MKW73 AA512 MKW73 AA522 (before TE shaft seal) (before EE shaft seal) Adjust three-way valves MKW73 AA511 and MKW73 AA521 so that seal oil flows via volume flow meters. 5 Volume flow meters are activated Start with next settings.3-5163-0500/1 0709 E .Turbogenerators Measurement of Seal Oil Volume Flows Operation 1 Measure volume flows 2 Open shutoff valves for seal oil volume flow measurement in air side circuit 3 Open shutoff values for seal oil volume flow measurement in hydrogen side circuit.

turn on the cooling water supply to cooler selected for operation so as to obtain the specified heat removal capacity. The vacuum should be between approximately 5 to 10 mbar. When a seal oil temperature more than 400C has been reached.3-5180-0500/1 0709 E . 6 Filling and startup procedures are completed being normal running routine BHEL.1 Turbogenerators Functional Testing of Pumps and Operation Exhausters Perform functional test 2 Check standby seal oil pump for proper operation 3 Check pumps for automatic operation 4. 5 Check bearing vapor exhausters for proper operation Measure vacuum in bearing compartments with a U-tube pressure gauge while the bearing vapor exhauster is in operation. Haridwar 2.

3-5210-0500/1 0709 E . to be filled with air for leakage testing or to be operated under load.2 Check if shutoff valves in seal oil circuit are open BHEL. The system will normally be ready for startup when it was shut down in accordance with the respective instructions. oil drain) MKW03 AA505 (for oil level gauge) MKW03 AA506 (for oil level gauge) MKW71 BP501 (adjustable orifice) MKW71 AA512 (after volume flow indicator MKW71 CF511) MKW71 AA522 (after volume flow indicator MKW76 CF511) MKW76 AA522 (after volume flow indicator MKW76 CF521) 2.Turbogenerators Startup of Air Side Seal Oil Circuit Operation 1 Startup of air side seal oil circuit The seal oil system must be in operation when the generator is : to be filled with hydrogen. Prior to startup. Place one bearing vapor exhauster in operation.1 Check to ensure that all pressure gauge shutoff valves are open 1. 1. Haridwar Open shutoff valves in specified sequence MKW01 AA503 (at seal oil storage tank) MKW11 AA504 (before A1 valves) MKW11 AA505 (after A1 valve) MKW31 AA504 (before A2 valve) MKW31 AA505 (after A2 valve) MKW11 AA501 (before seal oil pump 1) MKW21 AA501 (before seal oil pump 2) MKW31 AA501 (before standby seal oil pump 3) MKW11 AA003 (after seal oil pump 1) MKW21 AA002 (after seal oil pump 2) MKW31 AA003 (after standby seal oil pump 3) MKW31 AA004 (after standby seal oil pump 3) MKW11 AA004 (after seal oil pumps) MKW03 AA502 (before float valve. make sure that all indicating devices are ready for operating and that the Preparations for Starting have been carried out. oil inlet) MKW03 AA501 (after float value.

. MKW03 BB001 1. TE) (hydrogen side oil signal. This is caused by the lack of pressure in the generator. Seal oil pump 1 should then be kept in continuous operation.1. Oil will continue to flow from the hydrogen side of the shaft seal into the seal oil tank. the seal oil tank is simultaneously filled with seal oil via float valve MKW03 AA002. During filling of air side circuit. EE) Check oil level in seal oil pumps.5 Check oil level in seal oil tank MKW03 BB001 MKW11 AA506 MKW31 AA506 MKW23 AA503 MKW23 AA504 MKW71 AA513 MKW73 AA513 MKW71 AA523 MKW73 AA523 (air side oil signal to A1 valve) (air side oil signal to A2 valve) (gas signal to A1 valve) (gas signal to A2 valve) (air side oil signal.3-5210-0500/2 Start with filling of hydrogen side seal oil circuit.3 Verify that shutoff valves in signal lines of air side circuit are open 1. resulting in a rise of the oil level above the sight glass. EE) (hydrogen side oil signal. 2 Air side seal oil circuit is now in operation 2.4 Start air side seal oil pump 1. Place seal oil pump in operation. Note : To avoid a temporary excessive pressure build up in piping system. Start and immediately stop seal oil pump several times until all air is removed from the piping system. air in piping must be slowly displaced with oil. The float valve closes when the oil level reaches a predetermined level. TE) (air side oil signal.

3-5220-0500/1 0709 E .5 Start hydrogen side seal oil pump MKW13 AP001 2 Hydrogen side seal oil circuit is now in operation BHEL. 1 Start-up of hydrogen side seal oil circuit 1.3 Check to assure that shutoff valves in hydrogen side circuit are open no MKW13 MKW13 MKW13 MKW73 AA501 AA003 AA510 AA512 MKW13 AA513 (before hydrogen side seal oil pump) (after hydrogen side seal oil pump) (after C valve) (after volume flow indicator MKW73 CF511) (after volume flow indicator MKW73 CF521) (before seal oil cooler) MKW13 AA507 MKW13 AA505 MKW13 AA506 (signal equalization.Turbogenerators Startup of Hydrogen Side Seal Oil Operation Circuit The air side seal oil circuit must be in operation.4 Verify that shutoff valves in signal lines of hydrogen side circuit are open 1.1 Seal oil level is observable at sight glass of seal oil tank 1. C valve) (air side oil signal to C valve) (hydrogen side oil signal to C valve) MKW73 AA522 1. Haridwar Start with venting of seal oil circuits 2.2 Fill seal oil circuit 1.

2 Check seal oil filters for contamination and clean filters. A2.1 Turbogenerators Venting of Seal Oil Circuits and Operation Checking of Seal Oil Pressures Vent and check oil pressures 2 Vent coolers and filters 2.3-5230-0500/1 0709 E .3 Fill service seal oil cooler on water side and vent cooler 3.1 Vent seal oil coolers (oil side) and seal oil filters Keep vent valves of all seal oil coolers and vent plugs of seal oil filters open until the oil emerges without bubbles. 3. C valves and pressure equalizing valves.1 Vent oil signal lines. Cleaning will be required. When the indicator is completely red. if required The degree of filter contamination can be seen at the differential pressure gauge. 2.3 yes Is pressure gauge reading correct ? no BHEL. Haridwar 2. 2. Adjust A1.2 Ven pressure gauges 3.

if required. adjust operating values for seal ring relief 5 Seal oil pressures are set 2. when the seal oil is hot and when the generator operates at rated speed. . Start with functional tests.3 Oil pressures are in agreement with the previous operating values.3-5230-0500/2 no Note : Final adjustment of the pressure for ring relief can only be made when the generator has been filled with hydrogen to rated pressure. 4 Check and.

Begin with normal running routine BHEL. Haridwar 2.3-5280-0500/1 0709 E .1 Turbogenerators Checking Automatic Operation of Operation Seal Oil Pumps Perform functional test 2 Check standby seal oil pump for proper operation 3 Check automatic operation of pumps 4 When a seal oil temperature is more than 400C. 6 End of starting procedure. turn on the cooling water supply to cooler selected for operation so as to obtain the specified heat removal capacity 5 Check bearing vapour exhausters for proper operation.

Haridwar 2.3-6107-0500/1 0709 E .Turbogenerators Positions of Multi-Way Valves Operation in Gas System BHEL.

Close shutoff valves and three-way valves. With the power supply switched off. MKG25 MKG25 MKG25 MKG25 AA519 AA518 AA502 AA512 (H2 filter line) (CO2 filter line) (vent gas) (sampling) Scavenge piping system with hydrogen prior to electrical commissioning of the meter system. BHEL. Transmitter terminals not connected to an indicator must be connected to the equivalent resistor (200 or 290 ohm. 2. make setting in accordance with applicable service instructions. this should be done by means of the zero setter. H2 H2 H2 H2 bottle rack) unit) bottle rack) unit) Turn adjusting screws counterclockwise to bring each pressure reducer to lower end of low-pressure range.1 Prepare to scavenge measuring gas system During commissioning make sure that no hydrogen (H2) is introduced into the air filled generator. Check gas lines and wiring of the meter system for correct installation. incorporated in transmitter) by inserting a jumper (connect negative terminal with terminal (*)).1 Turbogenerators Scavenging the Electrical Operation Gas Purity Meter System Preparatory work 2 Set mechanical zeros Prior to activating the purity meter system. set output instruments to their mechanical zeros.2 Set H2 pressure reducers to minimum lowpressure setting Loosen the locks for the adjusting screws of H2 pressure reducers. In case of recorders. In case of indicators. 2. 1. leak tests of the generator and its auxiliaries must be finished.3-6110-0500/1 0709 E . Connect one full bottle of H2 to the bottle rack 3. MKG11 MKG19 MKG12 MKG19 AA001 AA001 AA001 A002 (H2 (H2 (H2 (H2 pressure pressure pressure pressure reducer reducer reducer reducer 1. 3 Scavenge measuring gas system 3. Haridwar 2.

8 Terminate scavenging procedure and set measuring gas volume flow 4 End of scavenging procedure 2.5 Set pressure reducer for measuring gas to minimum low-pressure setting. . Gas side of meter system is ready for measurement after a scavenging period of 30-60 Minutes. Set H2 pressure reducers 1 and 2 in H2 unit to rated gas pressure. 3. H2 unit) MKG19 AA502 (after H2 pressure reducer. H2 unit) or MKG11 AA501(H2 bottle) MKG11 AA531(H2 bottle rack manifold) MKG12 AA501 (before H2 pressure reducer. Flow path upstream of three-way valve MKG25 AA507 is now open. open the following shutoff valves : MKG11 AA501 (H 2 Bottle) MKG11 AA531(H2 Bottle rack manifold) MKG11 AA561(Before H2 pressure reducer-1. H2 unit) Set H2 pressure reducers 1 and 2 in bottle rack to a gauge pressure of approximately 8 bar. Loosen the lock for adjusting screw of the pressure reducer. Switch three-way valve MKG25 AA507 to H2 flow towards gas purity meter system.3-6110-0500/2 Increase gas volume flow at pressure reducer MKG25 AA003 until float in flow indicator MKG25 CF501 reaches a scale value of 220 (=20 dm3/h H2 ). Check and readjust flow rate several times during the next few minutes. H2 bottle rack) MKG15 AA504 (for H2 high pressure) MKG15 AA502 (before H2 pressure reducer-1.3. Start with setting of electrical zero.6 Three-way valve MKG25 AA507 To set the flow path.3 Set flow path of measuring gas. Turn adjusting screw counterclockwise to being pressure reducer to low end of low-pressure range. Open shutoff valves 3.7 Set scavenging gas volume flow 3. H2 bottle rack) MKG15 AA501 (after H2 pressure reducer-1. H2 unit) MKG15 AA501 (after H2 pressure reducer. the locks for adjusting screws of the pressure reducers must be retightened firmly. H2 bottle rack) MKG15 AA504 (for H2 high pressure) MKG17 AA505 (before H2 pressure reducer-2. Reduce gas volume flow at pressure reducer MKG25 AA003 until in flow indicator MKG25 CF501 reaches a scale value of 140 (=18dm3/h H2 ). 3.2.4 Set H2 pressure reducers to rated gas pressure. Subsequently. 3. H2 bottle rack) MKG16 AA501 (after H2 pressure reducer-2.

Turn range selector to positing III. Set electrical zero after a warm-up period of 30 minutes. MKG11 AA501 MKG11 AA531 MKG11 AA561 MKG15 AA501 MKG15 AA504 MKG15 AA502 MKG19 AA501 MKG25 AA507 or MKG11 AA501 MKG11 AA531 MKG12 AA501 MKG16 AA501 MKG15 AA504 MKG17 AA505 MKG19 AA502 MKG25 AA507 3 End of calibration procedure BHEL. Close shutoff valves and three-way valve. De-energize purity meter system and remove ammeter.7 mA. Hydrogen is now used as measuring and comparison gas and therefore the bridge must be balanced. H2 unit) (after H2 pressure reducer 2.. Any deviation can be adjusted by miens of zero adjusting resistor R3. regulator or recorder for electrical commissioning of the purity meter system. (after H2 pressure reducer 1... The output voltage of purity transmitter must be 0 mV. H2 unit) (after H2 pressure reducer 1. Indicator (100-76% H2 in air) should read 100% H2. Switch on power supply (if required) to amplifier. The H2 volume flow passing through the transmitter is now set and must not be changed. calibration) The electrical purity meter system is now calibrated purity measurements for CO2 and H2 filling and removal and for H2 operation can be performed. connect an ammeter with a range of 0 . H2 unit) (measuring gas. Haridwar (H2 bottle) (H2 bottle rack manifold) (before H2 pressure reducer 1. (for H2 high pressure) (before H2 pressure reducer 2. 0.3-6120-0500/1 0709 E .1 To check bridge supply current. 2.. The hydrogen volume flow set prior to checking of the bridge supply current is used for the setting of the electrical zero.5 A and an internal resistance of 750 milli-ohm between terminal (+) (balancing terminal of power supply) and the lead run from this terminal to terminal (+) of the purity transmitter. No current flows between the dividing points of the bridge..1 Turbogenerators Setting Electircal Zero of Operation Electircal Gas Purity Meter System Check bridge supply current 2 Set electrical zero 2. If another value is obtained. and accordingly a 100% H2 indication should be displayed on the indicators selected by means of the range selector switch. H2 unit) (measuring gas. calibration) (H2 bottle) (H2 bottle rack manifold) (before H2 pressure reducer 2. Bridge supply current must be 335 + 1. (for H2 high pressure) (before H2 pressure reducer 1. (after H2 pressure reducer 2. adjust ridge supply current at potentiometers R3 and R6 in power supply unit..

2 Turn range selector to position 1 1. The indicator should display a reading of 100% CO2 in air).Turbogenerators Purity Measurement During CO2 Filling Operation 1 Measure purity during CO2 filling 1. After a shortened warm-up period.1 Electrical commissioning of meter system 1. Haridwar Switch on power supply. Since the purity meter measures the vent gas purity.3-6130-0500/1 0709 E . CO2 filling can be terminated when the purity amounts to approximately 95% CO2 in air. 2. the system is ready for measurement during CO2 filling Turn range selector to position 1 (0 to 100% CO2 in air).3 Observe purity changes during CO2 filling 2 Terminate purity measurement used during CO2 filling BHEL. The flow path of the measuring gas (extracted before orifice MKG25 BP502) is as follows : Pressure reducer for measuring gas Flow meter for measuring gas CO2/ H2 purity transmitter To atmosphere. it can be seen from the indicator scale when the generator is filled with CO2.

1. 2 Terminate purity measurement used during H2 filling. 2. BHEL.3-6140-0500/1 0709 E .1 Turn range selector to position II. Turn range selector to position II (0 to 100 % CO2 in H2 ) The flow path of the measuring gas (extracted before orifice MKG25 BP502) is as follows : Shutoff valve for measuring gas (filling) Pressure reducer for measuring gas Flow meter for measuring gas CO2/H2 purity transmitter To atmosphere.2 Observe purity changes during H2 filling. Haridwar H2 filling is terminated when the purity is approximately 98% H2.Turbogenerators Purity Measurement During H2 Filling Operation 1 Measure purity during H2 filling 1.

2 Check measuring gas volume flow Turn range selector to position III (100 to 76% H2 in air) The meter system measures the purity of the measuring gas extracted from the generator housing The measuring has volume flow is to keep the float at a scale value of 140 in flow indicator ST11 F501. Haridwar 2. 2 The H2 purity meter system is ready for service.3-6150-0500/1 0709 E . 1. Start with normal running routine for supervision of purity in generator housing BHEL. Provide variations of the volume flow by pressure reducer ST11 N501.Turbogenerators Purity Measurement During H2 Operation Operation 1 Measure purity during H2 operation 1.1 Turn range selector to position III.

Never use fire or an open flame (welding. flame-cutting. etc.1 Turbogenerators Gas Filling Operation Replacing Air With CO 2 Hints and preparatory work. smoking.3 Open shutoff and three-way valves. Filling during turning gear operation will result in a higher gas consumption due to the whirling motion between the medium to be displaced and the medium admitted. All lines carrying gas during this procedure are represented by yellow lines on the mimic diagram of the gas valve rack.2 Switch on heater of CO2 flash evaporator. BHEL.) in the vicinity of the generator and the hydrogen system at any time. The seal oil system and the bearing vapor exhauster must be in operation and will positively remain in service period to starting with the gas filing procedure. Wait until thermostat switches off the heater at the preset temperature. Making this connection should only be done when compressed air from the station air system is required for removing the carbon dioxide (CO2) form the generator or for performing a leakage test. Filling and emptying the generator should be performed with the generator at rest or on turning gear. 2. even when starting with the preparations for generator filling. Ensure that the pose between compressed air filter MKG25 BT001 and shutoff valve MKG25 AA501 is nor connected. at the gas dryer and in the bottle rack are closed. 2 Fill generator with carbon dioxide (CO2). do not perform any filling or purging operations with the generator at higher speeds than during turning gear operation. Check to ensure that all shutoff and three-way valves in the gas valve rack. 2.3-6310-0500/1 0709 E .1 Open all pressure gauge shutoff valves. For this reason. 2. MKG25 MKG25 MKG25 MKG25 AA519 AA502 AA518 AA561 (three-way valve in position H2 vent gas) (shutoff valve in H2 vent gas line) (three-way valve in position CO2 filling) (shutoff valve for CO2 high pressure) 2. Haridwar Switch on heater of CO2 flash evaporator. CO2 flash evaporator was filled with heat transfer liquid up to lower edge of the riser. Observe temperature rise of heat transfer liquid at temperature gauge.

4 Turn range selector to position I and measure CO2 purity Check zero setting of CO2/H2 purity transmitter. Switch off heater of CO2 flash evaporator. 2. check to ensure that a sufficient amount of CO2 is available for the next generator purge. Start with H2 filling. 2.Then open shutoff valves at CO2 bottles and at CO2 bottle rack manifold. If the open CO2 bottles are not yet completely empty. Filling with CO2 may be terminated when a purity in excess of 95% CO2 in air has been reached. 2.3-6310-0500/2 . MKG25 AA 518 MKG51 AA 561 MKG25 AA 519 (three-way valve in CO2 filler line) (shut off value for CO2 high pressure) (three-way valve in H2 filler line) Close all shutoff values at CO2 bottle rack manifold and CO2 bottles.6 Close shutoff and three-way valves. 3 The generator is filled with carbon dioxide.5 Terminate filling with carbon dioxide. Replace empty CO2 bottles by full bottles. the residual carbon dioxide should also be admitted into the generator. Set range selector switch in CO2/H2 purity transmitter to position 1 (0-100% in air) 2. 2.7 Check if sufficient CO2 is available for next generator purge Prior to starting with H2 filling.

turn range selector switch to position III (100 to 76% H2 in air). In excess of 20% CO2 in H2.1 Turbogenerators Gas Filling Operation Replacing CO 2 With H 2 Fill generator with H2 to operating pressure All lines carrying gas during this procedure are represented by red lines on the mimic diagram of the gas valve rack. Pressure after pressure reducers in H2 unit must be set to rated gas pressure. In case of indicator (position II) shows H2 purity. if required. The increase in H2 purity can be seen at the indicator since the purity meter system continues to measure the vent gas purity. correct measuring gas flow. Haridwar Turn range selector in CO 2/H 2 purity transmitter to position II (0 to 100% CO2). 2. H2 filling should be performed by operating the H 2 bottles separately.2 Turn range selector to position II 1. Check and.3-6320-0500/1 0709 E . Note: Pressure after pressure reducers in bottle rack must be approximately 8 bar. Continue H2 filling until indicator gives a reading of approximately 98% H2 in air.3 Observe H2 purity indication and turn range selector to position III BHEL. 1. MKG25 AA518 1.1 Open shutoff and three-way valves MKG25 AA519 MKG19 AA501 MKG15 AA502 MKG15 AA504 MKG15 AA501 MKG11 AA561 MKG11 AA531 MKG11 AA501 or MKG25 AA518 (three-way valve in CO2 vent gas position) (three-way valve in H2 filling position) (shutoff valve after the pressure reducer) (shutoff valve before H2 pressure reducer 1) (shutoff valve in high-pressure H2 line) (shutoff valve for low-pressure H2) (shutoff valve for high-pressure H2) (H2 bottle rack manifold) (H2 bottle) (three-way valve in CO2 vent gas position) MKG25 AA519 (three-way valve in H2 filling position) MKG19 AA502 (shutoff valve after the pressure reducer) MKG17 AA505 (shutoff valve before H2 pressure reducer 2) MKG15 AA504 (shutoff valve in high-pressure H2 line) MKG16 AA501 (shutoff valve for low-pressure H2) MKG12 AA501 (shutoff valve for high-pressure H2) MKG11 AA531 (H2 bottle rack manifold) MKG11 AA501 (H2 bottle) Check to ensure that H 2 pressure reducers adjust operating pressure.

the generator will be filled to operating pressure. Start with normal running routine 2. The electrical purity meter causes a small gas loss since the measuring gas is vented to the atmosphere. When the generator operates at rated speed.4 Close shutoff valve MKG25 AA502 1.3-6320-0500/2 (shutoff valve in measuring gas line) (shutoff valve in measuring gas line) Activate mechanical gas purity meter system. . The contact settings for control of the seal oil pumps must be matched to the respective gas pressures.2 Activate mechanical gas purity meter system 4 The generator is filled with H2. the H2 purity can also be measured by means of the mechanical gas purity meter system. Set contacts to operating values when rated gas pressure has been reached. 2 Fill generator with hydrogen to operating pressure. For this reason.5 Set contacts for pump control in seal oil system. 3. Note : Adjust pressure of seal ring relief oil to match the changed gas pressures during generator runup. MKG05 AA501 MKG05 AA502 3 Measure H2 purity by means of mechanical purity meter. sufficient H2 must always be available.1 Open shutoff valves 3.1. When shutoff valve MKG55 AA502 is closed. Filling the generator to operating pressure may also be performed during operation at rated speed.

O2 is extracted from the primary water and discharged to the atmosphere via the vent gas line. A reliable nitrogen supply must be available. 10 hours after a refilling procedure during operation. corresponding to a bottle pressure drop of approximately 15 bar/h for a 40 dm3 nitrogen bottle. the primary water tank should be purged with nitrogen to reduce the oxygen content of the primary water.2 Check N2 purging gas volume flow The nitrogen volume flow rate should be 600 dm3/h.5 bar.99%. The N2 pressure reducer was set to a gauge pressure of 0.1 Turbogenerators N 2 Purging After Filing of Operation Primary Water System Preparatory work After initial filling of the primary water circuit and following the addition of larger quantities of primary water (>100 dm3 per month). MKG31 AA501 MKG31 AA502 MKG31 AA503 MKG35 AA501 MKF91 AA502 (at N2 bottle) (at N2 bottle rack manifold) (before N2 pressure reducer) (after N2 pressure reducer) (in N2 purging gas line) In addition.1 Open shutoff valves at bottle rack and in purging gas system Q The external primary water circuit was filled with water. open shutoff valve for N2 bottle pressure measurement. Note : The nitrogen used for purging must have a purity of 99. Prerequisites for N2 purging : Q Q Q 2 Purging the primary water tank with nitrogen (N2) 2. 2. Q Q 30 hours after initial filling with subsequent refilling of external circuit. A sufficiently low O2 content for the most diverse initial conditions is obtained after the following purging periods.3-6810-0500/1 0709 E .3 Perform nitrogen purging procedure Continue nitrogen purging until a sufficiently low oxygen content (≤ 100 µg/dm3) is reached in the primary water tank. Haridwar 2. 2. During purging. The primary water pumps must be in operation. Note : The primary water must be continuously maintained in circulation during nitrogen purging BHEL.

4 Terminate nitrogen purging 2.3-6810-0500/2 MKG31 AA501 MKG31 AA502 MKG31 AA503 MKG35 AA501 MKF91 AA502 (at N2 bottle) (at N2 bottle rack manifold) (before N2 pressure reducer) (after N2 pressure reducer) (for N2 purging gas) .5 Close shutoff valves at bottle rack and in purging gas system. 2. 3 continue filling or operation of primary water system.2.

3-7100-0500/1 0709 E . The oil levels in the bearings and direction of rotation must have been checked with pump uncoupled. 2 Preparatory work 2. Primary water circuit must have been cleaned [2] Primary water circuit must have been leak tested [3] The filter elements of all filters must be installed [4] the ion exchanger must be filled with resins. Haridwar 2.Turbogenerators Operation 1 Filling and initial operation of primary water system Filling and Initial Operation of Primary Water System Preparatory Work Caution : The primary water system may only be filled with water complying with our specification [1] Prerequisites for filling the primary water system : Q Q Q Q Q The primary water pumps must have been checked for proper alignment after installation of the connecting piping at the generator.1 Set mechanical and electrical zeros of the conductivity meter system [5] 2.2 Adjust primary water tank level system with probe not immersed [6] 2.3 Adjust the leakage water level detectors with probes immersed [7] 2.4 Check and set primary water volume flow indicators [8] 2.5 Adjust relief valve for makeup line [9] BHEL.

3 Fill external part of primary water system. 2.7 Set electrical zero of pressure transmitter 2.5-7382 [3] 2.3-4070 [10] 2.3-7520 [7] 2. Water in filler or makeup line should be at a sufficient pressure (ρ = 2 to 10 bar.) .3-7540 [9] 2.9 Ensure that water is available for filling of the primary water system.8 Ensure that pure nitrogen is available at required pressure and in sufficient quantity.6 Set mechanical zeros of all pressure gauges 2.2.1-1885 [2] 2. Also refer to following imformations : [1] 2.4-4740 [5] 2.3-7100-0500/2 Primary water specification Flushing external parts of Primary water circuit Leakage tests Maintenance and supervision of Primary water filters Activating the Primary water conductivity meter system Activating the Primary water level monitoring system Activating the Primary water level detector system Activating the Primary water Volume flow meter system Operating and setting values Gas specification ~ ¯ 30 to 145 psig. The filler line and make-up line should be carefully flushed with de-ionate prior to being connected to the primary water system inlet valves. Note : Use only nitrogen complying with our specification [10] Make sure that shutoff valves MKF60 AA504 and MKF60 AA520 are closed.5-0310 [4] 2.3-7510 [8] 2.3-7530 [6] 2.1-1883 2.

Q Q Q Q 2 Close valve Water treatment system Terminal bushings and phase connectors Stator winding MKF12 AA502 MKF 22 AA502 MKF52 AA521 MKF52 AA522 MKF52 AA523 MKF52 AA544 MKF52 AA581 MKF52 AA591 MKF52 AA593 MKF60 AA502 MKF60 AA504 MKF60 AA519 MKF80 AA506 MKF80 AA507 MKF80 AA509 MKF80 AA512 MKF80 MKF82 MKF83 MKF83 MKF91 MKF91 AA513 AA501 AA501 AA502 AA502 AA506 MKF12 MKF12 MKF22 MKF22 MKF52 AA501 AA504 AA501 AA504 AA501 (drain valve before pump 1) (drain valve before pump 2) (primary water drain valve for cooler 1) (primary water drain valve for cooler 2) (primary water drain valve for cooler 3) (primary water drain valve manifold) (drain valve at main filter 1) (drain valve at main filter 2) (shutoff valve after main filter 2) (control valve for water treatment system) (shutoff valve in makeup line) (shutoff valve after water treatment system) (shutoff valve before water level indicator. External part of the primary water system consists of the entire system except for.Turbogenerators Operation 1 Fill external part of primary water circuit Filling and Initial Operation of Primary Water System Filling External Part of Primary Water Circuit Prerequisites for filling external part of primary water circuit : Preparatory work was completed. bottom) (drain valve at level detector 1) (control valve before stator winding) (control valve before bushings) (shutoff valve after bushings) (shutoff valve for N2 purging gas) (shutoff valve for vent gas line) 3 Open valve BHEL. Haridwar (shutoff valve before pump 1) (shutoff valve after pump 1) (shutoff valve before pump 2) (shutoff valve after pump 2) (primary water shutoff valve before cooler 1) 2. bottom) (drain valve at water level indicator) (drain valve at level detectors) (shutoff valve before level detector 1.3-7110-0500/1 0709 E .

1 Open shutoff valve MKF60 AA520 in makeup line 4. 4.MKF52 AA502 MKF52 AA503 MKF52 AA511 MKF52 AA512 MKF52 AA513 MKF52 AA531 MKF52 AA532 MKF52 AA533 MKF52 MKF52 MKF52 MKF52 MKF80 AA545 AA580 AA582 AA583 AA503 MKF80 AA504 MKF80 AA505 MKF 80 AA508 MKF 80 AA511 MKF80 AA514 MKF91 AA505 MKF91 AA513 (primary water shutoff valve before cooler 2) (primary water shutoff valve before cooler ) (primary water shutoff valve after cooler 1) (primary water shutoff valve after cooler 2) (primary water shutoff valve after cooler 3) (primary water vent valve for cooler 1) (primary water vent valve for cooler 2) (primary water vent valve for cooler 3) (primary water vent valve manifold) (shutoff valve for main filter 1) (vent valve at main filter 1) (shutoff valve after main filter 1) (shutoff valve in main circuit. Vent external circuit through open vent valves. Open shutoff valve .3 Adjust gas pressure in primary water tank 2.2 Vent during filling 4. Terminate filling when primary water tank is filled with water up to 3/4 on the sight glass. Caution : Ensure that water does not enter purging gas line during filling or addition of makeup water.3-7110-0500/2 Note : Water used for filling mist be at the required pressure before shutoff valve MKF60 AA520. Throttle filler valve as soon as primary water tank is filled up to 1/2 on the sight glass. top) (vent valve at water level indicator) (shutoff valve before level detector 1. Close vent valves when water emerges without bubbles. delivery pipe) (shutoff valve in bypass of primary water tank) (shutoff valve before water level indicator. top) (vent valve at level detector 1) (drain valve in vent gas line) (shutoff valve at drain) 4 Filling procedure Fill circuit slowly with water.

Vent circuit several times.3-7110-0500/3 . the compressed air escapes via the outflow regulator. etc.3 Venting and purging procedure 5.5 Maintain circulation in external part of primary water circuit by means of pump 1 or 2 BHEL. since the sliding ring glands of the pumps must be continuously supplied with water. Carefully vent signal lines to pressure gauges via the test connections at the respective pressure gauge shutoff valve by filling them with water.1 Carefully vent signal lines to pressure gauges Adjust primary water tank level system at the full level [1]. as required. 5 Place external cooling circuit into service 5. 4. 2. Caution : Take care to prevent dry running of primary water pumps.2 Place primary water pump 1 in operation for approximately 10 minutes 5.4 Terminate filling procedure by closing shutoff valve MKF60 AA520 when tank is filled up to 3/4 on sight glass.4 Start pump 2 after pump 1 has been stopped 5.2 bar.Turbogenerators MKF91 AA506 Operation and close shutoff valve MKF91 AA505 (shutoff valve for vent gas line) (drain valve in vent gas line) Close all vent valves. 5. Haridwar Vent circuit carefully by opening each vent valve several times. Maintain primary water circulation for approximately four hours to clean the piping. When air pressure in tank exceeds 0. coolers.

start with filling and placing into service of water treatment system.6 Activate conductivity meter system MKF80 CQ001 [2] 7 External part of primary water circuit is filled with water.3-7350 Activating the primary water conductivity meter system 2. Also refer to following information : [1] 2.3-7520 Activating the primary water level monitoring system [2] 2.3-7110-0500/4 .

1 Close shutoff valves MKF60 MKF60 MKF60 MKF60 BHEL. In the limit of 10 µmho/cm is exceeded. Remove upper nozzle tray. primary water integrating flow meter) 2. the system must be drained and filled again with water (deionated) 2 Fill ion exchanger with resins Remove cover of ion exchanger tank after opening the flanged connection and removing pipe. To prevent products of decomposition from entering the primary water system. replace upper nozzle tray (nozzles facing the resin) and install cover.Turbogenerators Operation Filling and Initial Operation of Primary Water System Filling the Water Treatment System Prerequisites for filling the water treatment system : 1 Fill water treatment system Q Q External part of primary water circuit was filled with water. Haridwar AA510 AA517 AA511 AA522 (drain after ion exchanger) (drain for water treatment system) (drain at fine filter) (drain. Thoroughly mix cation and anion exchanger resins of a ratio of 1 : 1 and fill ion exchanger with mixture. Water in external part of primary water circuit must have a conductivity of less than 10 µmho/cm. the resin can decompose.3-7120-0500/1 0709 E . 4. After filling ion exchanger. Tighten cover flange bolts uniformly at opposite points to prevent flange distortion. the resins should be flushed. 3 Activate conductivity meter MKF60 CQ001 [1] 4 Flush ion exchanger resins Caution : During storage. Make sure gaskets are properly seated. Filling the ion exchanger with water should be done slowly to prevent whirling of the resin filling which may result in separation of resin compounds.

3 Perform flushing procedure MKF60 AA503 MKF60 AA509 MKF 60 AA512 MKF60 AA513 (vent before ion exchanger) (shutoff valve after ion exchanger) (vent at fine filter) (shutoff valve after filter) Open shutoff valve MKF60 AA504 in the makeup line so that water is admitted very slowly.3-7530 Activating the primary water conductivity [2] 2.3-6810 N2 purging after filling of primary water meter system system 2. Close makeup valve MKF60 AA504.3-7120-0500/2 . Discard flushing water. Adjust a volume flow rate of approximately 1 m3/h by means of control valve MKF60 AA502 (reading at flow indicator MKF60 CF502) 5. Close vent valves MKF60 AA 503 and MKF60 AA512 as soon as water emerges without bubbles. Vent inlet pipe via vent valve MKF60 AA503.2 Open shutoff valves 4.1 Treatment of water in cooling circuit 6 Purge primary water tank with N2 [2] The flow path through the water treatment system provides fro treatment of the primary water. start with filling of terminal bushings and phase connectors Also refer to following information : [1] 2. Adjust flushing water volume flow rate to approximately 1 m3/h by means of drain valve MKF60 AA 517 (reading at flowmeter MKF60 CF502). N2 Purging of primary water tank reduces the O2 content of the water in the external part of the circuit to < 100 ppb (100 µg/dm3) 7 Water in external part of primary water circuit is subjected to treatment. Terminate flushing procedure by closing drain valve MKF60 AA517 when conductivity after ion exchanger is ≤ 1 mmho/ cm (reading at conductivity transmitter MKF60 CQ001). Then open shutoff valve MKF60 AA519.4. 5 Place water treatment system into service Open control valve MKF60 AA502 slowly. Vent the system several times during this procedure.

1 Open shutoff and control valves MKF83 MKF83 MKF83 MKF83 MKF83 MKF83 MKF83 MKF83 MKF83 MKF83 MKF83 MKF83 MKF83 MKF83 AA502 AA501 AA503 AA504 AA505 AA506 AA507 AA508 AA513 AA514 AA515 AA516 AA517 AA518 (after bushings) (before bushings) (shutoff valve for flow (shutoff valve for flow (shutoff valve for flow (shutoff valve for flow (shutoff valve for flow (shutoff valve for flow (shutoff valve for flow (shutoff valve for flow (shutoff valve for flow (shutoff valve for flow (shutoff valve for flow (shutoff valve for flow indicator) indicator) indicator) indicator) indicator) indicator) indicator) indicator) indicator) indicator) indicator) indicator) 2 Filling procedure After opening of the above valves. Due to the open position of shutoff valve MKF80 AA504 in the bypass. the volume flow rate through the bushings and phase connectors is low. Note : Do not add make-up water during filling procedure Adding makeup water is only permissible after the stator winding as well as the terminal bushings and phase connectors were filled with water and isolated from the external part of the primary water circuit by closing the respective valves. The volume flow indicators may be placed into service only after proper venting. Check that water flows through sight glasses without bubbles. 1. Therefore venting takes place slowly. primary water is admitted to the branch circuit.3-7150-0500/1 0709 E .Turbogenerators Operation 1 Fill terminal bushings and phase connectors Filling and Initial Operation of Primary Water System Filling Terminal Bushings and Phase Connectors Prerequisites for filling the terminal bushings and phase connectors : Q Q Primary water in external circuit must have a conductivity of ≤ 4 µmho/cm. Primary water in external circuit must have an O 2 content of < 100 µg/dm3 (100 ppb). MKF83 BR501 MKF83 BR502 MKF83 BR503 BHEL. This O2 content is obtained by proper N2 purging. Haridwar (for primary water flow in phase UX bushings) (for primary water flow in phase VY bushings) (for primary water flow in phase WZ bushings) 2.

3-7150-0500/2 .3-7540 Activating the primary water volume flow meter system 2. start with filling of stator winding Terminal bushings can be placed into service again by opening the above control valves after the addition of makeup water to the primary water tank following filling of the stator winding and subsequent N2 purging.3 Activate volume flow indicators Activate volume flow indicators [1] : MKF83 MKF83 MKF83 MKF83 MKF83 MKF83 4 Close control valves CF001A CF001B CF011A CF011B CF021A CF021B (for (for (for (for (for (for volume volume volume volume volume volume flow flow flow flow flow flow in in in in in in phase phase phase phase phase phase R bushings) R bushings) S bushings) S bushings) T bushings) T bushings) Carefully vent transmission lines and flow indicators via the shutoff and equalizing valve assemblies. MKF83 AA502 MKF83 AA501 (before terminal bushings) (after terminal bushings) 5 Terminal bushings and phase connectors are filled. Also refer to following information : [1] 2. Check parallel connected flow indicators for identical volume flow readings.

Briefly open vents on inlet and outlet pipe at reasonable intervals. Primary water in external circuit must have a conductivity of < 4 µmho/cm. Primary water in external circuit must have an O 2 content of < 100 µg/dm3 (100 ppb). Haridwar Increase volume flow rate through stator winding by slowly opening control valve MKF82 AA501.Turbogenerators Operation Filling and Initial Operation of Primary Water System Filling the Stator Winding Prerequisites for filling the stator winding : 1 Fill stator winding Q Q Q Drain valves of primary water manifolds were closed and secured against opening. Simultaneously throttle shutoff valve MKF80 AA504 in bypass to obtain higher volume flow rate through stator winding. This O2 content is obtained by proper N2 purging. stator outlet) Carefully vent transmission lines and flow indicators via the shutoff and equalizing valve assemblies. 2. Activate volume flow indicators [1] MKF82 CF001A MKF82 CF001B (flow indicator for primary water volume flow. 5 Flush and vent stator winding BHEL. stator outlet) (flow indicator for primary water volume flow. Close vent valves as soon as water emerge without bubbles. Note : Do not add make-up water during filling procedure. 2 Open shutoff valves 3 Filling procedure 4 Activate volume flow indicators MKF82 MKF82 MKF82 MKF82 MKF82 MKF82 AA502 AA503 AA504 AA505 AA507 AA508 (vent before stator winding) (vent after stator winding) (shutoff valve for flow indicator) (shutoff valve for flow indicator) (shutoff valve for flow indicator) (shutoff valve for flow indicator) Slowly open control valve MKF82 AA501 (stator winding inlet).3-7160-0500/1 0709 E . Stator winding should be completely vented after a flushing period of approximately two hours. Check parallel connected flow indicators for identical flow readings. Adding make-up water is only permissible after the stator winding as well as the terminal bushings and phase connectors were filled with water and isolated from the external part of the primary water circuit by closing the respective valves.

MKF60 AA502 (before ion exchanger) and slowly open shutoff valve MKF50 AA504 (in makeup line) Slowly raise water level in primary water tank to 75% of nominal value. close shutoff valve. Adjust volume flow rate [3] by means of the above control valves.3-7540 Activating the primary water volume flow meter system [2] 2. 7 Isolate stator winding from external part of primary water circuit Isolate filled stator winding from external part of primary water circuit prior to restoring the required water level in the primary water tank by the addition of makeup water. Read nominal level at indicator of level detector MKF80 CL501. As soon as the water in the external part of the circuit has reached an O2 content of ≤ 100 ppb. open control and shutoff valves. fully reopen shutoff valve. N2 purging of primary water tank reduces the O2 content of the water in the external part of the circuit to ≤ 100µg/ dm3 (100 ppb).3-7160-0500/2 . 12 Stator winding is filled. MKF82 AA501 (before stator windings) MKF83 AA501 (before terminal bushings) MKF83 AA502 (after terminal bushings) Slowly close shutoff valve MKF80 AA504 in bypass. Also refer to following information : [1] 2. MKF80 AA504 (in bypass) and then close control valve 8 Adjust nominal water level in primary water tank MKF82 AA501 (before stator winding) After the stator winding and terminal bushing with phase connectors were isolated from the external part of the circuit.3-6810 Nitrogen purging after filling primary water system [3] 2. MKF60 AA504 (in makeup line) and reopen control valve 9 Purge primary water tank with nitrogen [2] 10 Open control and shutoff valves 11 Close shutoff valve MKF80 AA504 in bypass MKF60 AA502 (before ion exchanger).6 Carefully vent all signal lines to pressure gauges Carefully vent signal lines to pressure gauges via the test connections at the respective pressure gauge shutoff valve. start with filling of primary water coolers on cooling water side. To do this.3-4070 Operating and setting values 2. Then close shutoff valve.

start with necessary checks prior to startup. 2. Open shutoff valves before and after coolers. 3 Close shutoff valves Close shutoff valves before and after cooler MKF52 BC003 MKF52 AA551 MKF52 AA552 4 Open shutoff valves (and shutoff valves) (drain valve at cooler 1) (drain valve at cooler 2).Turbogenerators Operation Fill and vent coolers on cooling water side 1 Filling and Initial Operation of Primary Water System Filling Primary Water Coolers on Cooling Water Side Note: Fill coolers with water on cooling water side only one day before start-up and loading of generator. The third primary water cooler should not be filled on its cooling water side but left in a clean and dry condition with closed inlet and outlet valves and open drain and vent valves. Haridwar AA553 AA561 AA562 AA563 (drain valve at cooler 3) (vent valve at cooler 1) (vent valve at cooler 2) (vent valve at cooler 3). Close vent valves as soon as water emerges without bubbles.3-7180-0500/1 0709 E . 2 Check and activate primary water temperature control system. BHEL. Fill primary water coolers with water after opening shutoff valves. MKF52 BC001 MKF52 BC002 (cooler 1) (cooler 2) and shutoff valves MKF52 MKF52 MKF52 MKF52 5 Filling procedure 6 Primary water circuit is ready for operation. Note: Fill and vent only two of three primary water coolers on their cooling water sides 100% of the maximum cooler capacity required (at maximum cooling water temperature and maximum generator output) will then be in service.

1 Start one primary water pump and be sure the other pump is ready for starting 2 Are primary water pumps in operation ? no yes 3. Haridwar 2.Activating Primary Water System After a Shutdown of Less Than 48 Hours Turbogenerators Operation 1 The primary water must still be in the system. follow the corresponding instruction [1].3-7180 Primary water System 2.3-7210-0500/1 0709 E .1 Place water treatment system into service by slowly opening valves MKF60 AA502 and MKF60 AA519 3 Are all primary water branch circuits in service no 4 Check primary water circuit prior to startup[2] 5 Primary water system is now in service. Note : Close shutoff valve MKF80 AA504 after reactivation of stator winding branch circuit 3. For activating the primary water system after a shutdown in which the system or a branch circuit was drained.3 Activate stator winding branch circuit by slowly opening control valve MKF82 AA501.2 Activate bushing and phase connector branch circuit by slowly opening control valves MKF83 AA502 and MKF83 AA501 3. Activate primary water system after a shutdown of less than 48 hours 2.3-7610 Checks Prior to Startup 2. Start with normal running routine Also refer to the following information [1] [2] BHEL.3-7100 Filling and Initial Operation of to 2.

3-7100 .3-7180 [2] BHEL.3-7220-0500/1 0709 E .3-7610 Checks Prior to Startup 2.1 Fill and activate primary water system or any branch circuits [1] 2 Primary water circuit is completely filled no 3 Perform checks necessary prior to startup 4 Primary water system is now in service. to . Haridwar 2.Activating Primary Water System After a Shutdown of More Than 48 Hours Turbogenerators Operation 1 Activate primary water system after a shutdown of more than 48 hours 2.. start with normal running routine Also refer to the following information [1] 2. Filling and Initial Operation of Primary Water System 2..

5 µmho/cm position.Turbogenerators 1 Operation Activating the Primary Water Conductivity Meter System Activate conductivity meter system Prior to initial operation of the conductivity meter system. Switch on the power supply. check the wiring for compliance with circuit and connection diagrams. Select the range 0 to 2 µmho/cm by means of jumper on printed circuit board of transmitter module. Turn associated test selector switch to zero position. 3 Check electrical zero Note : This check can only be performed if conductivity transmitter is completely dry and therefore should be performed prior to filling the primary water system. Haridwar 2. With switch in this position. Check conductivity indication after a warm-up period of approximately 15 minutes. use jumper in transmitter module to select one of the higher ranges: 0 to 5 µmho/cm 0 to 10 µmho/cm 0 to 25 µmho/cm BHEL.3-7530-0500/1 0709 E . If conductivity of the primary water is still beyond the selected range. a zero indication is given at the conductivity indicator. Turn associated test selector switch to test value 1. a correction can be made at potentiometer P-O of transmitter module. provided that primary water system is filled and that water flows through the measuring device. With switch in this position. With switch in this position. instrument should indicate a value of 1. Turn test selector switch to the operation position. 2 Check mechanical zero of conductivity indicator Set and check mechanical zero by adjusting zero setting screw on the indicator. If the indication is not zero. 4 Check complete conductivity meter system by means of test switching unit This check may be performed either before or after filling primary water system. conductivity indicator indicates conductivity of primary water.5 µmho/cm.

Disconnect lead to terminal 3 of transmitter module.5 Check conductivity meter system at transmitter module by use of test resistor If the checks of conductivity meter system do not yield result as given in step 4. Conductivity indicator should indicate 30% of maximum deflection. Reconnect leads to terminal 3. Conductivity indicator should indicate conductivity of the primary water.3-7530-0500/2 Disconnect lead to terminal 2 of transmitter module. Disconnect test resistor from terminal 1 of transmitter module. The test procedure is as follows : Q Q Q Q Q Q Q Q 6 Conductivity meter system is ready for continuous monitoring of the primary water conductivity 2. Conductivity indicator should indicate zero. When using test resistor. . perform the following checks at the transmitter module by using the furnished test resistor. the correction may have to be repeated several times until the required accuracy is obtained for all scale points included in the check. Be sure that the lead from measuring device also remains connected to the terminal. The test resistor can be used to check the transmitter module and the conductivity indicator. Note : During generator operation. Connect test resistor terminal 2 to terminal 2 of transmitter module. This prevents a full-scale deflection of the conductivity indicator which would result in initiation of an alarm during normal operation. Conductivity indicator should indicate zero. A deviation between the results described above and the actual test results using the test selector switch and test resistor can be due to an influence of the leads between the conductivity measuring device and the transmitter module. Conductivity indicator should indicate zero. be sure to only disconnect the leads to terminals 2 and 3 of transmitter module. Lead to terminal 1 should not be disconnected. These deviations can be corrected by P-X or P-Y. Disconnect test resistor from terminal 3 of the transmitter module. Since these potentiometer settings influence each other. Conductivity indicator should indicate 30% of maximum deflection. Connect test resistor terminal 1 to terminal 1 of transmitter module. then terminal 2 of transmitter module. make sure that the connections are disconnected and reconnected in the correct sequence. Conductivity indicator would indicate value given on test resistor. Conductivity indicator should indicate 30% of maximum deflection. Connect test resistor terminal 3 to terminal 3 of transmitter module.

After venting. Haridwar 2.3-7540-0500/1 0709 E . Activate volume flow meter system 1 2 3 4 5 1 2 3 4 5 Fig.Turbogenerators Activating the Primary Water Volume Flow Meter System Operation 1 Prior to activating the flow meter system check wiring for compliance with circuit arrangement and connection diagrams. The measuring mechanism is now subjected to the differential pressure to be measured. BHEL.1 Span Potentiometer Zero indicator Zero switch Test jack Zero Potentiometer Differential Pressure Tranmitter 2 Vent medium-pressure cell With primary water cooling circuit filled and required primary water flow available. 3 Switch on auxiliary power supply The differential pressure transmitter is now ready for checking the lower range limit and upper range limit. 4 Check lower range limit and upper range limit Lower range limit and upper range limit can be readjusted independently from each other. follow descriptions [1] and [2]. To do this. close equalizing valve. open equalizing valve and the two shutoff valves and vent measuring mechanism. Check power supply voltage.

4.4 Correct zero setting 4. 4. reset zero switch to its N (normal) operating position. should indicate the upper range value of the output current = 20 mA. close equalizing valve of the equalizing valve assembly.2 Apply zero differential pressure to measuring mechanism To do this. After checking or correction of zero setting.6 Apply upper range differential pressure to meausring mechanism (upper range value < orifice design) If the pointer of the zero indicator is not exactly in the center position. Any required correction can be made with the span potentiometer (item 1). open equalizing valve of the equalizing valve assembly. the zero setting can be corrected with the zero potentiometer (item 5).5 Set zero to N (normal) position 4.8 Re-apply differential pressure to measuring mechanism To do this. 4.3-7540-0500/2 Pressure Transmitters .1-8412 Primary Water Volume flow Meter System 2.3 Check indication of zero indicator The electrical zero setting is indicated by the zero indicator.7 Correct upper range pressure setting An ammeter (voltage drop < 300 mV at 20 mA) connected to the test jack. 4. Note : Check to ensure that no impurities are introduced into the primary water circuit (apply upper range pressure at pressure gauge calibration rack). Flowmeter system is now ready for operation.4. 4.1-7370 [2] 2.1 Set zero switch to T (test) position For zero check. set zero switch to T (test) position. 5 Equipment is ready for volume flow measurement Also refer to the following information [1] 2.

BHEL. 2.3-7610-0500/1 0709 E . 3 Check or adjust vent and drain valves at primary water coolers Ensure that all three coolers are filled on their primary water sides.Turbogenerators Operation 1 Initial Operation of Primary Water System Checks Prior to Startup Perform necessary checks prior to startup 2 All primary water coolers are filled on their primary water side. Haridwar (shell side drain manifold of primary water coolers) (shell side vent manifold of primary water coolers) AA541 AA578 AA502 AA503 AA512 AA503 AA582 AA545 (vent before primary water cooler) (vent after primary water cooler) (vent before stator winding) (vent after stator winding) (vent at fine filter) (vent at ion exchanger) (vent at main filter) (shell side vent manifold of primary water cooler) Perform check by briefly opening vent plug at each respective pressure gauge shutoff valve. Make sure to open valves MKF52 MKF52 MKF52 MKF52 MKF52 MKF52 AA521 AA522 AA523 AA531 AA532 AA533 (shell side drain at primary water cooler1) (shell side drain at primary water cooler2) (shell side drain at primary water cooler3) (shell side vent at primary water cooler1) (shell side vent at primary water cooler2) (shell side vent at primary water cooler3) and close valves MKF52 AA544 MKF52 AA545 4 All units of primary water system are properly vented. Perform check by briefly opening shutoff valves MKF52 MKF52 MKF82 MKF82 MKF60 MKF60 MKF52 MKF52 5 All pressure gauges and pressure transmitters are properly vented.

3-7610-0500/2 Check that primary water coolers are filled on their cooling water sides and properly vented. start with regular monitoring of operation 2.6 Two primary water coolers are filled and vented on their cooling water sides 7 Primary Water Temperature control system is ready for operation 8 Primary water circuit is ready for operation. .

2 Turning Gear Operation Prior to operating the generator on turning gear. i. Use manual mode to adjust a cooling water volume flow through the hydrogen coolers of approximately 5 to 10% of the nominal flow rate. During runup. Changing over the H2 coolant temperature control system from the Manual to the Automatic mode is permissible as soon as the primary water temperature control system. the bearing and oil temperatures should be read and recorded at short intervals. During runup. If the generator is run up following prolonged turning gear operation. the cooling water volume flow through the hydrogen coolers should be increased by manual adjustment to maintain the cold gas temperature at least 5 K below the primary water inlet temperature. The H2 coolant temperature control system should be changed over from the Automatic to the Manual mode. drains should be inspected for proper operation.e. The generator may be filled with hydrogen prior to or during turning gear operation provided that leakage tests have been performed and the seal oil system is in operation. Haridwar 2. It may be necessary in certain exceptional cases to operate the generator without hydrogen. Open control valves in cooling water outlet lines as soon as the cold air temperature has risen to > 400C. In view of the high windage losses and the resulting high temperature rise of the air such air operation is only permissible for brief periods and only with generator nonexcited. Note : Do not run up generator to rated speed and voltage as long as generator casing pressure [1] is not at rated value. the hydrogen coolers should be placed into service. the supply of seal oil to the shaft seals must be ensured as well. After load pickup. To prevent these thermal unbalances during runup. Even minor temperature differences of 1-2 deg C between opposite sides of the rotor may result in rotor distortion which could lead to inadmissible vibrations due to unbalance. During runup. At higher cold air temperatures. This results in a lower dew point temperature in the generator interior due to the condensation of moisture contained in the gas on the cooler tubes and fins. Smooth running depends on several factors. the bearing oil inlet temperature should not be less than 350C but not higher than 450C. In addition. Turning Gear Operation and Runup of Generator During runup of the turbine-generator. the shaft lift oil pump and the bearing oil system must be placed into operation. The seal oil system for lubrication and sealing of that shaft seals and the primary water system must be placed into operation. 6 Generator Air Operation Besides the above mentioned operating conditions. 5 Runup During runup to rated speed. and the control valves in the lines downstream of the coolers are closed. no restriction regarding the rate of runup need be observed other than those required for the turbine. Also refer to the following information [1] BHEL.3-8010-0500/1 0709 E . adjust the two control valves so that equal cooling water outlet temperatures are obtained downstream of the cooler sections (measured by means of the thermometers in the outlet lines). The oil flow to the bearings and shaft seals should be checked prior to turning gear operation to ensure an adequate flow. set for the automatic mode. The cooling water volume flow through the hydrogen coolers should not be increased as long as the H2 cold gas temperature is not at rated value.1-1850 Reactive capability curve 2. the turbine-generator should be run on turning gear. the critical speed ranges should be passed through quickly and at a uniform rate. during initial runup of the unit to check the bearings and vibrations and for cleanup.Turbogenerators Operation 1 General The generator should be operated on the turning gear and brought up to speed in accordance with the turbine startup diagrams. opens the final control element for the cooling water downstream of the primary water coolers. The shutoff valves in the lines upstream of the coolers are open. In addition. The oil inlet temperature at the shaft seals should not be less than 380C. adjust control valves for a cold air temperature of < 400C. the cold air temperature requires particular attention. 3 Generator Cooling Gas Temperatures The hydrogen coolers should be placed into service on their cooling. During generator air operation. 4 Exciter Temperatures The exciter coolers must be filled with water and vented. The cold air temperature downstream of the coolers should not exceed 400C. water sides as soon as the generator is filled with hydrogen and on turning gear. Open control valves only to the extent required to adjust a cold air temperature of < 400C in the exciter.

Haridwar 2. control valves closed Coolant temperature control in operation Automatic voltage regulator ready for operation Command : Run up generator Drying system Heating system n >= 4 s–1 out of service n >= 4 s–1 out of service Bearing vibration Bearing metal temperature normal normal Exciter cooler at r cold air > 400C.3-8011-0500/1 0709 E . 380C.Turbogenerators Generator Startup Diagram Operation 1 2 Command : Start up generator Actual condition Bearing vapour exhausters Exciter drying system in operation in operation Primary water system in operation Seal oil system in operation Seal oil inlet temperature t = approx. adjust cooling water flow required for removal of loss heat. 10% of norminal flow) in operation and vented filled with water and vented. Generator hydrogen pressure Hydrogen purity p = rated gas pressure > 96% Measuring devices and supervisory equipment in operation Gas drying system in operation Hydrogen coolers Primary water coolers Exciter cooler in service with reduced flow (approx. Speed n= approximately 90% BHEL.

only within the region of the capability curve .Differential temperature between H2 cooling gas and cold primary water >5K Field circuit breaker closed Set point for rated voltage 3 set Speed Primary water volume flows n = rated speed set Bearing vibrations set seal ring relief oil pressure for shaft seals Synchronizing.3-8011-0500/2 to required load. parallelling and loading Synchronizing Paralleling Loading 2.

Haridwar 2.Turbogenerator Permissible Synchronizing Criteria Operation BHEL.3-8081-0500/1 0709 E .

Operation of the generator without full primary water service is not permissible. during voltage and frequency deviations 2. should a leak be present in the primary water system within the stator.3 . Load operation for long periods of time at reduced H2 pressure is. Dew point temperature of hydrogen atmosphere in generator is sufficiently below cold gas temperature. 2 Rate of Loading During operation load variation is permissible within the limits or the reactive capability curve. operating conditions may arise at the generator which require the generator to be operated at reduced load in order to avoid Q Primary water cooling system of generator is fully operational.1 Operation With Hydrogen Coolers Out of Service If one of the four hydrogen cooler sections is out of service.4 Deviation of Rated Voltage and Rated Frequency Loading of the generator with deviations from the rated generator voltage and/or frequency is only permissible up to the limits shown in the attached diagram [3]. 4.1850 Reactive Capability curve 2. high gas losses).Turbogenerators Permissible Load Limits of Generator Operation 1 Load Limits For permissible generator loading. Operation at reduced load presupposes. Unbalanced load is defined as the ratio of negative sequence current to rated current. In the event of a failure of this cooler.2 Deviation of Rated Hydrogen Pressure If the specified hydrogen pressure [1] cannot be maintained for unforeseeable reasons (e.1810 General and Electrical Data 2. Generator is operated at rated frequency Generator is operated at rated voltage. The actual rate of loading should be matched to the permissible limits of the turbine. Also refer to the following information [1] [2] [3] BHEL.F. damage to the unit.3-8170-0500/1 0709 E . with no leak developing in the generator interior during this period. lack of gas. change over control system from Automatic to Manual.3 Loss of Primary Water Supply If loss of primary water supply occurs. since the stator primary water pressure may then exceed the hydrogen pressure. 4 Load Restrictions During the service life of the generator.4 kg/cm2. This results in the possibility of primary water escaping into the hydrogen atmosphere. The following restrictions should be observed for the conditions indicated : 4. The following conditions are required : Q Q Q Q Primary water cooling system is fully operational. 4.1 . refer to the reactive capability curve [1]. the generator must be unloaded and de-excited when the rated pressure has dropped by 0. not permissible. The permissible rate of loading depends on the condition of the winding insulation Generators with a Micalastic stator winding insulation and a rotor winding of silver-alloyed copper with glass laminate insulation can be suddenly loaded and unloaded if an automatic coolant control system is provided and fully operational. This condition is normally obtained by drying the closed generator with the gas drying system for not less than four weeks. Note : The actual-value transmitter for the hydrogen temperature control is located after cooler a. with the rated current [2] not being exceeded in any of the three phases. The necessary corrections should be performed manually.1 . The cause of the gas loss should be identified and corrected. that Q Any desired load setting is possible within the limits indicated on the Reactive Capability Curve. however. however. 4.8181 Permissible Loading at Rated P.g. operation of the generator is permissible at not more than 67% of rated load. Haridwar 2. the generator is disconnected from the system by the generator mechanical equipment protection and de-excited. 3 Unbalanced Load The continuously permissible unbalanced load as specified [2] must not be exceeded under any operating condition. Generator is filled with hydrogen at the rated pressure and all four hydrogen cooler sections are in operation.

3-8181-0500/1 0709E . During Voltage and Frequency Deviations Turbogenerators Operation 40 30 PERMISSIBLE SHORT TIME OPERATION (IN MINUTES) WITH RATED MVA AT RATED PF WITH 10% VOLTAGE DEVIATION 20 10 10 9 8 7 6 VOLTAGE DEVIATION (%) 5 4 3 2 1 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 0 1 2 3 4 5 -1 Continuous Operation At Rated MVA Only Short Duration Operation At Rated MVA (But Continuous Operation at reduced load not permitted) Continuous Operation At Reduced MVA OR Rated MVA for Short Duration -5 FREQUENCY DEVIATION (%) BHEL.F.Permissible Loading at Rated P. Haridwar 2.

Turbogenerators Operation Continuous Operatopn Generator Capability With Hydrogen Coolers Out of Service on Water Side Short time operation Only permissible for cooler cleaning 100 % MVA 66.3-8184-0500/1 0709 E . Haridwar 2.6 % MVA 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 Cooler in service Cooler out of service Operation with less coolers or higher output than shown is not allowed BHEL.

500 45.00 S i22 t =0.000 MVA (500 MW) kV kA Hz bar (G) Cel 6 4 TIME T IN SECONDS 3 2 8 101 3 3 4 8 6 10 2 3 4 6 8 -1 0 10 2 3 4 6 10 8 1 4 6 8 100 2 3 4 6 i22 t =10. Haridwar 2.000 21.3-8187-0500/1 0709 E . CONTINUOUS 8 102 2 3 4 6 8 103 RATED GENERATOR OUTPUT S N RATED ARMATURE VOLTAGE U N RATED ARMATURE CURRENT I N RATED FREQUENCY FN POWER FACTOR PF PE RATED H 2 PRESSURE COLD GAS TEMPERATURE TK PER UNIT NEGATIVE SEQUENCE CURRENT BHEL.000 0.850 3.166 50.Turbogenerators Unbalanced Load-Time Curve Operation = = = = = = = 588.08 .000 16.

2 2.) FIELD VOLTAGE (P.3-8188-0500/1 0709 E STATOR CURRENT (P.BHEL. Haridwar 1 1.U. ARMATURE WINDING SHORT TIME THERMAL REQUIREMENTS (STATOR CURRENT VS TIME) OVERLOAD CAPABILITY 1000 Turbogenerators Current Overload Capability Operation 2.6 1. FIELD WINDING SHORT-TIME THERMAL REQUIREMENTS (FIELD VOLTAGE VS TIME) 1.2 1.4 1.8 2 2.) .4 1 10 2 1 TIME IN SEC 100 2.U.

5 0.2 0.1 0.8 0.3-8190-0500/1 0709 E . TIME IN MINUTES 48 47 5 4 3 2 1 1.Turbogenerators Runback for Loss of Stator coolant Operation 50 CAUTION 49 IF STATOR COOLANT IS NOT RESTORED WITHIN 50 MINUTES OF INITIATION OF RUNBACK.0 0 CURRENT PER UNIT AMPERE BHEL.1 1.3 0.7 0.4 0.0 0.9 0. Haridwar 2. THE TURBINEGENERATOR MUST BE TRIPPED.6 0.

Cooling Water Inlet Temperature 60 55 53 COLD PW TEMPERATURE (Deg. Haridwar 2.C) 51 47 45 49 52 50 46 48 COLD GAS TEMPERATURE (Deg.3-8191-0500/1 0709E .C) 44 42 40 0 100 200 300 400 500 62 Operation 54 Unloading Schedule For Increased PERMISSIBLE LOAD OUTPUT (MW) 600 Turbogenerators BHEL.

3-8310-0500/1 0709 E . This results in a lower dew point temperature in the generator interior due to the condensation of moisture contained in the gas on the cooler tubes and fins. the H 2 coolant temperature control system (if provided) should be changed over from the automatic to the manual mode. The coolers should be operated with this cooling water volume flow for approximately 15 hours. Haridwar Before the unit reaches turning gear speed. Use manual control to adjust a cooling water volume flow through the H2 coolers of approximately 5 to 10% of the nominal flow rate. 2. the turning gear must be started as soon as the turbine-generator coasts down to the speed (turning gear speed) specified for the turbine (normally automatic) and maintained in operation without interruption until the rotor has cooled down to nearly room temperature.Turbogenerators Shutdown of Generator Operation During shutdown of the generator. the shaft lift oil pump must be started as soon as the unit reaches the speed specified in the Turbine Instruction Manual. To prevent any difficulties during a subsequent runup due to thermal unbalances and the resulting rotor distortion. BHEL.

3-8311-0500/1 0709 E .05 SN Generator main circuit breaker automatic trip through reverse-power protection.5s–1 inoperation Turning gear operation see Turbine Instruciton Maual Seal oil system in operation Gas system in operation Primary water system in operation Speed n = 0 s–1.Turbogenerators Generator Shutdown Diagram Operation 1 Command : Unload generator Actual condition Generator load SN < 0. at room temperature Shutdown procedures completed BHEL.5s–1 inoperation n<3. Haridwar 2. Speed approximately 90% Excitation field circuit breaker tripped Exciter dryer Anticondensation heating system n<3.

Gas and Primary Water System Out of Operation Preservation measures will have to be taken when the generator is to be shut down for a period exceeding two months with the seal oil. Gas and Primary Water System in Operation Due to operational conditions. In addition. the coolers should be flushed with the full water flow twice weekly. on the overall conditions in the vicinity of the unit and on the extent to which checks and inspections are possible during such period. To maintain the generator in satisfactory dry condition. 2 Generator at Standstill With Seal Oil. All observation required for a generator partly taken into service should be performed. the bearing oil system can be taken out of service. the exciter enclosure must be kept closed and the exciter drying system must remain in operation. e. In the absence of any operational needs. After removal of the hydrogen from the generator. making sure that the exciter drying system is functioning properly. the coolers should be supplied with a small water flow. Special measures should be taken to prevent corrosion damage to the tubes of the hydrogen. 2. exciter and seal oil coolers should be drained to their water sides and dried by suitable measures. In the case of prolonged outages. To prevent the formation of a moisture film due to condensation on the exciter coolers. The scope of the preservation work required depends on the duration of the shutdown. gas and primary water systems to be taken out of operation.. such observations being essentially limited to the seal oil. the water and hydrogen should remain in the generator in order to retain the most favorable prerequisites for a dry condition. the coolers should be drained on BHEL. Care should be taken to ensure that this equipment is connected in such a way that a circulation through the entire generator interior will be accomplished.g. it is recommended to open the generator by removing two manhole covers and to connect a dryer or hot air blower for continuous drying or circulation of the air in the generator. the mechanical hydrogen purity meter cannot give an indication due to the lack of differential fan pressure. Normally it can be assumed that the generator was operated with the gas dryer during the preceding service period. These measures are intended to prevent any condensation in the generator interior even under varying environmental conditions to minimize the risk of stress corrosion cracking of the austenitic rotor retaining rings. In the case of prolonged outages. Haridwar Supervision of Generator During Standstill General their water sides. primary water. During a brief outage. dried and maintained in dry condition to prevent standstill corrosion in the cooler tubes. gas and primary water systems. primary water and exciter coolers during idle periods. With the unit at rest or on turning gear. When the unit at standstill.Turbogenerators Operation 1 Generator at Standstill With Seal Oil. the cooling water supply should be isolated immediately after shutdown of the unit. the coolers should be drained on their water sides and dried. inspection or faults on generator. it may become necessary to shut down the generator for a short period.3-8400-0500/1 0709 E . The hydrogen. The generator interior will thus be in dry condition provided that the cooling gas was not replaced.

2. Haridwar Supervision of Generator During Standatill Coolers to supply the coolers with a small water flow and to flush them with the full water flow twice weekly. In the case of a prolonged outage.Turbogenerators Operation Suitable measures will have to be taken on all coolers taken out of service to prevent standstill corrosion in the cooler tubes. In the case of a brief outage. be drained on their cooling water sides and dried. it will mostly be sufficient BHEL. the coolers should however.3-8440-0500/1 0709 E .

Haridwar Supervision of Generator During Standstill Seal Oil System monitoring of the generator must be continued.Turbogenerators Operation After gas removal from the generator. the seal oil system can be taken out of operation. BHEL. All seal oil pressure and temperature should be recorded at the previous intervals. if the seal oil system remains activated. 2. However. and monitoring of the generator is no longer required.3-8500-0500/1 0709 E . and attention should be given to all special occurrences.

Turbogenerators Shutdown of Seal Oil System Operation 1 Shutdown of seal oil system 2 Shut down turbine-generator The system should be taken out of service only for a prolonged shutdown of the generator requiring removal of the gas due to a major fault in the seal oil system. Draining of the seal oil circuit will not be required for other work.3-8510-0500/1 0709 E . the branch circuits should be refilled with seal oil and placed in operation. replace any defective shutoff valves or temperature gauges BHEL. 2. drain seal oil from respective pipe. Haridwar If new shutoff valves or temperatures gauges must be installed. e. Remove defective component and install a new part. water must be drained completely from the seal oil cooler or a small amount of water must pass through the coolers continuously in order to prevent standstill corrosion. In the event of a longer shutdown of the turbine-generator. 5 Terminate normal running routine 6 Remove all faults. The turbine-generator should be shut down and the generator rotor should be at standstill (n = 0 s–1) 3 Remove H2 gas from generator 4 Stop seal oil pumps Deactivate controls of seal oil pumps and bearing vapor exhausters.g. To restart seal oil system if oil has been drained from part of the circuit.

BHEL.3-8520-0500/1 0709 E . seal oil cooler 1) (vent. and the generator rotor must be at standstill (n = 0 s–1).1 Close shutoff valves 2. seal oil cooler 2) After draining on their water sides. MKW51 MKW51 MKW51 MKW51 AA507 AA509 AA506 AA508 (drain. 3 Draining of air side seal oil circuit is complete Start with draining of hydrogen side seal oil circuit. seal oil cooler 1) (drain.Turbogenerators Operation 1 Preparatory work for draining seal oil circuit Draining the Air Side Seal Oil Circuit The turbine-generator must have been shut down.3 Open cooler drain and vent valves on water side Before opening cooler drain and vent valves on water side. seal oil cooler 2) Air side seal oil circuit is now drained via the two drain valves.2 Open cooler drain and vent valves on oil side MKW01 MKW11 MKW31 MKW11 MKW21 MKW31 AA503 AA505 AA505 AA501 AA501 AA501 (after seal oil storage tank) (after A1 valve) (after A2 valve) (before seal oil pump1) (before seal oil pump 2) (before standby seal oil pump 3) MKW51 MKW51 MKW51 MKW51 AA505 AA511 AA504 AA510 (drain. seal oil cooler 1) (drain. the coolers should be dried to prevent standstill corrosion of the cooler tubes. Haridwar 2. seal oil cooler 2) (vent. 2. and all seal oil pumps should be out of operation. close cooling water inlet valves. The hydrogen must have been removed from the generator. 2 Drain air side seal oil circuit 2. seal oil cooler 2) (vent. seal oil cooler 1) (vent.

2 Drain hydrogen side seal oil circuit 2. The remaining seal oil can be drained through the drain plug in bottom of seal oil tank.Turbogenerators Operation 1 Preparatory work for draining seal oil circuit Draining the Hydrogen Side Seal Oil circuit The turbine-generator must have been shut down.4 Open shutoff valve MKW113 AA503 2. seal oil cooler 2) Hydrogen side seal oil circuit is now drained via the two drain valves. The hydrogen must have been removed from the generator. seal oil cooler 1) (vent. and all seal oil pumps should be out of operation. and the generator rotor must be at standstill (n = 0 s–1). seal oil cooler 2) (vent.1 Close shutoff valves at seal oil unit MKW03 MKW13 MKW03 MKW13 pump) AA501 AA503 AA502 AA510 (after seal oil tank) (after hydrogen side seal oil pump) (before seal oil tank) (bypass of hydrogen side seal oil 2.5 Open cooler drain and vent valves on oil side MKW53 MKW53 MKW53 MKW53 AA505 AA511 AA504 AA510 (drain. The seal oil pump should be kept in operation only until the seal oil has been removed from the seal oil tank MKW93 BB001.2 Open shutoff valves at seal oil unit.3-8521-0500/1 0709 E . seal oil cooler 1) (drain. MKW13 AA504 MKW13 AA511 (hydrogen side seal oil drain) (hydrogen side seal oil drain) 2. BHEL. Haridwar 2.3 Start seal oil pump Start hydrogen side seal oil pump. 2. Stop seal oil pump immediately afterwards.

3 Draining of hydrogen side seal oil circuit is complete 2.3-8521-0500/2 Start with draining of signal lines. seal oil cooler 2) After draining on their water sides. seal oil cooler 1) (drain.2. seal oil cooler 1) (vent. the coolers should be dried to prevent standstill corrosion of the cooler tubes. seal oil cooler 2) (vent. .6 Open cooler drain and vent valves on water side Close cooling water inlet valves : MKW53 MKW53 MKW53 MKW53 AA507 AA509 AA506 AA508 (drain.

2.Turbogenerators Operation 1 Draining the Seal Oil Signal Lines and Seal Ring Relief Piping Draining seal oil signal lines and seal ring relief piping 2 Drain signal pipes 2. EE) (hydrogen side vent valve. that all vent and drain valves are closed and that valves closed for seal oil draining are reopened. 5 Draining of seal oil circuit is complete BHEL. TE) (air side vent valve.1 Close shutoff valves in seal oil valve rack MKW76 AA513 MKW76 AA523 (TE seal ring relief) (EE seal ring relief) Loosen flanges at shutoff valves and drain seal oil from pipes for seal ring relief. 4 Drain seal ring relief piping 4.2 Open vent valves in seal oil valve rack 3 Drain seal oil filters MKW11 MKW31 MKW13 MKW13 AA507 AA507 AA508 AA509 (oil (oil (oil (oil signal signal signal signal to to to to A1 valve) A2 valve) C valve) C valve) MKW71 MKW73 MKW71 MKW73 AA514 AA514 AA524 AA524 (air side vent valve.1 Open drain valves in signal pipes 2. ensure that all flanges are bolted to the shutoff valves. Haridwar When restarting the system. EE) Drain seal oil filters through drain plugs in filter housings. TE) (hydrogen side vent valve.3-8522-0500/1 0709 E .

Haridwar Supervision of Generator During Standstill Gas System normal operation. be removed from the generator if the seal oil system is taken out of service or for carrying out welding work within the range of the gas supply system or work on the generator. It should. however.Turbogenerators Operation It is recommended to leave the hydrogen in the generator and to reduce the hydrogen pressure if the generator is to be shut down for a period up to two months. Monitoring of the gas system must be continued as during BHEL. however. The gas must.3-8600-0500/1 0709 E . 2. the seal oil system can be taken out of service. be observed that all alarm devices must be set to the new operating values. If the generator is filled with air.

H2 bottle rack) (before H 2 pressure reducer 1. the generator must be at standstill or on the turning gear. H2 unit) (for H2 high pressure) (after H2 pressure reducer 1.Turbogenerators Operation 1 Preparatory work Gas Removal Lowering Hydrogen Gas Pressure in Generator Prior to removing hydrogen (H2) from the generator housing.1 bar by opening shutoff valve MKG25 AA 502. H2 bottle rack) Close all shutoff valves at H2 bottle rack manifold and at H2 bottles. H 2 unit) (after H2 pressure reducer.1 Check zero setting of CO 2 /H 2 purity transmitter 1. 2. H 2 unit) (before H2 pressure reducer 1. H2 bottle rack) (after H 2 pressure reducer 2. Haridwar Lower the gas pressure in the generator to approximately 0. H2 bottle rack) (before H 2 pressure reducer 2. Carbon dioxide must be available in sufficient quantity.3 Lower gas pressure in the generator 2 Generator is ready for filling with CO2 BHEL. H2 unit) (before H2 pressure reducer 2. 1. 1. Switch three way valve MKG25 AA519 in position H2 Vent Gas and vent the gas to atmosphere via orifice MKG25 BP502. Check to ensure that the CO2 flash evaporator is filled with heat transfer liquid up to lower edge of riser.3-8610-0500/1 0709 E .2 Close shutoff valves and three-way valves MKG25 MKG19 MKG19 MKG15 MKG17 MKG15 MKG15 AA519 AA501 AA502 AA502 AA505 AA504 AA501 MKG11 AA561 MKG16 AA501 MKG12 AA501 (H2 filler line) (after H2 pressure reducer.

Switch off heater of CO2 flash evaporator. The CO2/H2 purity system measures the purity of the vent gas. 1. MKG25 AA502 MKG25 AA518 MKG59 AA507 evaporator) MKG51 AA561 MKG25 AA519 Gas) (shutoff valve in H 2 vent gas line) (three-way valve in position CO 2 Filling) (shutoff valve after CO 2 flash (shutoff valve for high-pressure CO2) (three-way valve in position H 2 Vent Then open shutoff valves at CO 2 bottles and CO 2 bottle rack manifold.2 Switch on heater of CO2 flash evaporator 1. 2.3-8620-0500/1 0709 E .5 Measure CO2 purity 1. Wait until the thermostat switches off the heater.6 Terminate filling with CO2 2 Generator is filled with CO2 BHEL.4 Close three-way valve MKG25 AA507 1. Then close shutoff valves : MKG25 AA518 (three-way valve in CO 2 filler line) MKG25 AA519 (three-way valve for measuring gas) MKG51 AA561 (shutoff valve or high-pressure CO 2) MKG59 AA507 (shutoff valve after CO 2 flash evaporator)and all shutoff valves at CO2 bottles and CO2 bottle rack manifold. Replace empty CO 2 bottles by full bottles.Turbogenerators Operation Gas Removal Replacing H2 With CO2 Fill generator with carbon dioxide All lines carrying gas during this procedure are represented by yellow lines on the mimic diagram on the gas valve rack. The generator is filled with CO2 when the indicator shows a purity reading in excess of 95% CO2 in H2 Filling with CO2 can be terminated. Haridwar Switch on heater of CO2 flash evaporator. Observe temperature rise of heat transmitting liquid at the temperature gauge.1 Set range selector switch to position II Set range selector switch in CO 2/H2 purity transmitter to position II (0 to 100% CO2 in H2) 1 1.3 Open shutoff valves and three-way valves 1. Start with air filling.

the carbon dioxide has been driven out of the generator.Turbogenerators Operation 1 Fill generator with air 1.6 Close shutoff valves and three-way valves 2 When the indicator gives a reading of 0% in air. Close shutoff valves MKG25 AA501 and MKG25 AA509. Stop normal running routine of gas system BHEL. the seal oil supply to the shaft seals may also be shut down.2 Establish hose connection 1.5 Remove hose connection 1. Haridwar 2. After purging. After approximately 15 minutes.3 Open shutoff valves Gas Removal Replacing CO2 With Air All lines carrying gas during this procedure are represented by blue lines on the mimic diagram of the gas valve rack. Adjust the compressed air pressure by means of shutoff valve MKG25 AA509 so that the pressure in the generator will not exceed 1 bar. MKG25 AA501 (shutoff valve in compressed air line) MKG25 AA509 (shutoff valve in compressed air line) MKG25 AA518 (three-way valve in position CO2 Vent Gas) Ensure that compressed air is clean and dry. Establish hose connection between compressed air filter MKG25 BT001 and shutoff valve MKG25 AA501.3-8630-0500/1 0709 E . except for the pressure gauge shutoff valves. Disconnect hose connection between compressed air filter MKG25 BT001 and shutoff valve MKG25 AA501 at bayonet fitting. Open shutoff valves downstream of the liquid level detectors and close three-way valve MKG25 AA518 for purging the terminal box and the pipes to the level detectors. Set range selector switch in CO2/H2 purity transmitter to position I (0 to 100% CO2 in air). switch three-way valve MKG25 AA518 to position CO2 Vent Gas and close shutoff valves downstream of liquid level detectors. 1. With the generator rotor at standstill (n = 0s–1). close all shutoff valves and three-way valves of the gas supply that are still open.4 Terminate filling with air 1.e. i.1 Set range selector switch to position I 1. neither oil nor water should be entrained in the air.

2.2 Check nitrogen purging gas volume flow 2.5 Close shutoff valves in N2 bottle rack and purging gas system MKG31 MKG31 MKG31 MKG35 MKG91 AA501 AA502 AA503 AA501 AA502 (at N2 bottle) (at N2 bottle rack manifold) (before N 2 pressure reducer) (after N2 pressure reducer) (in N2 purging gas line) 3 Continue shutdown of primary water system BHEL. Q Q 2 Purge primary water tank with nitrogen 2.3 Perform nitrogen purging procedure Primary water pumps must be in operation. Haridwar 2. During purging. After a purging period of 12 hours. the hydrogen removed is vented to the atmosphere via the vent gas line.99%. A reliable nitrogen supply must be available.3-8650-0500/1 0709 E .Turbogenerators Operation 1 Preparatory work N2 Purging Before Draining of Primary Water System Primary water tank must be purged with nitrogen prior to complete or partial draining of primary water circuit to ensure a removal of the H2 atmosphere and of the H2 contained in the primary water. there will be no potential hazards due to hydrogen atmosphere. MKG31 MKG31 MKG31 MKG35 MKG91 AA501 AA502 AA503 AA501 AA502 (at N2 bottle) (at N2 bottle rack manifold) (before N 2 pressure reducer) (after nitrogen pressure reducer) (in N2 purging gas line) The nitrogen volume flow rate should be 600 dm 3/h. corresponding to a bottle pressure drop of approximately 15 bar/h for a 40 dm3 nitrogen bottle. Note : The nitrogen used for purging must have a purity of 99.4 Terminate nitrogen purging 2.1 Open shutoff valves in N2 bottle rack and purging gas system 2.

2. This condition is permissible for a prolonged period of time. If the water circulation is to be stopped for longer periods of time.Turbogenerators Operation After shutdown of the turbine-generator. complete or partial draining of the primary water circuit will be required.3-8700-0500/1 0709 E . the primary water supply to the generator is maintained by keeping the primary water pumps in service. Haridwar Supervision of Generator During Standstill Primary Water System Water circulation in the primary water circuit or in individual branch circuits can be stopped for shutdowns up to 48 hours if work must be performed on the primary water system. BHEL. Monitoring of the primary water system must be continued as during normal operation.

Close control valve MKF82 AA501. Shut down primary water system for less than 48 hours Q Q 2 Will entire primary water cooling circuit be deactivated? Yes 2. If primary water circulation cannot be maintained because of faults in the primary water cooling circuit. the primary water pumps can be maintained in operation. Haridwar (control valve before bushings) (shutoff valve after bushings) 2. MKF83 AA501 MKF83 AA502 BHEL.1 Stop primary water circulation No Stopping water circulation in branch circuits by closing respective valves. primary water remains in stator winding branch circuit. When this valve is closed.1 Take stator winding branch circuit out service 3. Primary water circulation is stopped by taking primary water pumps out of service. Shutdown is defined as any of the following.Turbogenerators Shutdown of Primary Water System for Less Than 48 Hours Operation 1 Caution : The primary water system may only be shut down when generator is carrying no load and has been taken out of operation (n = 0s–1).3-8720-0500/1 0709E . Caution : Open shutoff valve MKF80 AA504 prior to taking stator winding branch circuit out of service. Completely or partially draining primary water system. Take bushing and phase connector branch circuit out of service by closing valves.2 Primary water cooling circuit can be left in this condition for a period up to 48 hours 3 Take branch circuits out of service 3.2 Take bushing and phase connector branch circuit out of service When taking branch circuits out of service. Temporary drinking of individual branch circuits should be performed in accordance with the following instructions. the entire cooling circuit may be shut down for a period up to 48 hours. 2.

MKF60 AA502 (control valve for water treatment system) MKF60 AA519 (shoutoff valve after water treatment system) 4 Primary water can be left in individual branch circuits for periods up to 48 hours 2.3-8720-0500/2 .3 Take water treatment system out of service Isolate the water treatment system by slowly closing valves.3.

For shut downs of more than 48 hours complete of partial draining of the primary water circuit is required. Primary water tank must be purged with nitrogen prior to complete or partial draining of primary water cooling system. During nitrogen purging. The primary water system should be deactivated only when faults occur in primary water system or during prolonged turbine-generator shutdowns requiring preservation measures. the primary water must be circulated by means of the primary water pump to ensure a uniform removal of the H 2 gas in the entire primary water cooling circuit.Turbogenerators Operation 1 Shut down primary water system for more than 48 hours 2 Purge primary water tank with nitrogen (N2)[1] 3 Reduce pressure in primary water tank Shutdown of Primary Water System for More Than 48 Hours Caution : The primary water system may only be shut down when generator is carrying no load and has been shut down (n = 0s–1). If only one branch circuit is drained for performing the repair works.3-8730-0500/1 0709 E . Haridwar Complete of partial draining of primary water circuit is necessary only if work must be performed on the circuit which requires an empty system. remaining branch circuits may remain filled provided that Q Electrical measuring devices in remaining branch 2. purge with inert gas for 12 hours to avoid potential hazards due to hydrogen atmosphere. Caution : Primary water contains dissolved hydrogen. Reduce pressure in primary water tank to atmospheric level by adjusting overflow regulator MKF91 AA003. 4 De-energize electrical equipment in primary water system De-energize : Conductivity transmitters Level detector system at primary water tank Q Volume flow indicators for stator winding and bushings Q Temperature detectors Q Coolant temperature control system Q Power circuits of pumps Q Q 5 Drain compeleteprimary water circuit or branch circuits BHEL.

Primary water is treated.3-8730-0500/2 .circuits remain activated. 6 Stop normal running routine of branch circuits taken out of service 2. Primary water circulation is maintained by primary water pumps Draining of individual branch circuits should be performed in accordance with the following instruction. Q Q Q Nitrogen purging of primary watertank is continued.

With deposti fuild-up. If operation can presumably be resyume within theee days. Haridwar 2. the cooling water should be drained and the tubescleaned and flushed with clean water. the water is drained from the coolers filled on their cooling water sides. Close drain valve of standby cooler not filled on its cooling water side. Make sure that compressed air is free from oil.3-8732-0500/1 0709 E . 5 Primary water coolers are dained and dry on their cooling water sides BHEL. Reopen drain valve of standby cooler as soon as water has been drained from coolers. After opening of the valves. During brief shutdowns (less that three days) the coolers may also be kept in service at low cooling water velocities if this serves to avoid deposits in the tubes. 4 Dry coolers with compressed air Establish a compressed air connection at vent manifold of primary water coolers. the coolerw may remain filled with cooling water provided that the cooler tubes are free from deposits. Close shutoff valve before and after coolers filled on their cooling water sides. Blowing out may be rerminate when air leaving the drain vlaves is free of atomized water. Teh water channels whould be kept open untill the unit is restarted. the coolers shoud be drained and dried. Check shutoff valves of standby cooler for closed position.Turbogenerators Operation Drain primary water coolers on cooling water side 1 2 Close shutoff valves before and after coolers 3 Open drain and vent valves at coolers Draining the Primary Water System Primary Water Coolers (Cooling Water Side) If the coling qwater cirvulation is stopped for maore than three days. Ten open drain and vent valves of coolers filled on their cooling water sides. dust and other contaminants.

Purging period should amount to approximately two hours. Open drain valve at exciter end primary water manifold briefly several times during blowing-out procedure to drain accumulated water. BHEL. Stator winding is drained by blowing out winding with compressed air. Open drain valves at primary water manifolds. Establish a compressed air connection at primary water inlet flange of exciter end water manifold.3-8734-0500/1 0709 E . Establish hose connections between waste water wywtem and drain. dust and other contaminants. Measuring devices and supervisory equipement in this primary water branck cirvuit nust have been deactivated. N2 purging should be performed daily. Remove inlet and outlet pipes. Close control valve before stator winding. valves of primary water manifolds. Carefully close inlet and outlet after purging. Close drain valve at exciter end primary water manifold when water is no longer being drained. Haridwar 2. Make sure that the compressed air is free from oil. Open compressed air valve fully when only a small amount of water accumulates. Blowing out stator winding may be terminated when air leaving the system is free of atomized air.Turbogenerators Operation Draining the Primary Water System Stator Winding Prerequisites for draining : 1 Drain stator winding Q Q 2 Preparatory work prior to draining 3 Blow out stator winding with compressed air 4 Purge stato winding with N2 Primary water tank was purged with N2 [1]. Shut off compressed air supply at times during this procedure to allow water to accumulate. permitting water to be driven out via the drain valve at the turbine end primary water manifold. Slowly empty one nitrogen bottle through the stator winding. Open compressed air valve briefly at reasonable intervals. clean the two strainers inthe sttor winding inlet and outlet. If required. connect nitrogen supply to primary water inlet flange of exciter end manifold.

3-8650 N2 Purging Before Draining the Primary Water System 2. obtain the help of manufacture’s product service personnel. 6 Stator winding is drained and preserved After refer to the following information [1] 2.5 Pressure stator winding If the stator winding is to be preserved for a prolonged shutdown.3-8734-0500/2 .

Turbogenerators Operation Draining the Primary Water System Terminal Bushings and Phase Connectors Prerequisites for draining : 1 Drain terminal bushings and phase connectors Q Q 2 Preparatory work prior to draining Primary water tank was purged with N2 [1]. Deactivate voulume flow indicators MKF83 MKF83 MKF83 MKF83 MKF83 MKF83 CF001A CF001B CF011A CF0011B CF021A CF021B (phase (phase (phase (phase (phase (phase A bushings) A bushings) B bushings) B bushings) C bushings) C bushings) by closing shutoff valves at valve assemblies. Carefully close inlets and others after ourging. 4 Purge phase conectors and bushings with N2 BHEL. dust and other contaminants. 3 Blow out phase conectors and bushings with compressed air Phase connectors and bushings are drained by blowing them out with compressed air. 2. Establish a hose connection between the waste water system and the outlet fkange. Connect a compressed air source to inlet flange. Blowing out can be terminated when air leaving the system is free of atomized air.and the bottle pressure should drop by approximately 5 bar (70 psi). Measuring devices and supervisory equipement in this primary water branch circuit have been deactivated. N2 purging should be performed daily. The purging period should amount to approximately two hours. purge phase connectors and bushings with nitrogen. and blow out phase connectors and bushings for several hours.3-8738-0500/1 0709 E . Intermittetly shut off compressed air supply during this procedure. Haridwar To prevent oxidation. allowing water to accumulate. Open compressed air valve. Connect nitrogen supply to inlet flange. Close valves: MAKF83 AA501 MAKF83 AA501 (before bushings) (after bushings) Remove inlet pipe near the neutral point. Make sure that the compressed air is free from oil.

3-8650 N2 Purging Before Draining the Primary Water System 2.3-8738-0500/2 .5 If the phase connectors and busings are to be preserved for a polonged shutdown. Pressure phase conectors and bushings 6 Phase conectors and bushings are drained and preserved After refer to the following information [1] 2. Obtain the help of manufacturerer’s product service personel.

To do this. make sure that ion exchanger resins remain immersed in water. Connect vent valve MKF60 AA503 to compressed air system.3-8650 N2 Purging Before Draining the Primary Water System BHEL. dust and other contaminants.3-8746-0500/1 0709 E . Blowing out can be terminated when air leaving the drain valve is free of atomized air.fine filter) (vent. Haridwar 2.Turbogenerators Operation Draining the Primary Water System Water Treatment System Prerequisites for draining : 1 Drain water treatemnt system Q Q 2 Take ion exchanger out of service Primary water tank was purged with N2 [1]. Note: When draining primary water treatment system. 5 Water treatment system is drained and dry Also refer to the following information [1] 2. water treatment system). primary water treatment system) (drain. fine filter) (drain. Drain water treatment system by closing shutoff valve MKF60 AA519 (shutoff valve for primary water treatment system) and opening shutoff valves: MKF60 MKF60 MKF60 MKF60 MKF60 4 Drain and dry piping system with compressed air AA503 AA511 AA512 AA510 AA517 (vent before ion exchanger) (drain. Measuring devices and supervisory equipement in this primary water branch circuit have been deactivated. Make sure that the compressed air is free from oil. isolate ion exchanger by closing valves: MKF60 AA502 MKF60 AA509 3 Drain water treatment system (control valve before ion exchanger) (shutoff valve after ion exchanger).

Make sure that the compressed air is free from oil. however. Isolating branch circuits is. dust and other contaminants. 2 Dry piping system with compressed air Establish a connection to the compressed air system at a suitable point (high static head of the external primary water circuit. All branch circuits were drained or isolated from external part of primary water circuit by closing valves. Primary water pumps are not in service. 3 External part of primary water circuit is drained and dry Also refer to the following information [1] 2.Turbogenerators Operation Draining the Primary Water System External Part of Primary Water Circuit Prerequisites for draining : Q 1 Drain external part of primary water circuit Q Q Primary water tank was purged with N2 [1]. only permissible if external part of primary water circuit is filled again with water and taken into service within 48 hours. Haridwar 2. Blowing out can be terminated when air leaving the vent and drain valves is free of atomized air.3-8748-0500/1 0709 E .3-8650 N2 Purging Before Draining the Primary Water System BHEL. Drain primary water from external primary water circuit by closing all drain and vent valves in the external primary water circuit.

Caution : Never place dryer into operation without BHEL.3-8900-0500/1 0709 E . the dryer and the space heaters must be in operation. In the case of a prolonged outage. a protective coating should be applied to the measuring sliprings.Turbogenerators Operation With the generator on turning gear or at standstill. Haridwar Supervision of Generator During Standstill Exciter make-up air filter. 2. The brushes of the ground fault detection system should be lifted off the measuring sliprings to prevent the formation of rust on the sliprings. The filter pads installed at the dryer inlet should be carefully checked for contamination at regular intervals and cleaned or replaced in due time.

The turbine-generator should be shout down and the hydrogen should be replaced with carbon dioxide. The individual measures required depend on the mode of operation. their possible causes and the corrective measures cannot be considered complete in every respect.Turbogenerators Operation The details given herein on faults. since all possible troubles cannot be covered in advance. the services of the manufacturer should be requested. If required. sufficient details will be found in the Turbogenerator Manual. 2.3-9000-0500/1 0709 E . however. Haridwar Fault Tracing General Unless corrective measures can be taken in accordance with the following instruction. In most cases. BHEL. the operator will have to decide on the measures to be taken. In most cases.

a turbine trip is activated via the generator mechanical equipment protection. defective hydrogen cooler section. The permissible rated stator current should not be exceeded in any stator phase. Such a check should only be made with the generator at rest and in non-excited condition. The generator should be shut down if it is impossible to distribute the system load more uniformly over the three phases. Lower cold gas temperature of disturbed cooler by adjusting the cooling water volume flow with the cooling water outlet valve. primary water or moisture condensate. Ensure that cold gas temperatures after all hydrogen coolers are of equal magnitude. care must be taken that the continuously permissible unbalanced load is not exceeded [1]. oil from shaft seals. Check to ensure that the cooling water inlet valve is fully open. close shutoff valve before level detector Q Q BHEL. steps should be taken for bringing about a uniform system load. In many cases. a fault can be cleared by recalibration of the RTD's. the final control element should be manually opened. Insufficient cooling water flow volume through hydrogen coolers. Set temperature control from Automatic to manual mode and increase cooling water volume flow by opening the final control element. Verify cause of disturbance by checking analog indicators (uniform rise of temperatures at all coolers). Liquid in generator The liquid in the generator casing should be inspected to determine its origin. Verify cause of disturbance by checking analog indicators (temperature rise at one cooler).Turbogenerators Operation Fault/Cause Differences in slot temperatures between individual phases of stator winding High hot gas temperature and/or High cold gas temperature Fault Tracing Stator and Generator Supervisory Equipment Remedy The embedded RTD's should be checked when different slot temperatures are indicated while stator currents are of equal magnitude in all the three phases. i. If necessary. the measuring point selector switches and the indicators. Note: If cold gas temperature continues to rise. The check should include resistance measurements as well as testing of the detector leads. The unbalanced load is defined as the ratio of negative sequence current to rated current. Unbalanced load due to unequal phase loading of the system connected to generator If the generator is operated with unbalanced load due to particular system conditions. Haridwar 2. Hydrogen temperature control is disturbed. Care should be taken during resistance measurements of the embedded RTD's to ensure that they are not heated as this will falsify the results.3-9200-0500/1 0709 E .e. When the unbalanced load. To do this. Insufficient cooling water volume flow through a single hydrogen cooler.

liquid accumulation in the generator can only occur in case of a larger leakage (tube failure. Reduce generator load [2] and take cooler section out of service by closing the shutoff valves. Q Oil Oil level control in seal oil tank is disturbed.3-9440 2. which will be the case on occurrence of a large leakage.Oil Level in Seal Oil System .Fault/Cause Remedy which activated the alarm. the generator should be shut down immediately. A hydrogen sample should be extracted from the generator and examined in a laboratory to determine its moisture content. Q Moisture condensate Very small water quantities are indicative of moisture condensate. however. Q Primary water Since the primary water pressure is lower than the H2 casing pressure during generator operation at rated hydrogen pressure.3-8170 2. Repeat this procedure until no liquid is drained from the shutoff valve.3-9561 General and Electrical Data Permissible Load Limits of Generator Fault Tracing-Coolers Fault Tracing. a shutdown of the turbine-generator. Fault tracing and corrective action may be started as soon as the generator is filled with air. Drain the liquid via the shutoff valve after the level detector and inspect liquid. As soon as the generator has been disconnected from the system and de-excited. Remove hydrogen from the generator immediately. Q Cooling water from a defective hydrogen cooler Larger amounts of water point to a leaking cooler section. Identify defective cooler section.1-1810 2. Prechambers in generator are overflowing. If the liquid cannot be drained from the generator in this manner within a reasonable period of time. burst Teflon hose).3-9200-0500/2 2. Also refer to the following information [1] [2] [3] [4] 2. Take corrective actions as described in [4] immediately. Then close shutoff value after level detector and reopen shutoff valve before level detector. The leakage water quantities require. take primary water pumps out of service and close control valves before stator winding and bushings. Place gas dryer in operation. Then take measures outlined in the respective instruction [3].

If necessary. Q Q Hydrogen temperature control is disturbed. Cooling water volume flow through hydrogen coolers is insufficient. Verify cause of disturbance at analog indicators.3-9280-0500/1 0709 E .Turbogenerators Operation Fault/Cause Fault Tracing Generator Supervisory Equipment Coolant Temperature Control Remedy Low coolant differential temperature The temperature difference between the cold primary water and the cold gas amounts to 3 K only. Low coolant differential temperature Caution: Temperature difference between cold primary water and cold gas has dropped to 1 K. Change over control to manual mode and increase cooling water volume flow until a temperature difference of 5 K is obtained. throttle control valve manually on unit. Change over control to manual mode and increase cooling water volume flow until a temperature difference of 5 K is obtained. Q Hydrogen or primary water temperature control is disturbed. This will normally be the case when the closed generator was dried with the gas dryer for not less than four weeks and provided that no leakage occurred in the generator interior during this period. change primary water temperature control over to manual mode and throttle cooling water volume flow through primary water coolers. If the temperature difference cannot be increased by this corrective measure. it is recommended to unload and de-excite the generator at once. Haridwar If the temperature difference between the cold primary water and the cold gas cannot be increased by\ the above corrective measures. Verify cause of disturbance at analog indicators. Cooling water volume flow through primary water coolers is excessive. If the temperature difference cannot be increased by this corrective measure. BHEL. Primary water temperature control is disturbed. Note: On-load running is possible when the dew point temperature of the hydrogen in the machine is sufficiently below the cold gas temperature. open control valve manually on unit. If necessary. 2. Condensation may occur on primary water cooled components when surface temperature of these components drops below dew point of surrounding hydrogen atmosphere. change hydrogen temperature control over to manual mode and increase cooling water volume flow through hydrogen coolers.

Unload and shut down turbine generator as soon as feasible if cause cannot be located and corrected for severe condition. Since it is very difficult in most cases to find a definite cause. Haridwar Fault Tracing Rotor Remedy Check whether the deteriorated running condition originated due to the turbine or whether the rotor bearings are damaged. 2. A deterioration of the running condition may be caused by a change in the balancing condition or by a rotor winding short.Turbogenerators Operation Fault/Cause Sudden deterioration of rotor running condition.3-9310-0500/1 0709 E . it is advisable to obtain the help of manufacturer's product service personnel. BHEL.

Repeat this procedure until no liquid is drained through the shutoff valves. First.3-9440-0500/1 0709 E . Identify the defective cooler section. Drain the liquid by means of shutoff valves after the level detectors. The cooler section should be filled with water and BHEL. Fill generator with air to a gauge pressure of approximately 0. Plug the defective tube at both ends. Detach cooling water lines. To reassemble the components. follow disassembly procedure in reverse order. 1 2 3 4 1 2 3 4 Shutoff valve before level detector Level detector Sight glass Shutoff valve after level detector Fig. Haridwar 2.5 bar (7 psig). the defective tube can be easily identified since air bubbles emerge from this tube.Turbogenerators Operation Fault/Cause Fault Tracing Coolers Remedy Liquid in Generator Q This fault is due to a leaking or defective H2 cooler tube. Ensure that gaskets are not damaged. 1 Arrangement of Level Detectors Shut down generator and remove the hydrogen with carbon dioxide. seal cap and inlet/outlet water channel. Remove the return water channel. After removal of the cover of the return water channel. Close shutoff valve before the level detectors that have initiated the alarm. Mark defective tube and drain cooling water. close cooling water outlet of this cooler section and then the cooling water inlet. This procedure ensures that no hydrogen can escape form the generator through the shutoff valves. Ensure that gaskets are not damaged. Insert plugs by light hammer blows into upper and lower tube sheets.

at which time the tube bundle or defective cooler tube should be replaced.3-9440-0500/2 .Fault/Cause 1 2 3 4 1 2 3 4 Plug Upper tubesheet Cooler tube Lower tubesheet Fig. This temporarily repaired cooler may be maintained in operation until next inspection or outage. synchronized and loaded. The generator should be filled with gas. run up. 2 Plugging a Defective Cooler Tube vented. Check water channels to ensure there is no leakage. 2.

This check is performed by counting the number of turns or by measuring the travel. If bearing temperature exceeds permissible value. Temperature variations at the generator bearings may be due to different causes. If. The fault may be due to a leak at the check valve in the lift oil pipe. close globe valve in the lift oil line. BHEL. Check first to determine whether the pressure drop was caused by an oil temperature variation. If not. turbogenerator should be shut down. Turbogenerator can be kept in operation as long as permissible bearing temperature is not exceeded. Prior to closing valve. the check valve is leaking. If bearing temperature rise does not result from a variation of these values. the shaft lift oil system should be checked for leakages.Turbogenerators Operation Fault Tracing Bearings Fault/Cause Remedy Generator bearing temperatures vary. the pressure gauge shows an increase over the previous operating valve. A precise adjustment of the throttling element will again be necessary during re-commissioning. Replace or repair the check valve at the next shutdown or inspection. Oil pressure depends in part on the bearing oil inlet temperature. Bearing oil pressure indicated in the shaft lift oil pipe drops. Haridwar 2. first check cold oil temperature (oil temperature after cooler) and bearing oil pressure for deviation from normal. To determine if the check valve is leaking. the oil pressure indicated in the shaft lift oil pipe should be checked. check and record the setting (Throttling valve as set for operation). If a deviation occurs. When a variation is noted. the operating temperatures should be carefully monitored to ensure the limit temperature is not exceeded.3-9450-0500/1 0709 E . on closing the globe valve.

Bearing vapour exhauster 2 failed. Check fuses and thermal overload device. Verify that voltage is a available. 2. resulting in failure of bearing vapour exhauster. loss of control voltage. Haridwar Identify cause of blown fuse (overcurrent or short in cable). Check fuses and thermal overload device. Identify cause of blown fuse (overcurrent or short in cable). Bearing vapour exhauster 1. BHEL. Examine bearing vapor exhauster 2 for proper electrical and mechanical condition. resulting in failure of bearing vapour exhauster 1. Examine bearing vapor exhauster 1 for proper electrical and mechanical condition. Bearing vapor exhauster 1 automatically takes over venting of generator bearing compartments. resulting in loss of control voltage. Q Fuse has blown. Q Fuses or thermal overload device have tripped main contactor. Replace defective fuse and restart bearing vapor exhauster 2.3-9521-0500/1 0709 E . Bearing vapor exhauster 2 automatically takes over venting of generator bearing compartments.Turbogenerators Operation Fault/Cause Fault Tracing Bearing Vapour Exhausters Remedy Bearing vapour exhauster 1 failed. Bearing vapour exhauster 2. Verify that voltage is available. Replace defective fuse and restart bearing vapor exhauster 1. loss of control voltage. Check operating points of flow transmitters. Check operating points of flow transmitters. Q Fuses or thermal overload device have tripped main contactor. resulting in loss of control voltage. Q Fuse has blown.

resulting in failure of seal oil pump 2. In the event of a failure of seal oil pump 2. Replace defective fuse and ensure that seal oil pump 2 can be restarted. Haridwar Fault Tracing Seal Oil Pumps Remedy In the event of a failure of seal oil pump 1. loss of control voltage Fuse has blown. resulting in loss of control voltage. resulting in loss of control voltage. Check if voltage is available. de-excite and shut down generator and remove hydrogen gas promptly. Identify cause of blown fuse (overcurrent or short in 2. Examine seal oil pump 2 for proper mechanical and electrical condition. If another seal oil pump cannot be started immediately. Bring three-way valve MKG19 AA519 to H 2 vent gas position and place CO2 flash evaporator in operation. Identify cause of blown fuse (overcurrent or short in cable). Displace hydrogen with carbon dioxide. Replace defective fuse and ensure that seal oil pump 1 can be restarted. Check fuses and thermal overload device. Hydrogen side seal oil pump is stopped simultaneously. Caution: If one of the two failed seal oil pumps cannot take over the seal oil supply to the shaft seals immediately. Seal oil pump 2 failed Fuses or thermal overload device have tripped main contactor.3-9523-0500/1 0709E . seal oil pump 2 automatically takes over the seal oil supply to the shaft seals. Examine seal oil pump for proper mechanical and electrical condition. BHEL. Identify cause of blown fuse (overcurrent or short in cable). resulting in failure of seal oil pump 3 (stand by seal oil pump). Seal oil pump 3. Start seal oil pump 1 after fault is corrected. Correct fault immediately so that seal oil pump can be promptly restarted. seal oil pump 3 (stand-by seal oil pump) automatically takes over the seal oil supply to the shaft seals if seal oil pump 1 has failed too. Seal oil pump 1. Check if voltage is available. resulting in loss of control voltage.Turbogenerators Operation Fault/Cause Seal oil pump 1 failed Fuses or thermal overload device have tripped main contactor. Seal oil pump 3 failed Fuses or thermal overload device have tripped the main contactor. loss of control voltage Fuse has blown. Caution: Hydrogen glows into generator bearing compartments via sealing gap and is extracted by bearing vapour exhauster in service. Isolate H 2 supply to generator by means of the respective shutoff valves. Seal oil pump 2. resulting in failure of seal oil pump 1. loss of control voltage Fuse has blown. make all preparations for shutdown of generator and gas removal. Sealing and lubrication of shaft seals with seal oil can no longer be maintained. Check fuses and thermal overload device.

3-9523-0500/2 Shaft seals are now supplied with seal oil from the air side seal oil circuit only. Air entrained in seal oil escapes into generator. Hydrogen side seal oil pump failed Fuses or thermal overload device have tripped main contactor due to loss of control voltage. Note: Seal oil saturated with air is now also supplied to hydrogen side shaft seals. Verify that voltage is available. Verify that pressure gauges indicate previous operating values. resulting in a deterioration of H2 purity. Seal oil drained towards the hydrogen side of the shaft seals is returned to the seal oil storage tank via seal oil tank MKW03 BB001 and float valve MKW03 AA001. 2. Replace defective fuse and ensure that seal oil pump 3 can be restarted. .Fault/Cause Remedy cable). Start pump immediately after the fault is corrected. Visually examine pump to determine condition of mechanical parts. Check fuses and thermal overload device.

Air side seal oil pump MKW11 AP001 or MKW21 AP001 is disturbed. Seal oil filter MKW51 BT002 is contaminated. High seal oil temperature after air side / Hydrogen side cooler Cooling water flow is too low or cooler is contaminated. BHEL. Low hydrogen side seal oil pressure. Check and. Alarm is activated through pressure gauge with contact. Check air side seal oil pump in service. Place stand by cooler in operation by means of rotary valve set. Deactivate contaminated filter. TE/EE A1 or A2 valve no longer controls to operating value. Haridwar Verify that correct relationship exists between cooling water flow and seal oil temperature. clean hydrogen side seal oil filter. Low air side seal oil pressure.Turbogenerators Operation Fault/Cause Low seal oil pressure after air side oil filter Seal oil filter in service is contaminated. High differential pressure across air side oil filter Seal oil filter in service is contaminated. Deactivate contaminated filter. High differential pressure across hydrogen side oil filter Seal oil filter in service is contaminated. Remove filter cover and screen filter.3-9531-0500/1 0709 E . Remove filter cover and screen filter. Check settings of A1 and A2 valves. clean air side seal oil filter. Low differential seal oil pressure. Thoroughly clean cooler taken out of operation on its water side. If cooling water flow is too low. Low differential seal oil pressure. Fill filter housing with turbine oil prior to reassembly. if required. Check setting of C valve. Vent pressure equalizing valve. EE Preset differential pressure between air side and hydrogen side seal oil systems no longer exists. TE Preset differential pressure between air side and hydrogen side seal oil systems no longer exists. Ensure that other cooler is properly vented on its oil and water sides. Change over to stand by filter with changeover valve assembly. Fill filter housing with turbine oil prior to reassembly. if required. Check hydrogen side seal oil pump. Failure of seal oil temperature to decrease is indicative of a dirty cooler. Seal oil filter MKW53 BT002 is contaminated. Hydrogen side seal oil pump MKW13 AP001 is disturbed. TE/EE C valve no longer controls to operating value. Fault Tracing Seal Oil Pressures and Temperatures Remedy Place stand by filter into service in order to determine whether pressure drop is due to a contaminated filter. Change over to stand by filter with changeover valve assembly. 2. Thoroughly clean screen filter and reassemble filter. Check and. Vent pressure equalizing valve. Thoroughly clean screen filter and reassemble filter. increase the cooling water flow by opening the shutoff valves in cooling water outlet pipes.

Thoroughly vent all lines and regulating valves. Q Q Remedy Variations in oil pressure are usually due to entrapped air in regulating valves or oil delivery lines. 2. Check whether mechanical vibrations transmitted to movements are due to lines or foundation. Insufficient control range of A2 valve: Keep shutoff valve MKW31 AA505 closed until pressure gauge readings remain constant. Transmission of mechanical vibrations. Insufficient control range of C valve: Keep shutoff valve MKW13 AA505 closed until pressure gauge readings remain constant.3-9531-0500/2 . Insufficient control range of differential pressure regulating valves Insufficient control range of A1 valve: Keep shutoff valve MKW11 AA505 closed until pressure gauge readings remain constant.Fault/Cause Varying pressure gauge indications Q Entrapped air in pipes.

MKW11 AA506 and MKW11 AA504 and MKW11 AA505 and check that A1 valve regulates to operating pressure. Open shutoff valve MKA23 AA504. resulting in a rise of seal oil pressure before the shaft seals. MKW31 AA504 and MKW11 AA508. Relief valve MKW13 AA001 operates. BHEL. Ensure that previous operating values are restored during operation with A1 valve. Disconnect gas signal line from valve head. Take hydrogen side seal oil pump out of service. Refit valve head and gas signal line. Main bellows in A1 valve is defective. readjust A1 valve. Close shutoff valves MKW31 AA504 and MKW31 AA505. Disconnect gas signal line from valve head. If required. Open shutoff valve MKW11 AA508. Dismantle valve head and replace main bellows. Ensure that previous operating values are restored during operation with A1 valve.3-9551-0500/1 0709 E . Open shutoff valves MKW31 AA504 and MKW31 AA505 and close shutoff valve MKA23 AA504. MKW11 AA506. Check that A2 valve regulates to operating pressure. Shutoff valve MKW13 AA510 is closed. Close shutoff valve MKW23 AA503 in gas signal line and shutoff valve MKW31 AA506 in oil signal line. A2 valve may only be taken out of service when operation with A1 valve is ensured. Fault Tracing Relief Valves in Seal Oil System Remedy Open shutoff valves MKW11 AA505 and MKW11 AA504. Main bellows in A2 valve is defective. Open shutoff valve MKW13 AA510. Open shutoff valve MKW31 AA505. A1 valve may only be taken out of service when operation with A2 valve is ensured. resulting in a rise of seal oil pressure before the shaft seals. Vent oil signal line through vent plug. Relief valve of seal oil pump in service operates during operation with A2 valve Shutoff valves MKW31 AA505 and MKW31 AA504 are closed.Turbogenerators Operation Fault/Cause Relief valve of seal oil pump in service operates during operation with A1 valve Shutoff valves MKW11 AA505 and MKW11 AA504 are closed. Refit valve head and gas signal line. Slowly open shutoff valve MKA23 AA503 and afterwards shutoff valve MKA31 AA506. Main bellows in C valve is defective. Slowly open shutoff valve MKA23 AA504 and afterwards shutoff valve MKW11 AA506. MKW11 AA504 AND MKW11 AA505. Haridwar 2. The shaft seal are now supplied with seal oil from the air side seal oil circuit only. Vent oil signal line through vent Valve MKW31 AA507. Open shutoff valves MKW11 AA504 and MKW11 AA505 and close shutoff valve MKW11 AA508. Close shutoff valve MKA23 AA504 in gas signal line and shutoff valve MKW11 AA506 in oil signal line. Dismantle valve head and replace main bellows. Close shutoff valves MKW11 AA504 and MKW11 AA505. resulting in a rise of seal oil pressure before the shaft seals.

Place hydrogen side seal oil pump in operation. readjust C valve. Open shutoff valve MKW13 AA507. Ensure that previous operating values are restored.3-9551-0500/2 . Close shutoff valve MKW13 AA507.Fault/Cause Remedy Close shutoff valve MKW13 AA510. Refit valve head and air side seal oil signal line. Then open shutoff valves MKW13 AA505. MKW13 AA506 and MKW13 AA510. Vent hydrogen side and air side seal oil signal lines through vent plugs. If required. Disconnect air side seal oil signal line from valve head. Dismantle valve head and replace main bellows. 2. Close shutoff valve MKW13 AA505 in air side seal oil signal line and shutoff valve MKW13 AA506 in hydrogen side seal oil signal line.

3-9561-0500/1 0709 E . If unsatisfactory. and shutoff valve MKW 03 AA501 OPEN. BHEL. Correct fault immediately. Caution: If the shutoff valve is left open. Haridwar Make sure that shutoff valve MKW03 AA504 is closed. Determine cause of trouble and correct it. Check level detector and probe. control valve MKW03 AA001 is not functioning properly. With valve open. Make sure that oil level remains visible in oil sight glass. 2. Corrective action is only practicable following shutdown and emptying of generator and lowering of oil level in seal oil tank. the complete oil volume contained in the seal oil tank is forced into the seal oil storage tank. If the level detector is no longer immersed in seal oil. Shut down generator and remove gas immediately. Oil level control is malfunctioning. Leak in seal oil storage tank In the event of a leak in the seal oil storage tank. the seal oil pumps can no longer draw oil for supply to the shaft seals. Cautiously open shutoff valve MKW03 AA504 by a small amount. Hydrogen flows into the seal oil storage tank via the seal oil tank. Close shutoff valve MKW03 AA504 immediately when oil level is visible in oil sight glass. the level detector stops the hydrogen side seal oil pump to prevent dry running of the pump. oil level control should maintain in a constant level of oil in seal oil tank. Seal oil is forced into the seal oil storage tank by the H2 casing pressure acting on the oil in the tank. Emergency operation is possible with manual control of valve MKW03 AA504. Low oil level in seal oil storage tank Level detector is malfunctioning Fault Tracing Oil Level in Seal Oil System Remedy Make sure that valve MKW03 AA501 is fully open. Low oil level in seal oil tank Low oil level in seal oil tank has dropped to such an extent that level detector is no longer immersed in oil.Turbogenerators Operation Fault/Cause High oil level in TE/EE prechambers Oil level in generator prechambers has risen to such a height that one level detector is immersed in oil.

Q There are leaks at generator or piping. Note: Reduce load when gas pressure drop amounts to 0. Q Setting of pressure reducers incorrect.Turbogenerators Operation Fault/Cause Fault Tracing Gas Pressures Remedy Low H 2 bottle pressure. Haridwar 2. Q H2 bottle connected is empty. Low H2 casing pressure. Check whether leaks are due to generator.3-9640-0500/1 0709 E . Set H2 pressure reducers to operating pressure. Connect now H2 bottle. Identify leaks by means of a leak detector. BHEL. Unload and shut down generator when pressure continues to drop. piping or gas dryer.4 bar.

interrupt measuring gas flow to meter system by means of threeway valve MKG25 AA519.5% to the positive terminal of the power supply and the lead originating at this terminal. Isolate measuring gas supply to meter system by means of three-way valve MKG25 AA519 and remove BHEL. If when setting the electrical zero. resulting in deterioration of the H 2 purity. Fault Tracing Gas Purity Meter System Remedy The H 2 purity should be re-established through scavenging with Hydrogen. the indication is higher than 100% H2 and cannot be reset to zero by the zero point adjuster. Haridwar 2. Switch on power supply. Deviations from the desired value of more than 10 mA are indicative of a fault in the power supply. The supply of measuring gas to CO2 /H2 purity transmitter MKG25 CQ001 has been interrupted. No indication at indicators of purity meter system. Pressure in generator will decrease.7 mA by means of potentiometer R6. Pure hydrogen is automatically replenished via the pressure reducers. Warning: Be sure no explosion hazard exists. In this case. The thermal gas analyser cell should then be replaced. Check the complete meter system for CO 2/H 2 purity transmitter MKG25 CQ001. Check bridge supply current. Warning: Isolate all H2 carrying lines prior to opening gas flow path to prevent mixing of gases. Switch off power supply voltage and disconnect ammeter. Check bridge supply current Switch off power supply voltage ahead of power supply. leaking comparison gas cell is indicated. replace fuses. Connect an ammeter with an internal resistance of 750 mili-ohm and of an accuracy class below 0. if required. Momentarily bring three-way valve MKG25 AA518 to CO2 vent gas position. Gas flow decreases in spite of constant operating pressure.3-9680-0500/1 0709 E . Check output voltage of transmitter by means of a voltmeter. the air entrained in the air side seal oil circuit will escape into the generator. Check burden resistor for correct value and ensure that all necessary equivalent resistors have been inserted. Check setting of electrical zero. resulting in faulty indication of the instrument. Bring three-way valve MKG25 AA507 in H2 calibration position and re-calibrate meter system with pure hydrogen. Check power supply fuses and. Faulty indication of electrical purity meter system. Check output voltage of transmitter by means of a voltmeter. Check power supply voltage at power supply input. The bridge supply current can be set to the desired value of 335 ± 1.Turbogenerators Operation Fault/Cause Low H2 purity Seal oil pump MKW13 AP001 supplying the hydrogen side of the shaft seal has failed. To do this.

Fault/Cause Remedy and clean dust filter. If required. 2. re-insert throttle.3-9680-0500/2 . Remove and clean throttle by means of a throttle needle. since the explosion proof design may be adversely affected. insert new filter. Warning: Do not perform any work on purity transmitters other than that described under Fault Tracing. Warning: Isolate all H2 carrying lines prior to opening gas flow path to prevent mixing of gases.

Check pump for mechanical defect. After clearing the fault. 2. loss of control voltage Q The fuses have operated. Check fuses or miniature automatic circuit breakers and thermal overload devices. The starting contactor has dropped out due to loss of voltage. The pump is activated either by a drop of the pressure downstream of the pre-selected pump or by a loss of voltage. BHEL. In the event of a failure. The starting contactor has dropped out due to loss of voltage Check whether voltage is available.3-9720-0500/1 0709 E . the standby pump is automatically started and takes over the water circulation as long as the fault prevails. return pump to service immediately. Haridwar Take corrective actions as described for the above fault.Turbogenerators Operation Fault/Cause Fault Tracing Primary Water Pumps Remedy Primary water pump 1 failed or Primary water pump 2 failed Q Q The fuses or thermal overload devices have operated. loss of control voltage or Primary water pump 2. Primary water pump 1.

and contaminations from outside are also not feasible. Haridwar Take water treatment system out of service and replace filter inserts in fine filter [1]. if necessary shut down generator. Should it nevertheless occur. Cleaning the main filter during operation is possible as described above. place main filter 2 into operation and take main filter 1 out of service by filter changeover [2]. due to precautions inherent in the plant design and mode of operation the occurrence of such a fault is very unlikely.3-9730-0500/1 0709 E . A contamination of the main filter will thus normally not occur.Turbogenerators Operation Fault/Cause Low pressure after primary water pump 1 or Low pressure after primary water pump 2 Primary water circulation disturbed. Check system for hydrogen leakage by determining hydrogen losses of generator. with the outflow regulator being unable to handle leakage gas flow. External part of primary water circuit is assembled with extreme care and thoroughly flushed and cleaned prior to startup. make sure that specified operating data have been restored. The standby pump is automatically started and takes over the water circulation. 2. In the event of a leak being detected. Low pressure in stator winding Main filter is contaminated. the outflow regulator being unable to release corresponding gas quantities. High pressure in primary water tank Q Q Gas in primary water tank is compressed due to primary water being added at an excessive rate. Reduce rate of make-up primary water. Contaminations originating from the primary water circuit are possible due to resins in the water treatment branch circuits and due to corrosion products. BHEL. After changeover to the stand by main filter. After filter cleaning. High differential pressure across main filter Main filter is contaminated. Fault Tracing Water Pressures and Temperatures in Primary Water System Remedy Correct disturbance and/or identify cause immediately. Generator operation with insufficient cooling water pressure will impair cooling of the unit and is thus not permissible. operation of the primary water system can be continued either with the cleaned filter of with the filter placed into operation by filter changeover. reduce outflowing gas quantity by reducing hydrogen pressure in generator. However. High differential pressure across fine filter Fine filter is contaminated. Excessive hydrogen leakage.

if necessary. Remedy In case of cooler fouling.4-4740 [2] 2. return cooler to service by cooler changeover. Q Primary water temperature control disturbed. change over to manual control. place standby primary water cooler into operation and take fouled cooler out of service by cooler changeover. The standby cooler should be drained or. its cooling water side and. Always check vents prior to performing any cooler changeover. cleaned and dried. Q Insufficient venting of coolers. Open vent values (primary water side and cooling water side) until only water emerges.3-9730-0500/2 Maintenance and Supervision of Primary Water Filters Filters in Primary Water System .Fault/Cause High temperature after primary water cooler Q Cooler fouling (cooling water side). if required.3-9740 2. Check the primary water temperature control system and. Also refer to the following information [1] 2. After cooler cleaning.

Fault Tracing Filters in Primary Water System Remedy Take fine filter out of service by closing shutoff valves: MKF60 AA509 (after ion exchange). Close shutoff valve BHEL. MKF60 AA513 (after fine filter).3-9740-0500/1 0709 E . Haridwar 2. Open filter housing and replace filter element [1]. and contaminations from outside are also not feasible. However. Should it nevertheless occur. (after fine filter) External part of primary water circuit is assembled with extreme care and thoroughly flushed and cleaned prior to startup. Close vent valve MKF60 AA512 as soon as the primary water emerges without bubbles. due to precautions inherent in the plant design and mode of operation the occurrence of such a fault is very unlikely. Place main filter 2 into operation by opening shutoff valves: MKF52 AA590 (before main filter 2) MKF52 AA592 (vent at main filter) MKF52 AA593 (after main filter 2). Contaminations originating from the primary water circuit are possible due to resins in the water treatment branch circuits and due to corrosion products. Discard water.Turbogenerators Operation Fault/Cause High differential pressure across fine filter Fine filter is contaminated. Open shutoff valve MKF60 AA513 High differential pressure across main filter Main filter is contaminated. Open shutoff valve MKF60 AA509 (after ion exchange) to admit primary water into the fine filter. A contamination of the main filter will thus normally not occur. place main filter 2 into operation and take main filter 1 out of service by filter changeover [1]. Recommissioning the fine filter: Close shutoff valve MKF60 AA511 (drain at fine filter). Open shutoff valves: MKF60 AA512 MKF60 AA511 (vent at fine filter) (drain at fine filter) to drain the primary water from the filter.

Fault/Cause MKF52 AA591 (drain at main filter 2) immediately and shutoff valve MKF52 AA592 (vent at main filter 2) as soon as water emerges without bubbles. Discard water. Open shutoff valves: MKF52 AA581 (drain at main filter 1) MKF52 AA582 (vent at main filter 1) to drain the primary water from main filter 1. MKF52 AA580 (before main filter 1) MKF52 AA583 (after main filter 1). operation of the primary water system can be continued either with main filter 2 or with cleaned main filter 1.3-9740-0500/2 Maintenance and Supervision of Primary Water Filters . Also refer to the following information [1] 2.4-4740 2. Take main filter 1 out of service by closing shutoff valves. When using main filter 1. After filter cleaning. Main filter 2 is now in service. operate valves as specified above.

Q Defective primary water cooler. If the primary water pressure exceeds the pressure in the cooling water system.3-9760-0500/1 0709 E . the defective cooler should be taken out of service by primary water cooler changeover. water will enter into the waste gas system causing damage to the equipment. The primary water tank is dimensioned so that expansion of water due to temperature rise during operation will not cause the water level to rise above the high level mark if the tank is filled to an excessive level. the level should be corrected by draining. Low water level in primary tank Q Q Leakage in primary water system. If the tank overflows. BHEL. evaporation and water sampling. Immediately take measures for shutdown of the turbinegenerator. the primary water cooler should likewise be checked for leaks. If it is no longer practicable to maintain water circulation. Haridwar 2. Fault Tracing Water Level in Primary Water Tank Remedy A rise of the primary water level in the tank above the high level mark calls for particular attention. Should the rise of the water level be due to leakage of cooling water.Turbogenerators Operation Fault/Cause High water level in primary water tank Q Natural expansion of primary water due to temperature rise. Add water to restore required water level in primary water tank. Any leakage of cooling water into the primary water circuit can only take place when the pressure in the cooling water circuit is higher than in the primary water circuit. shut down generator. Water losses due to filling operation. Stop the leakage and restore normal water level in primary water tank by adding fully demineralised water.

Bayer Leverkusen AG Sparte OC. the cover of the ion exchanger tank should be lifted off. (drain after ion exchanger). According to the manufacturer's instructions. Terminate draining by closing shutoff valves: MKF60 AA503 MKF60 AA510 (vent before ion exchanger). After opening flanged connection and removing connecting pipe. Fill ion exchanger with new resins of quality KR and place ion exchanger into service again [1].Turbogenerators Operation Fault Tracing Conductivity in Primary Water System Fault/Cause Remedy High conductivity after ion exchanger Q Ion exchanger resins are exhausted and should be replaced. Haridwar 2. or from BHEL Haridwar in order to maintain the recommended quality and a long. the resins must be thoroughly flushed to prevent the entrance of reactivating agent into the primary water circuit. Deactivate the water treatment system by closing valves: MKF60 AA502 MKF60 AA519 (control valve for water treatment system) (shutoff valve after water treatment system). storage of the resins at approximately 200 C should not exceed three months. Drain water from ion exchanger tank by opening shutoff valves: MKF60 AA503 MKF60 AA510 (vent before ion exchanger). Note: The use of reactivated resins is only permissible in exceptional cases. Tilt tank in its tilting device. Remove upper nozzle tray. It is recommended to procure new resins in due time either directly from the competent representative of the supplier. The resins should be stored so that they are protected form frost and prolonged exposure to temperatures in excess of 30 0 C.3-9782-0500/1 0709 E . (drain after ion exchanger). BHEL. Vertrieb 1-2 D 5090 Leverkusen. In such a case. reliable service period of the water treatment system. taking care that the nozzles in the lower nozzle tray are not damaged. remove exhausted resin mixture form the tank and discard it.

Clean electrodes and remove any residual acid by rinsing in condensate or a similar medium prior to reinstalling transmitter. Even minor traces of acid at transmitter electrodes may result in a significant temporary increase in the primary water conductivity. the insulation resistance should not be less than 1 mega ohm. Q Take corrective actions as described above.3-9782-0500/2 Filling the Water Treatment System Activating the Primary Water Conductivity Meter System .3-7120 [2] 2. It is recommended to measure the insulation resistance (500 V megger) between terminals 1/2 and 2/3 after transmitter cleaning. Any leakage of cooling water into the primary water circuit can only take place when the pressure in the cooling water circuit is higher than in the primary water circuit. Take corrective actions are described above. Remedy Check the conductivity meter system [2]. High conductivity in main circuit and/or High conductivity after ion exchanger Q Ion exchanger resinsd are exhausted and should be replaced. A defective primary water cooler will result in a rise of primary water conductivity before the generator. with minimum effect on the conductivity after the ion exchanger.3-7530 2.Fault/Cause Q Erratic behavior of conductivity meter system. the defective cooler should be identified and taken out of service by service by cooler changeover. With a dry transmitter. Defective primary water cooler. Also refer to the following information [1] 2. Q Erratic behavior of conductivity meter system. When it is obvious from these observations that a cooler is defective. Disturbances which seem to be caused by the transmitter may possible be corrected by the following measures: Remove transmitter form flow vessel and dip in chromosulfuric acid.

Turbogenerators Operation Fault/Cause Low Low Low Low Q flow flow flow flow rate rate rate rate Fault Tracing Volume Flow Rates in Primary Water System Remedy in in in in stator winding phase A bushings phase B bushings phase C bushings Insufficient discharge pressure. clogging or leakage.3-9784-0500/1 0709 E . Prior to reloading the generator. Since the effects of a cooler failure become effective very quickly. with the generator being disconnected from the system and shut down. 2. a further drop in the flow rate causes the signals to act on the generator mechanical equipment protection. Haridwar Insufficient cooling water flow results in insufficient heat removal and mostly in serious damage to the generator. the fault must be removed and/or identified. BHEL.

the insulation resistance should not be less than 1 mega ohm. Apart from the faults/causes covered in this instruction. It should. Clean electrodes and remove any residual acid by rinsing in condensate or a similar medium prior to reinstalling transmitter. Adding make-up water to the primary water circuit too quickly can result in a decrease in conductivity below the limit value. No further action required. Roth. Haridwar Low volumetric flow rate in treatment circuit High conductivity in treatment circuit High conductivity in main circuit Cable breakage in measuring circuit Defect of metering pump 2. If the alkalizer unit has been deactivated due to a fault. see manufacturer's instructions. be always attempted to continue NaOH injection by changing over the metering pump from the automatic to the manual mode. Check the conductivity meter system. Even minor traces of acid at transmitter electrodes may result in a significant temporary increase in primary water conductivity. It is also recommended to measure the insulation resistance (500 V megger) between terminals 1/2 and 2/3 after transmitter cleaning. also faults of the alkalizer unit itself are possible which can lead to a deactivation or failure of the alkalizer unit. Faults which seem to be caused by the transmitter may possibly be corrected by the following measures: Remove transmitter from flow vessel and dip in RBS solution (available from Messrs.3-9785-0500/1 0709 E . Q Make-up water was added too quickly. For details on fault tracing or repair of the alkalizer unit. Q Measuring circuit of conductivity transmitter is faulty. the loss of primary water conditioning will not immediately result in a risk for the generator. Cancel alarm at the alkalizer unit after the addition of make-up water has been completed. Karlsruhe) or chromosulfuric acid. Alkalizer unit has been deactivated because metering pump was stopped The following criteria result in stopping of the metering pump and thus in deactivation of the alkalizer unit: Q — — — — — BHEL.Turbogenerators Operation Fault/Cause Fault Tracing Alkalizer Unit for Primary Water System Remedy Note: All possible alkalizer unit faults are displayed as single alarms on the control panel of the alkalizer unit and normally also as a group alarm in the control room. however. Maintaining the alkalizer unit in operation on occurrence of faults in the general supervisory system of the generator is only permissible with intensive operator supervision ! Low conductivity in treatment circuit Cancel alarm by pressing the acknowledge key on the alkalizer unit as soon as the conductivity has decreased below the limit value after fault removal. With a dry transmitter.

Then start metering pump by pressing the Metering Pump On key twice and reset controller for automatic mode. change over controller to manual mode and lower controller output current to zero. Take corrective actions as described above. NaOH injection can be continued until the fault is removed. if necessary. Alarm provided via CB Trip group alarm. In an alkalizer unit equipped with a model 2 metering pump. Signal transmitters and metering pump have been deactivated due to loss of supply voltage. taking into account also other alarms prevailing at the same time. if necessary. correct controller setting. Fine-wire fuse of metering pump is defective. The controller adjusts the conductivity to the set point level within approximately 10 to 15 minutes. Q Q Q Q Q Controller is disturbed.3-9785-0500/2 Cancel alarm by pressing the acknowledge key as soon as the conductivity has decreased below the limit value after fault removal. the fine-wire fuse is located behind the front panel. To do this. the controller output current rises to the maximum value preset by parameterizing. Automatic circuit breaker F3 has tripped. change over metering pump to the manual mode and adjust stroking rate to get the required conductivity. replace fine-wire fuse at right-hand top of metering pump (mode 1) front panel. Reactivate control circuit. correct controller setting. e. If circuit breaker is tripped again. 2. Start metering pump and reset controller for automatic mode. The controller attempts to restore the conductivity to the proper level. It is therefore advisable to change over the controller to the manual mode and to lower the controller output current to zero. Check and if necessary. The alkalizer unit is de-energized. carefully remove the front panel. identify and correct tripping cause.Fault/Cause Remedy Trace and correct fault. Check and. Since the conductivity does not respond after the metering pump has been stopped. The controller adjusts the output current to the safety set point level. Check and. Alarm provided Via CB Trip group alarm.g. After having shut off the voltage supply. The fault display on the controller front lights up. Prior to restarting the metering pump. Automatic circuit breaker F1 has tripped. Controller and A/D converter have been deactivated due to loss of supply voltage (no flashing light signals). Conductivity has decreased because the pump was stopped. activating the automatic circuit breaker F1 and loosening of the screws. Alarm provided Via CB Trip group alarm. Automatic circuit breaker F2 has tripped. Low conductivity in main circuit Q Measuring circuit of conductivity transmitter is faulty. Re-close automatic circuit breaker F1 in control cabinet of alkalizer unit. Take corrective actions as described above. . Re-close automatic circuit breaker F3 in control cabinet of alkalizer unit. Press reset key and try to reactivate the controller.

Haridwar 2. Re-close automatic circuit breaker F1 in control cabinet of alkalizer unit. the metering pump is stopped. Low volumetric flow rate in treatment circuit Note: The alarm signal also stops the metering pump. A group fault alarm is displayed in the control room. Remaining quantity its only sufficient for about 40 hours. with in turn activates an alarm for low conductivity in treatment circuit after a short time.Fault/Cause Q Turbogenerators Operation Alkalizer unit has been deactivated for several hours. Controller deactivated The lamp is extinguished when the controller is deactivated. change over metering pump to the manual mode at once [3] and adjust stroking rate to get the required conductivity. Low NaOH level in tank Q Sodium hydroxide solution has been largely consumed. Correct fault and switch on supply voltage. High conductivity in treatment circuit and/or High conductivity in main circuit Check valve positions in treatment circuit and readjust volumetric flow rate. If possible. All pilot and status indicating lamps should light up. which in turn adivates an alarm for low conductivity in treatment circuit after a short time. Then renew soda lime filter [1].3-9785-0500/3 0709 E . Loss of supply voltage The supply voltage lamp on the control panel is extinguished. Note: If the conductivity continues to rise. — Press Metering Pump On key twice. a lamp test should be performed first. BHEL. After fault removal. Q Power supply of alkalizer unit has failed. Metering pump stopped The Metering Pump On lamp is extinguished when the pump has been stopped by a planned shutdown or due to a limit-value excursion. Q Automatic circuit breaker F1 has tripped. reactivate alkalizer unit as follows: — Press acknowledge key. press lamp test key. — Press On key for controller. identify and correct tripping cause. Note: The following status indications are signalled by lamps on the alkalizer unit. If one of the lamps fails of light up during NaOH injection. If circuit breaker is tripped again. Q A valve in treatment circuit was throttled or closed due to incorrect operation. Remedy Take corrective actions as described above. The alarm is signalled to the control room and to the generator supervisory control board as a single alarm. Fill NaOH tank with dilute sodium hydroxide solution [1]. Details on possible causes and the corrective actions required are given elsewhere in this manual [2]. To do this.

identify and correct tripping cause.Fault/Cause Q Automatic circuit breaker F3 has tripped. If the circuit breaker is tripped again.Conductivity in Primary Water System.3-9785-0500/4 Maintenance and supervision .3-9782 2. .Alkalizer Unit Fault Tracing . Remedy Re-close automatic circuit breaker F3 in control cabinet of alkalizer unit.4-4785 [2] 2. Also refer to the following information [1] 2.

In such a case. because cool down of turbine is still in progress. detach contact splice strap of the heat sink by unscrewing lock nut. Work on the exciter should be performed with the field ground fault detection system shown and the measuring brushes lifted off the sliprings. To do this. Remove the exciter enclosure and half of the enclosure over the rotating rectifier wheels. the recommended voltage steps being 500 V. the cause of the fault (defective diode) should be located by megger test. While rotating the shaft. disconnect flexible lead from the threephase power lead. If the number of blown fuses per bridge arm and rectifier wheel has reached the maximum admissible value. A controlled DC voltage source of not less than 1000V with constant output voltage must be available for the measurements. the BHEL. To remove defective fuse. A mechanical fault is unlikely. it may be necessary to observe the respective operating limitations [1]. the turbine-generator must be shut down immediately. it si no longer permissible to continue on-load operation of the generator. Rotate entire shaft assembly of turbine-generator until defective fuse is brought to an accessible position. both flexible leads must be disconnected. 750 V and 1000 V. To obtain the blocking characteristic of a diode. If this limit is exceeded.g. visually check all fuses in both wheels. Unlock and unscrew the screw attaching the fuse to the wheel on front side. Connect a micro-ammeter for determination of reverse current in circuit between the voltage source and the diode connection. the diode must be replaced. The number of blown fuses indicates a severe fault in the excitation system. A continuity test of the fuse will indicate whether fuse failed due to an electrical or mechanical fault. In cases where two diodes are mounted in each heat sink. Haridwar 2. Apply DC voltage to diode in reverse direction. increase applied voltage in steps up to a maximum level of 1000 V and determine the reverse current for each step. If fuse failed electrically.Turbogenerators Operation Fault Tracing Fuses on Rectifier Wheels Fault/Cause Remedy Fuse indicator operated Q Failure of one or several diodes.3-9901-0500/1 0709 E . If the shaft assembly cannot be shut down for several hours. Use another connection to tie the rectifier wheel to the voltage potential. The maximum permissible reverse current at 1000 V amounts to 500 µ A. the cause of which must be identified and removed. To do this. the measuring setup described above can probably not implemented. At least three measurements are necessary for plotting the characteristic. e. Note: After operation of one or several fuses.

Prior to re-assembly of the exciter enclosures. Running behaviour of the exciter will not be affected by an exchange of diodes and fuses because of small differences in the weights of replacement parts.1 mm is measured between fuse and wheel.Fault/Cause Remedy shaft should be stopped for brief periods only to enable a replacement of the diode(s) in the respective branch circuit. the generator may again be placed in service. Finally. The defective diode(s) should be cautiously unscrewed from the heat sink using the special diode wrench. If measured by a megger applying a measuring voltage of 500 volts. Use self-locking nuts for attaching the flexible leads to the three-phase power lead. Checking the characteristic data before installing new diodes and fuses will thus not be required. t h e following checks must be made: After cleaning the heat sink. the insulation resistance between isolated heat sink and wheel must be measured using a 500 to 1000 volt megger. should be checked. insulation resistance must not be below 1 M Ω. Af t e r i n s t a l l a t i o n o f the enclosures and reactivation of field ground fault detection system. If a distance of more than 0. i n s u l a t i o n r e s i s t a n c e o f e x c i t e r. Only make sure that each replacement diode is of the same type as the defective diode (observe forward direction). Before installing any replacement diodes. Fuses and diodes are both individually tested at the BHEL factory.3-9901-0500/2 General and Electrical Data . Diodes should be screwed into the heat sink by hand and then torqued to 10 mkg. No replacement of fuses or diodes must take place without checking. Plotting the blocking characteristic and assessing the reusability of the diode(s) can then be done while the unit is running. Be sure that the contact surface (front face) of fuse bears flush against the contact surface of wheel. check clearances between fuse and wheel using a feeler gage. fuse should be re-filing of bore in fuse strap. B e f o r e i n s ta l l i n g n e w d i o d e s a n d f u s e s . i n c l u d i n g r o t o r winding. If several fuses and diodes are to be replaced. Also refer to the following information [1] 2. this procedure should be repeated. the front-side set screw should be locked.1-1810 2. apply a lubricant (Teflon spray) to the threads and coat diode/ heat sink contact surface with a contact agent (silicone paste). Insulation resistance should be more than 10 MΩ Ω. After the fuse has been properly screwed into the wheel and strap of the heat sink.

2. We recommend cleaning the exciter coolers on the air side as weld. higher cooling water flow is required for removal of the loss heat. Q Trapped air has accumulated in cooler.Turbogenerators Operation Fault/Cause High hot air temperature at main exciter and/ or High hot air temperature at rectifier exciter Q The cause is a change in the cooling water conditions. the trapanlins should be removed and the exciter enclosure placed in position over the exciter. Increase cooling water flow. BHEL. Thoroughly clean individual cooler tubes with a tube cleaning brush. Remove the exciter enclosure. Make sure the emergency ventilation flaps are in the emergency ventilation position so that the dirt removed from the fins cannot enter the exciter. Vent cooler by means of vent screws. the generator should be operated at a reduced load. For this purpose. Q Cooler is fouled on water side. Unload and shutdown the generator at the next possible occasion. If this should not lead to the desired result. the coolers should be disassembled and cleaned by hydraulic or chemical means. Use new gaskets for refitting water channels. After careful cleaning. Blow out coolers with clean and dry compressed air. Check to make sure the seals are tight around the exciter enclosure to prevent the exciter from drawing unfiltered air into the enclosure. Haridwar Fault Tracing Exciter Temperatures Remedy With a rise in cold water temperature. If the cold air temperature continues to rise above the permissible level. rectifier wheels and pilot exciter with a tarpanlin. Increase cooling water volumetric flow rate up to the maximum permissible limit. cover main exciter.3-9911-0500/1 0709 E . High cool air temperature Q The cause is an insufficient cooling water flow. isolate the cooling water supply and detach return water channel for cooler cleaning.

use rubber plugs at one end and a hollow plug with a small tube fitting for connection to a water or air line at the opposite end. Drain the water from the cooler. air bubbles will escape from the tube(s). Leakage Test With Air in Water Dry the individual tubes by blowing air through the tubes. a pressure gauge can be installed in the line. Note that isolated air bubbles may rise from accumulations of trapped air in the cooler section BHEL. Identify the defective cooler section. Plug all tubes of the cooler section at one end and place cooler section in a water basin. 1 1 2 3 4 2 3 4 Compressed air hose Hose Hollow Plug Cooler section Fig. a visual examination on the air side must be possible. If the leakage test in performed without pressure gauge. See Fig. which will indicate a pressure drops even for minor leaks after a short time.3-9914-0500/1 0709E . Close cooling water inlet and outlet of this cooler section. Each tube can now be leak tested with air at 0. If the defective cooler tube cannot be identified by a simple visual examination. max. Haridwar 2. During the leakage test.Turbogenerators Operation Fault/Cause Liquid in exciter Q The cause is a leak or a tube rupture at the cooler tube bundle. disassemble the cooler section remove water inlet/outlet and return water channels. Leakage Test of Individual Tubes To perform the leakage test.5 bar. 1 5 6 5 6 7 7 Tube Plug Tube sheet Identifying a Defective Cooler Tube Plug the tube to be tested at both ends and apply a low test pressure via the air or water line. All cooler tubes must be separately subjected to a leakage test. 1. For checking purposes. Fault Tracing Exciter Cooler Remedy Unload and shut down turbine-generator.

Note: If several defective tubes are identified.3-9914-0500/2 .Fault/Cause 1 1 2 3 4 2 3 4 Plug Tube sheet Cooler tube Tube sheet Fig. it must be decided right away whether the heat removal capacity remaining after plugging of the defective tubes is sufficient for emergency operation.2. The cooler section may remain in operation until the next inspection or outage. at which time the cooler section should be replaced. If no leak is detected. Plug the defective tube at both ends as shown in Fig. Remove all plugs from the remaining tubes. filled with water and vented. Then bolt on water inlet/outlet and return water channels and perform a leakage test of the cooler section at the specified test pressure. 2 Plugging a Defective Cooler Tube which have nothing to do with the leak to be identified. the cooler section should be installed. 2.

the cause may be a short on another printed circuit board. replace printed circuit board 3. abt. Plug board 1. 7. Replace printed circuit board identified in this manner.3-9941-0500/1 0709 E . Note: Voltage specified below may vary within a tolerance range of ± 15 %. abt. Printed circuit board 1 defective Supply voltage of 220 V is available at pins 3 and 8. printed circuit board viewed from below 1 2 3 4 5 6 7 8 9 10 11 12 13 Relay d1 must pick up on depressing the On push button. the push button should be pressed again and held in position. replace printed circuit board provided that voltage is available at pins 13 + 11. Measure voltage at pins 11 and 5 with respect to ground (15 V DC). Printed circuit board 2 defective Supply voltage of 220 V is available at pins 1 and 9. Printed circuit board 3 defective Plug board 3. 11 and 12. Haridwar 2. on pressing the On push button (hold push button if relay fails to pick up) the supply voltage is available at pin 2/3 and 8/9 and is not available at pins 6. replace printed circuit board 2.Fault Tracing Stroboscope Type LX5 (220 V) Turbogenerators Operation Fault/Cause Remedy Stroboscope defective Pins 2 and 9 on plug board 2 are interconnected for a supply voltage of 220 V. 23 V DC 15 V DC 5 V AC 6-9 V AC If no voltage is available at pin 7 or with 15 V or 0 V at pin 9. Verify that following voltages are available: Ground/pin Ground/pin Ground/pin Ground/pin 12 6 7 11 abt. BHEL. If the relay drops out again on releasing the push button. If voltage is available. If one of the voltages measured at these pins greatly deviates from the specified value. If no voltage is available. Extract printed circuit boards 2 to 4: voltages at the pins must now reach or exceed the specified value. Plug board 2. 310 V DC 23 V DC 5 V AC 24 V AC Replace printed circuit board if. abt. Switch off stroboscope and insert one printed circuit board after the other until voltage at the respective measuring point collapses. printed circuit board viewed from below 1 2 3 4 5 6 7 8 9 10 11 12 13 Ground/pin Ground/pin Ground/pin Ground/pin 13 7 11 9 abt. printed circuit board viewed from below 1 2 3 4 5 6 7 8 9 10 11 12 13 Check to ensure that supply voltage is available at pins 1 and 9 on plug board 2. abt. If no voltage is available. check cable and fuse. abt. abt.

Replace printed circuit board if above voltages are not obtained. If only one flash tube functions properly. 2.Fault/Cause Remedy Defect on plug board 4 Plug board 4. Replace failed flash tube. 310 V DC Ground/pin 11 abt. Functional check: Interchange the flash tube connectors.3-9941-0500/2 . printed circuit board viewed from below 1 2 3 4 5 6 7 8 9 10 11 12 13 One flash tube failed Verify that the following voltages are available: Ground/pin 12 abt. the cause of the malfunction is the flash tube and not the control unit. 310 V DC Ground/pin 9 voltage should not exceed 280 V but must not be zero.

Following a short cool down period. Haridwar Maintenance and Supervision Exciter Dryer 2. Check 6. i. Open door in exciter enclosure behind which the dryer is located from the operating floor. motor-actuated flap is hot in Open position. In most cause is no or an insufficient air flow. Fault Tracing Exciter Drying System Remedy Set lever for manual operation at flap shaft to Open position and lock lever with locking device. Q Overheat protection has switched off the exciter dryer.e. If yes. Also refer to the following information [1] 2. If no air is drawn in via both intake parts.4-4925 BHEL. The exciter dryer should be de-energized.Turbogenerators Operation Fault/Cause Exciter dryer disturbed Q Limit switch failed to operate. the lever should remain in the Open position. the overheat protection automatically returns the dryer to service. Check flap including actuator for proper mechanical condition. disassembled and returned to the manufacturer's works for repair. Inspect prefilter in door for contamination [1].3A fine-wire fuse of flap motor for continuity. Check whether air is drawn in via the intake parts on both side of the air dryer. the air flow passage is obstructed. the ventilator motor in the dryer has failed. A2 kW heater-blower should be used inside the exciter enclosure for dehumidification as long as the dryer is not available due to repair.3-9955-0500/1 0709 E . After fault removal and loosening of the lever lock.

check system once more for ground faults at rated speed before exciting the generator again. Install carbon brushes and plug-in brush holders strictly in accordance with maintenance instruction [1]. and the generator is disconnected from the system and de-excited. Low-resistance ground fault in exciter circuit (RE < 5 k Ω) At RE < 5 k Ω.3-9980-0500/1 0709 E . If no ground fault can be identified by the insulation resistance measurement. Also refer to the following information [1] 2. Haridwar Maintenance and Supervision or Ground Fault Detection System Insulation Resistance Measurements on Rotor and Exciter Windings 2. the generator must be removed from service. If an insufficient insulation resistance is measured. High-resistance ground fault in exciter circuit (RE < 80 k Ω ) Immediately investigate cause of ground fault alarm. Measure insulation resistance in exciter circuit if the generator can be disconnected from the system and deexcited [2]. Q Exciter voltage response takes longer than 5 s. Fault alarm is automatically extinguished after removal of cause. The manufacturer should be notified and entrusted with the fault removal.Turbogenerators Operation Fault Tracing Ground Fault Detection System in Exciter Field Circuit Fault/Cause Remedy Ground fault detection system disturbed Q Carbon brushes have poor or no contact with measuring sliprings. If the insulation resistance measurement confirms the ground fault.5-3300 BHEL. operation of the generator should be continued only after consultation with the manufacturer to avoid possible major damage.4-4990 [2] 2. a TUSA trip is activated by the electrical generator protection.

in the case of any special conditions being noted in the operating log. Some maintenance work should preferably be performed with the unit at rest. while other maintenance work may be carried out during normal operation. BHEL.4-4200-0500/1 0709 E .g. Haridwar 2. The maintenance work required on the generator described herein is specified in detail in the following.Turbogenerators Maintenance Maintenance and Supervision Introduction The turbogenerator and its auxiliaries require continuous maintenance and supervision to assure reliable operation and serviceability of the complete plant. e. Maintenance and monitoring are required both during operation and when the unit is at standstill.

the generator should be unloaded and de-excited when the pressure has dropped by 0. 3 Hydrogen Pressure in Generator On-load running should always be performed at the specified hydrogen pressure. The temperature between the top and bottom bars of the stator winding are measured with resistance temperature detectors (RTD’s).4 bar (5. To prevent undue stressing of the generator. 5 Primary Water Temperature Continuous recording of the primary water temperature is essential to ensure safe on-load running of the turbine-generator. If the specified hydrogen pressure cannot be maintained for unforeseeable reasons (e. 2. Other small temperature differences may be due to different mounting conditions at the RTD’s. The BHEL. If there exists the danger of overheating. Therefore. it is desirable to maintain a constant temperature in the generator by control of the cooling water flow. since it results in minimum thermal stresses in the generator interior. 4 Primary Water Flow Rates An insufficient primary water flow results in insufficient cooling of the water-cooled components. If a temperature deviation is observed the cause must be determined immediately and the original temperature restored. The setting of the cooling water flow should be made by changing the adjustment of the cooling water outlet valves. venting etc.Turbogenerators Maintenance and Supervision of Stator Maintenance Check grounding brushes Monitoring the Temperature of Components It is important that all temperatures remain within the specified upper and lower limits. high gas losses). The RTD’s installed after the coolers indicate the temperature of the gas used for generator cooling.). while the cooling water outlet temperature should be measured separately for each cooler section in the cooling water outlet pipe after each cooler section. The RTD’s are embedded in the winding and distributed uniformly over the three phases. a check should be performed to determine if the slot RTD’s are correctly calibrated and/or compensated. compensating resistors and tolerances caused by differences in the contact at the measuring point selector switch. the flow rate must not fall below the lower limit value. The cooling water supply to the individual cooler sections should be adjusted so that the gas outlet temperatures at all cooler sections are approximately identical. This is particularly important for a disturbed cooler performance (fouling. In addition to the gas temperatures. The cooling water inlet temperature of all cooler sections should be measured in the cooling water inlet pipes.g. Differences in the temperature indication upto 5°C m a y b e d u e t o t o l e r a n c e s i n t h e s l o t RT D ’s. a corresponding load reduction should be made.7 psig). The RT D ’s i n t h e s t a t o r w i n d i n g s h o u l d t r a n s m i t approximately identical values for identical currents in all three phases. Many faults can thus be recognised and remedied at an early stage. the cooling water temperature is also measured. lack of gas. 2 Monitoring the Cooling Gas and Cooling Water Temperatures The temperature of the cooling gas in the generator is measured with one RTD before and after each cooler section. If different temperatures are indicated with identical currents in the three phases.4-4210-0500/1 0709 E . Haridwar Annualy Every 6 Months Monthly × Check sight glasses after level detectors for liquid level 1 Weekly Daily Work required Every 3 Months Maintenance Intervals × cooling water inlet valves at the individual cooler sections should be fully opened.

7 Liquid Leakage Detection at Level Detectors Liquid entering the generator housing is sensed by level detectors.4-4210-0500/2 2. During operation. To avoid any risk in cooling of the stator winding. The d i ff e r e n c e b e t w e e n t h e p r i m a r y w a t e r i n l e t temperature and the cold gas temperature is measured directly and monitored continuously. Also refer to the following information [1] 2. the useful length of each individual carbon brush can be determined by a visual inspection. Note: Ensure to insert the grounding brushes so that the brush with carbon layer is followed by a brush with silver layer when looking in the direction of rotation of the rotor shaft. Major changes with rising tendency may be indicative of a disturbance in uniform cooling in individual branch circuits. For limits of wear. Sight glasses.Note: The temperature of the cold primary water should be higher than the H 2 cold gas temperature by not less than 5°K (9°F) under all conditions of operation in order to positively avoid the formation of moisture condensate on the components carrying primary water. When no differential temperature exists any longer or when the primary water inlet temperature is even lower than cold gas temperature. the generator must be unloaded and de-excited at once. permit any leakage to be readily detected before the liquid level will have risen up to the level detectors. An a l a r m i s a c t i v a t e d w h e n t h i s d i ff e r e n t i a l temperature drops below the predetermined value. 8 Grounding Brushes The carbon brushes should be checked at regular intervals. see Description [1]. located before and after the level detectors.1-1820 Mechanical data . The carbon brushes should be replaced with new ones having contact faces which match the rotor shaft contour. 6 Primary Water Pressure Before Stator Winding The pressure of the primary water before entering the stator winding can be taken as a reliable criteria for a safe cooling water supply to the various branch circuits. A small change in pressure up to a maximum of 10% has no influence on cooling of the stator winding. it is recommended to contact manufacturer’s product service department and to ask for removal of the cause.

the cooling water flow through all cooler sections. 2 Cooler Section (disassembled) Weekly Daily Work required Every 3 Months Maintenance Intervals Coolers During normal operation.4-4240-0500/1 0709 E . etc. there exists the danger that microorganisms on the tube walls may die and decay due to a loss of fresh water supply (lack of oxygen). Special measures should be taken to prevent corrosion damage to the cooler [1]. the coolers should be frequently cleaned with brushes. the condition may arise that the coolers are supplied with smaller cooling water flows for long periods. this may result in deposits due to the lower water velocity in the cooler. it is recommended to install a continuous cooler water purification system. such measures are often unfeasible. In addition.Turbogenerators Maintenance Maintenance and Supervision of Generator Coolers Check cooler vents 1 General Annualy Every 6 Months Monthly × the measures outlined below should be taken.3-5003 Hints for cooler operation 2. cleaned. For heavy cooler contamination and if operational restrictions and shutdowns are undesirable. it is therefore recommended to rinse the coolers with the full water flow during short outages. In such cases. In addition to many other corrosive influences. locally differing deposits. Ammonia is formed from such decay which may lead to stress corrosion cracking. Cooler sections having no cooling water flows for some time may be subject to standstill corrosion. To prevent cooler damage. Purification Brush Also refer to the following information [1] BHEL. completely dried and maintained in a dry condition. such as the different elements of the cooling water. Depending on the purity of the cooling water. particularly in cases of short outages. Since the coolers are designed for 100 % capacity at maximum cooling water temperature. 1 Fig.. With the generator in commercial operation. Corrosion damage can only be properly prevented if the cooler is drained on the water side. Haridwar 2. raw materials. 2 Fig.

The oil pressure should be recorded in the operating log. For the purpose. no service or maintenance work is required on the bearings of the generator. and oil pressures should be continuously monitored. the components coming into contact with the shaft are separated from the shaft by an oil film. bearing vibrations. or defective pressure limiting and check valves. At higher speeds. Consequently. With the generator running.5-0300 Checking the Bearing and Seal Insulation 2. Also refer to the following information [1] 2. following brief shutdown. The generator bearings require particular attention during each new startup.4-4250-0500/1 0709 E . oil temperatures. Haridwar spective bearings should be checked. the lift oil pressure will settle at 40 to 80 bar.12 % of the bearing diameter). Careful monitoring will also be necessary within the first few minutes after runup until the normal operating values are restored. To prevent any damage to the bearings the shaft lift oil system must be in operation at speeds as specified in the turbine instruction manual. The temperature of the lubricating oil supplied to the bearings is controlled by the cooling water flow to the bearing oil cooler. however. the unit should be shut down immediately. the potential of the insulated shaft seals and bearings is accessible external to the generator. bearing temperatures. a non-defined resistance value is set up at the potential measuring points of the shaft seals and bearing sleeves which is dictated by the magnitude of the resistances of the oil film and insulating parts. If a lower oil pressure is observed the re- Monthly Daily Work required Weekly Maintenance interval X 1 Fig. The lift oil pressure for the shaft journals should be adjusted so that the shaft is lifted by not more than 50 % of the bearing top clearance (top clearance amounts to 0. Such pressure reduction may be indicative of damage in the area of contact surface. the bearing babbitt.Turbogenerators Maintenance Maintenance and Supervision of Bearings Check EE ground bearing insulation Annualy Every 6 Months Every 3 Months X Check EE shaft seal insulation X Check exciter bearing insulation General During normal operation. 1 Generator Bearing and Seal Insulation BHEL. which has insulating properties. 2 Checking the Shaft Seal and Bearing Insulation Checking the shaft seal and bearing insulation during operation [1] may be done by way of the shaft voltage prevailing with the generator running in an excited condition. If the operating values prevailing after a restart exceed the permissible limit values. leaking supply pipes. The temperature of the generator sleeve bearings are displayed in the control room.

5 – 3300 Insulation Resistance Measurement on Rotor and Exciter Windings BHEL. Should a change in vibration characteristics be noted. it is recommended to have the manufacturer’s product Annualy Every 6 Months Monthly Weekly Daily Work required Every 3 Months Maintenance Intervals × service personnel determine the cause and assist in correcting any problems. Haridwar 2.Turbogenerators Maintenance Maintenance and Supervision of Rotor Measure insulation resistance 1 Monitoring Rotor Vibrations The vibrations of the generator rotor should be monitored and any change should be carefully observed.4-4310-0500/1 0709 E . Also refer to the following information [1] 2. 2 Measuring Insulation Resistance The insulation resistance of the rotor winding towards ground should be measured once a year [1].

unless this has already been accomplished through the oil supplied to the oil inlet of the pump. Venting Screw/oil filling plug Discharge flange Pressure relief valve Drive shaft Fig. 1 Seal Oil Pump 1 2 Regreasing device Drive motor Fig. Repack regreasing devices with grease every six months. start standby pump by 1 2 3 4 Annualy Every 6 Months Monthly Weekly Daily Work required Every 3 Months Maintenance Intervals × manual control. start standby pump by manual control. 2 Bearing Vapour Exhausters The bearing vapor exhausters are provided with a regreasing device for the axial shaft seal. the oil ensures proper sealing of the shafts for pump priming. Check to ensure that the indications showing that the standby seal oil pump is in operation are displayed during the short running period. The exhausters should be changed over once per month. Check pump delivery pressure and then change over to normal-service pump. follow the same procedure as for the seal oil pumps. To do this. Perform functional check of standby seal oil pump 3 once per month. Perform changeover to standby pump once per month. this pump will then be automatically stopped again after elapse of a present time delay. Change over seal oil pumps 1 and 2 at monthly intervals. After a short running period. Haridwar 2.Turbogenerators Maintenance Maintenance and Supervision Seal Oil Pumps and Bearing Vapor Exhausters Change over seal oil pumps 1 and 2 × Perform functional check of standby seal oil pump × Change over bearing vapor exhausters × Repack regreasing devices of bearing vapor exhauster shaft seals with grease 1 Seal Oil Pumps To prevent dry running of the pump and to ensure proper lubrication of the shaft seal. 2 Bearing Vapour Exhauster BHEL. each new or overhauled seal oil pump should be filled with turbine oil via the oil filling plug. Then stop pump so far in service by manual control. In addition. To do this. To do this.4-4520-0500/1 0709 E .

During cleaning. since dry dirt deposits are more difficult to remove. After completion of cleaning and refitting of the upper water channel. while it should be empty. The use of Perlon brushes ensures both a careful treatment of the tube wall and good cleaning results. which actuates both valves simultaneously. Cooler Changeover When changing over the coolers. 2. The three-way valves should be changed over by turning the common handwheel. The seal oil cooler removed from service should be cleaned with tube brushes. To ensure thorough tube cleaning. Deposits which cannot be removed by mechanical means may require chemical cleaning.Turbogenerators Maintenance Maintenance and Supervision Seal Oil Coolers Check service cooler for proper venting × Check seal oil supply lines and shutoff valves for leakages × 1 General One of the two seal oil coolers in the air side and hydrogen side seal oil circuits will be in service. it is recommended to have this cleaning work performed by a suitably qualified contractor. 3. The changeover procedure does not result in an interruption of the oil flow. The cooling water vent and the drain valve should be kept open to maintain the cooler in a dry condition. When making a changeover on the oil side. the standby cooler must first be filled on its water side. The right-hand seal oil cooler is placed into service on its oil side by turning the handwheel counter-clockwise upto the stop. If there is insufficient experience and equipment available. Serving as standby unit. the second cooler is filled on its oil side. the cooler should briefly be flushed with the full water flow for the complete removal of any residual dirt deposits. clean and dry on its cooling water side in order to preclude standstill corrosion on the cooling water side.4-4540-0500/1 0709 E . the cooler can be kept filled on its oil side. Cooler Cleaning In-service cleaning of the standby seal oil cooler on its cooling water side is possible after disassembly of the upper return water channel. If the handwheel is turned clockwise. take BHEL. The cooling water volume flow for the cooler taken into service should be adjusted at the outlet valve so that the specified oil outlet temperatures obtained. Haridwar Annualy Every 6 Months Every 3 Months Weekly Daily Work required Monthly Maintenance Intervals care that the three-way valve for cooling water inlet is actuated simultaneously. 2. the tube interior should be wet. with care being taken to ensure that the cooler is properly vented on both the water and oil sides. the left-hand cooler is taken into operation.

BHEL. Clean the filters during each inspection.Turbogenerators Maintenance Maintenance and Supervision Seal Oil Filters Check degree of contamination of seal oil filters The degree of contamination of the seal oil filter can be directly seen at the differential pressure indicator. corresponding to an increase in the pressure drop across the seal oil filter. Prior to reassembly. The screen filter should be removed and cleaned thoroughly.4-4550-0500/1 0709 E . Haridwar 2. Open filler valve and vent the filter. the standby filter should be placed in service and the contaminated filter removed from service by means of the Annualy Every 6 Months Every 3 Months Weekly Daily Work required Monthly Maintenance Intervals × change-over valve assembly. an alarm signal is activated. a higher differential pressure is indicated. Drain the seal oil from the filter housing via the drain plug and remove the filter cover. Check filter valve for closed position. The filter housing should be filled with turbine oil and the filter reassembled. When the alarm signal has been activated. At a preset value. As the contamination of the filter increases. the filter should be flushed with turbine oil to remove any solvent residue.

the loss of H 2 gas must be monitored continuously on the basis of H 2 consumption. In the event of the gas leakage losses exceeding 12m3 (s. 2 Weekly Daily Work required Every 3 Months Maintenance Intervals Gas quantities escaping uncontrolled are those lost through leaks in the generator and gas system.t. The total gas consumption consists of the hydrogen quantities escaping both controlled and uncontrolled. Part 3). The gas quantity escaping under control is composed of the hydrogen flowing out continuously via the purity meter system for measuring the gas purity in the generator.Turbogenerators Maintenance Maintenance and Supervision Gas Consumption Check gas consumption 1 Annualy Every 6 Months Monthly × Check shutoff valves for free movement × Check gas supply lines and shutoff valves for leaks × General Caution: The CO2 bottle rack should be equipped with full bottles so that a sufficient quantity of carbon dioxide will be available for any required displacement of the hydrogen. In case such measures are not successful.p.6d in VDE 0530. and the gas removed from the generator through the seal oil and discharged into the vent gas line. the unit should be shut down and the hydrogen removed from the generator (see section 4. Gas Consumption During operation. Note that with a leakage gas lighter than air the leak detection should be carried out above the object and with gases heavier than air underneath of the test object. the location of the leak must be determined [1]. Haridwar 2. it should not amount to more than 12m 3 (s.4-4610-0500/1 0709 E . only the open H 2 bottles would be emptied at a faster rate.p. Fig. In addition an alarm is activate to alert the operator in due time.) during 24 hours. only the hydrogen bottles in service should be connected to the hydrogen bottle rack. Since this leakage gas may present a danger to the environment. to improve the operating reliability. Part 3.t.5-0310 Leakage Tests BHEL.6e in VDE 0530.1 Handling the Handy-Tector The sniffer probe of the Handy-Tector should be led over the surface of the test object as slowly as possible. 2. It is recommended that. According to section 4.) during 24 hours. The connection of new gas bottles should be entered in the operating logs. leak tests should be performed and the gas losses reduced below this limit. On occurrence of a leak and the resulting higher gas consumption. even on reduction of the gas pressure in connection with a corresponding load reduction. while the other connections should be isolated by means of the shutoff valves at the H2 bottle rack manifold. If an undue loss of gas occurs on the unit. 1 Handy-Tector Also refer to the following information [1] 2. A sufficient number of full hydrogen bottles should be kept in stock at all times taking into consideration the gas consumption rate of the unit and the availability of new hydrogen. not more than two H 2 bottles should be connected and open during normal operation.

Haridwar Annualy Every 6 Months Monthly Weekly Daily Work required Every 3 Months Maintenance Intervals × 2 Checking Readiness for Starting To ensure that the standby pump is ready for operation on a continuous basis. start and immediately stop this pump once a week. The oil should be changed after about 3000 operating hours (at least once a year). 2. BHEL. The exact oil level in the pump in service cannot be determined at the oil sight glass due to oil foaming.4-4720-0500/1 0709 E . The oil level in the pump in service should be visible in the middle of the oil sight glass.Turbogenerators Maintenance Maintenance and Supervision Primary Water Pumps Check oil level in bearing housings of primary water pumps × Check that standby primary water pump is ready for operation × Change over primary water pumps 1 Checking Oil Levels in Pump Bearing Housings The shafts of the primary water pumps are supported in oil-lubricated bearings. Check oil levels in bearings at regular intervals. 3 Changing Over Pumps The primary water pumps should be changed over at regular intervals (at least once a month) so that they will be alternately in service.

main filter 1).Turbogenerators Maintenance Maintenance and Supervision Primary Water Filters Check service cooler for proper venting × Check seal oil supply lines and shutoff valves for leakages × 1 General The degree of contamination of the primary water filters can be seen at the differential pressure indicator.4-4740-0500/1 0709 E .3-9740 BHEL. Insert new filter element and close filter. Open shutoff valves : Annualy Every 6 Months Monthly Weekly Daily Work required Every 3 Months Maintenance Intervals MKF52AA581 (drain. close shutoff valve MKF52AA591 (drain. place main filter 2 in operation and take main filter out of service. care should be exercised because of resulting degassing of water. Haridwar Primary Water System Filters in Primary Water System 2. Hold filter insert at handle and turn clockwise until filter insert is firmly locked in filter housing. 3 Fine Filter The fine filter can also be taken out of service during normal operation for replacement of the contaminated one-way filter element. Close shutoff valve : MKF52AA592 (vent. main filter 2) Open shutoff valves : MKF52AA590 MKF52AA593 (before main filter 2) (after main filter 2). Hold filter insert at handle and turn counterclockwise. The procedure for any required filter element replacement of the fine filter is as follows : Take fine filter out of service [2]. To do this. Remove contaminated filter element. main filter 1) MKF52AA582 (vent. Should it nevertheless become necessary to clean the main filter during service. Main filter 2 is now in service. Fine filter can be taken into service [2]. Fit and tighten one hex nut until the support plate rests on the upper seating ring. Withdraw contaminated filter element. Also refer to the following information [1] 2. During each inspection of the unit. Close shutoff valves : MKF52AA580 MKF52AA583 (before main filter 1) (after main filter 1). Uniform contact pressure must be obtained by tightening nuts alternately at opposite points. When draining he filter. operation of the primary water system can be continued either with main filter 2 or with cleaned main filter 1. the main filters should be cleaned and the filter element of the fine filter replaced. main filter 2) as soon as water emerges without bubbles. Warning : Primary water contains dissolved hydrogen. Main filter 1 can now be cleaned [1]. Refit vent pipe to filter cover so that a tight connection is obtained. clean filter sealing faces and seating rings and check O-rings for damage. alarms are activated in addition to signal filter contamination. At predetermined differential pressures. Cleaning during operation will therefore normally be not required. Install filter element and replace bottom seating ring. 2 Main Filter The main filter is only insignificantly contaminated even after a service period of several years due to the purity of the primary water and the cleanliness of the entire primary water system. Prior to installing a new filter element. Discard primary water drained from main filter 1. Fit and firmly tighten (lock) second hex nut.5-7300 [2] 2. Remove vent pipe and hex nuts from filter cover and lift off cover. After filter cleaning. loosen hex nuts and remove bottom seating ring. After removal of filter insert from filter housing. Reposition and bolt down filter cover.

drained. To p r e v e n t c o o l e r d a m a g e . t h e c o o l e r s s h o u l d b e frequently cleaned with brushes. cleaned and dried. 2.4-4750-0500/1 0709 E . particularly in cases of short outages. due to the cooling water conditions and the heat loss to be dissipated. the condition may arise that the coolers are frequently supplied with small cooling water volume flows for long periods. All continuous vents should be checked for proper functioning. filled on its primary water side. the cooling water flows through two cooler sections. When making a cooler changeover take care that the primary water flow through the coolers is not interrupted. Ammonia is formed from such decay which may lead to stress corrosion cracking.Turbogenerators Maintenance Maintenance and Supervision of Primary Water Coolers Check primary water cooler vents 1 Maintenance of Coolers on Primary Water Side With normal cooling water conditions and the generator carrying rated load. it can be taken out of service on its cooling water side. such as the different elements of the cooling water. this may result in deposits due to the lower water velocity in the cooler. i t i s t h e r e f o r e recommended to rinse the coolers alternately with the full cooling water volume flow during short o u ta g e s .. completely dried and maintained in a dry condition. 2 Maintenance of coolers on Cooling Water Side The standby cooler. i. it is recommended to install a continuous cooler water purification system. the measures outlined below should be taken: During normal operation. With the generator in commercial operation. Cooler sections having no cooling water flows for some time may be subject to BHEL. I n a d d i t i o n . locally differing deposits. cleaned. The standby third cooler should be filled on its primary water side. In such cases. should be empty. In addition to many other corrosive influences.. Since the coolers are designed for 100 % capacity at maximum cooling water temperature. etc. Depending on the purity of the cooling water.e. In this way. deterioration of the conductivity of the primary water volume in the cooler can be avoided. such measures are often unfeasible. Haridwar Annualy Every 6 Months Every 3 Months Weekly Daily Work required Monthly Maintenance Intervals x standstill corrosion. A small amount of primary water continues to flow through the standby cooler via the parallel-connected drain and vent valves. Corrosion damage can only be properly prevented if the cooler is drained on the water side. For heavy cooler contamination and if operational restrictions and shutdowns are undesirable. two of the three primary water coolers will be in operation. Note: If the second primary water cooler is not required for a longer period of time. there exists the danger that micro organisms on the tube walls may die and decay due to a loss of fresh water supply (lack of oxygen). Sp e c i a l m e a s u r e s s h o u l d b e t a k e n t o p r e v e n t corrosion damage to the coolers. The vent and drain valves on the secondary side should be kept open to maintain the cooler in satisfactorily dry condition. raw materials. clean and dry on its cooling water side in order to preclude standstill corrosion.

A sufficient water level in the primary water tank is the prerequisite for reliable primary water circulation.Turbogenerators Maintenance The Primary water tank is mounted on the stator frame and serves as an expansion tank during operation. Check volume flow at volume meter MKF60 CF502. If it is necessary to add make-up water to the primary water system during operation. (in make-up line) as soon as the water level in the primary water tank has reached its nominal value. the flow velocity should not be higher than during normal operation of the water treatment system. purge the primary water tank with nitrogen [1].4-4760-0500/1 0709 E .3-6810 BHEL. MKF60 AA502 (before ion exchanger) Maintenance and Supervision of Water Level in Primary Water Tank Note: During make-up operation. The water level in the primary water tank is displayed on a local water level gauge. Reopen shutoff valve MKF60 AA502 (before ion exchanger). Haridwar N 2 Purging After Filling of Primary Water system 2. Any loss of primary water in the total circuit can be compensated for by introducing make-up water upstream of the ion exchanger. Added water volume is totally on volume flow meter MKF60 CF501. During make-up operation. a maximum of 100 dm (26 US gallons) of water may be added to the primary water circuit. making sure that no primary water enters the vent gas system. During this procedure. Nitrogen purging must also be performed if the cumulative amount of added water exceeds 100dm 3 within the past month. The quantity of makeup water is totally at a water meter and is indicative of the leak tightness of the primary water system. One capacitive level monitoring system is provided to activate a low water level alarm. close control valve. However. the water level in the primary water tank should be observed carefully. 3 and then open shutoff valve Addition of water is stopped by closing shutoff valve MKF60 AA504 (in make-up line) MKF60 AA504 to admit water into the primary water system via the ion exchanger. Also refer to the following information [1] 2. if this amount of make-up water is insufficient.

With the ion exchanger out of operation. With switch in this position.1 Replacing Ion Exchanger Resins A replacement of the ion exchanger resins is required when the conductivity downstream of the ion exchanger is higher than in main circuit or rises to a value 0. The main circuit may be left in operation during resin replacement. With switch in this position.4-4780-0500/1 0709 E .5 µmho/ cm.5mmho/cm has been reached in the main circuit. a zero indication is given at conductivity indicator. Turn associated test selector switch to test value 1. this value will be obtained after a few days only. Turn associated test selector switch to zero position Xk=0 µmho/cm. The various operations for resin replacement should be accomplished so that the work will be completed before a conductivity of 1. For details on the replacement of the ion exchanger resins. Turn test selector switch to operation position X k = µ mho/cm. instrument should indicate a value of 1.5mmho/cm. conductivity indicator indicates current conductivity of primary Annualy Every 6 Months Monthly × × Check conductivity meter system by means of test selector switch 1 Weekly Daily Work required Every 3 Months Maintenance Intervals water. Also refer to the following information [1] 2. 2.Turbogenerators Maintenance Maintenance and Supervision Conductivity Meter System Record conductivity after ion exchanger and in main circuit Conductivity Meter System Maintenance work to the conductivity meter system is restricted to monthly checking of the transducer by means of the test selector switch. see under Fault Tracing [1].3-9782 Conductivity Meter System BHEL. Ion Exchanger 2. The check can be performed while the units is in operation. With switch in this position. Haridwar 2.5 µmho/cm .

and a corresponding alarm will be activated in the control cabinet of the alkalizer unit. Replace the lime filter in the NaOH tank vent each time the NaOH tank is refilled. Cancel the alarm by depressing the Acknowledge button as soon as conductivity of the treated water has been restored to its nominal value. observe this procedure: Hold glass vessel and loosen wing bolt until clamping fixture can be moved. refilling the tank with sodium hydroxide will be required at intervals of about two months. With the given capacity of the NaOH tank. make sure to observe the applicable safety regulations.Turbogenerators Maintenance Maintenance and Supervision Alkalizer Unit Check level in NaOH tank × Analyze water sample taken from treatment circuit × Level in NaOH Tank Check and record level in NaOH tank during daily inspection of turbogenerator.1 Adding Sodium Hydroxide Solution When preparing the sodium hydroxide solution and filling the NaOH tank of the alkaline unit.4-4785-0500/1 0709 E . About 2dm 3 of dilute sodium hydroxide is injected into the primary water circuit each day. Fill NaOH tank with dilute sodium hydroxide solution after a low level alarm has been given at the latest. Set controller in control cabinet of alkaline unit for BHEL. Stir solution for proper mixing. 1. To do this. Caution: When handling sodium hydroxide (caustic soda). make sure to avoid the formation of carbonates as far as practicable by reducing the time of free exposure to the atmosphere to the absolute minimum. To do this. Reclose NaOH tank so that it is tightly sealed and secure against opening. Note: Due to temporary deactivation of the alkalizer unit.1 mmho/cm. observe the following procedure: Prepare concentrated sodium hydroxide solution in laboratory (observing the specification [1]). Haridwar Annualy Every 6 Months Monthly × Analyze water sample taken from primary water circuit The controller in the alkalizer unit maintains the conductivity of the treated primary water at a constant value. Reset controller for automatic control. 1 Weekly Daily Work required Every 3 Months Maintenance Intervals manual control and then lower manipulated variable (controller output current) to zero. Alkalizer unit monitoring requires regular checking of the volumetric flow rate and level in the NaOH tank and water sampling. the conductivity of the treated water will drop to < 0. dissolve the necessary quantity of sodium hydroxide (caustic soda) in approximately 8-10dm 3 of water [2] to obtain the specified concentration of 10 to 20g of NaOH per dm3. Position clamping fixture with wing bolt beneath 2. Open NaOH tank and add concentrated sodium hydroxide solution. Fill NaOH tank with water [2] to the required level. To prepare the sodium hydroxide solution and to fill the NaOH tank.

The anions are normally absorbed by the anion exchanger resins in the mixed-bed filters and can have a permanently detrimental effect on the alkalization process only when the ion exchanger is exhausted.0 µmho/cm 8. Parameters Normal Conductivity pH Na+ ion concentration Cu concentration Fe concentration 1. Fill glass vessel to about 80-90% with soda lime complying with the applicable specification [1]. 300 ppb 10 ppb 10 ppb Normal and Limit Values of Primary Water Chemistry Also refer to the following information [1] 2. 2 Water Analysis We recommended chemical analysis of the primary water in the main circuit and treatment circuit (sampling downstream of fine filter) at monthly intervals. SO 4. CO3. the conductivity at 25 oC should be ≤ 0.8-2. such as HCO 3-.1 µmho/cm. When correct water treatment.4-4785-0500/2 . Keeping the sample excluded from the atmosphere at a constant temperature of 25 oC.and Cl . indicate abnormalities and the cause must be investigated.1-1885 Primary Water Specification [3] 2.can be admitted with the makeup water air or H2 leakage filter elements or ion exchanger resins not complying with the specifications [3]. the following parameters should be determined: Conductivity pH Na+ ion concentration Cu concentration (total) Fe concentration (total) Table 1 shows the normal and limit values to be expected.0 µmho/cm 2.1-1887 Specification for Ion Exchange Resins 2. The measurement should be performed with the sample excluded from the atmosphere to prevent a falsification of the reading by the carbon dioxide contained in the ambient air.. The conductivity provides information on the presence of other unwanted anions in addition to the OH ions that determine the alkalinity. Clean sealing faces and slowly press glass vessel against gasket from below by moving it to and fro.-. the conductivity of the water should be measured downstream of a highly acidic cation exchanger (H + form).5-9 Table1 25 to 250 ppb <5 ppb <5 ppb Limit Operation at the limits given in Table1 involves no imminent risk for the generator: these limits. however.the glass vessel and carefully tighten wing bolt. Slowly lower glass vessel to a point below the immersion tube. If the results of the water analysis do not provide conclusive proof of correct water treatment.1-1888 Additive Specification for Alkalizer Unit [2] 2. Unwanted anions.

A check is required at once following abnormal operating conditions. it is necessary to know in which arm of the bridge each blown fuse belongs. By pressing the feed or return pushbutton. In normal operation. Haridwar General and Electrical Data Excitation System 2.4-4910-0500/1 0709 E .5-1810 [2] 2. the fuse has blown. Also refer to the following information [1] 2. normal running routine may be continued. press the On push-button. shortcircuit on the system close to the power plant.5-9000 BHEL.Turbogenerators Maintenance Maintenance and Supervision Fuses on Rectifier Wheels Check Fuses × × Measure insulation resistance 1 Annualy Every 6 Months Monthly Weekly Daily Work required Every 3 Months Maintenance Intervals Fuse Monitoring With the aid of the stroboscope whose light frequency is automatically controlled. e. 2 Measuring the Insulation Resistances Check the insulation resistances of the windings to ground and the insulation resistances between the diode heat sinks and the rectifier wheel [2].g. To activate the stroboscope. The position of the fuse indicator shows whether a fuse is intact or blown due to diode failure. The operating limitations [1] must be observed if several fuses have blown. asynchronous running. If the exciter is operated with defective fuses. the flashes can be timed so that a continuous slow-motion observation of each fuse is possible. the fuses should be monitored at least once each day. It is then possible to select either flash tube 1 or flash tube 2 by pressing the corresponding push-button Lamp1 or Lamp2 to observe each successive fuse on the rectifier wheel. etc. To determine the condition of the entire rectifier wheel. The bridge arm can be determined from the color marking above the fuse on the edge of the rectifier wheel. monitoring should be done on an hourly basis. If the color-coded fuse indicator has taken a radial position. If no additional fuses have blown after two further shifts. it is possible to observe each separate fuse on both wheels.

With proper and regular maintenance of the prefilter. The prefilter is installed in the door behind which the exciter dryer is located. Remove filter frame with dust filter. This door is an integral part of the exciter enclosure.4-4925-0500/1 0709 E . if necessary. After replacement of both dust filters. Open the door containing the prefilter. A slightly contaminated coarse filter can be cleaned by beating or blown out with compressed air from the air-leaving side. Refit connection branch and turn it clockwise before tightening the screws. De-energize the exciter dryer. For reassembly of the filter. replace prefilter 2 1 2. The prefilter consists of a coarse (Acelan) filter and a fine (Microsorlit-F) filter. In case of more severe contamination. The fine filter can be reused if in proper condition. The coarse filter is located upstream of the fine filter. Loosen screws at connection branch by about three turns Turn connection branch counterclockwise for removal.1 Replacing the Prefilter To inspect or replace the prefilter. replace dust filter in Exciter dryer Prefilter Monthly Daily Work required Weekly Maintenance Intervals Dust Filters One dust filter each is provided behind the intake branches on both sides of the exciter dryer. replace dust filter. if necessary.1 Replacing the Dust Filters 1. and remove dryer. Disconnect electrical and mechanical connections.Turbogenerators Maintenance Maintenance and Supervision Exciter Dryer Inspect and. If necessary. dust filters will be required only once per year. Close door and energize exciter dryer. It is recommended to inspect the prefilter at shorter intervals during the commissioning phase because of the high dust content of the air and the relatively long period of exciter dryer operation. Every 3 Months × Inspect and. Loosen wing nuts and then remove filter frame and the two filter pads. both filter pads should be replaced. Haridwar Annualy Every 6 Months × Note : The life of the prefilter depends on the dust concentration in the power house and on the service hours of the exciter dryer. The exciter dryer is ready for further operation. follow the same procedure in reverse order. Blow out dust filter with compressed air from the air-leaving side or wash dust filter. 2. open the door accommodating the prefilter. making sure that the filter frame joint is in the bottom center position. properly restore all connections. BHEL. if necessary. Reinsert filter frame with clean dust filter into the dryer.

4-4930-0500/1 0709 E . if necessary. Depending on the operating conditions. the ball bearing of the ventilator and the generator should be filled with new grease every two to three years. They should be checked at regular intervals and replaced.Turbogenerators Maintenance Maintenance and Supervision Ventillation and Make-Up Air Filter of Exciter Check make-up air filters in exciter enclosure × Perform functional check of exciter drying system and clean filters. Haridwar Annualy Every 6 Months Every 3 Months Monthly Daily Work required Weekly Maintenance Intervals 2 Exciter Drying System Slightly contaminated filter pads should be blown out with clean compressed air from the clean air side or washed in a water bath at a water temperature of approximately 30oC. × 1 Make-up Air Filters in Exciter Enclosure The make-up air filters in the exciter enclosure are contaminated by the continuous addition of the air in the exciter cooling circuit. BHEL. 2 . adding a neutral detergent. if required.

In addition. such measures are often unfeasible. Cooler sections having no cooling water flows for some time may be subject to standstill corrosion. In addition to many other corrosive influence. such as the different elements of the cooling water. For heavy cooler contamination and if operational restrictions and shutdowns are undesirable. Corrosion damage can only be properly prevented if the cooler is drained on the water side. Depending on the purity of the cooling water. the coolers should be frequently cleaned with brushes. it is therefore recommended to rinse the coolers with the full water flow during short outages. locally differing deposits. In such cases. this may result in deposits due to the lower water velocity in the cooler. Haridwar 2 . With the generator in commercial operation. the condition may arise that the coolers are supplied with smaller cooling water flows for long periods.4-4940-0500/1 0709 E . Ammonia is formed from such decay which may lead to stress corrosion cracking. special measures should be taken. the cooling water flows through the cooler sections. it is recommended to install a continuous cooler water purification system.Turbogenerators Maintenance Maintenance and Supervision of Exciter Coolers Check exciter cooler vents 1 General Special measures should be taken to prevent corrosion damage to the cooler[1]. raw materials. Since the coolers are designed for 100% capacity at maximum cooling water temperature. etc. Also refer to the following information [1] 2. To prevent cooler damage. Annualy Every 6 Months Every 3 Months Weekly Daily Work required Monthly Maintenance Intervals × 2 Exciter Coolers During normal operation. particularly in cases of short outages.3-5003 Hints for Cooler Operation BHEL. cleaning completely dried and maintained in a dry condition. there exists the danger that micro-organisms on the tube walls may die an decay due to a loss of fresh water supply (lack of oxygen).

make sure that silver layer comes after carbon layer in direction of rotation 2 . BHEL. 2. as described below. 3.Turbogenerators Maintenance Maintenance and Supervision of Ground Fault Detection System Check carbon brushes of ground fault detection system Annualy Every 6 Months Every 3 Months Weekly Daily Work required Monthly Maintenance Intervals × 1 Ground Fault Detection System The ground fault detection system runs continuously. The ground fault detection system should be disconnected at the brush gear or isolated if a changeover switch is provided. When inserting a new double-layer carbon brush. the insulation resistance should be measured with a 500V megger. The normal service life of a set of carbon brushes may be determined by keeping a record of brush replacements over a period of several years. If the insulation resistance drops during the measurement. Haridwar 1 1. exchange polarities at the megger for checking purposes and repeat measurement. 2 3 4 5 Terminal board Bore for gage stick Plug-in brush holder Brush carrier segment Slipring Fig. If insulation resistance measured is not sufficient. If a carbon brush must be replaced. If a ground fault is indicated.1 Brush Holder for Ground Fault Detection Note: Remove only one brush holder at a time in order not to disturb proper operation of the ground fault detection system. making sure that the carbon layer comes before the silver layer in direction of rotation and that the new brush has a contact face which matches the slipring contour. the measurement is performed with the generator running and excited. the brush holder should be released from its lock and a new carbon brush fitted. 4. 2 Carbon Brushes of Ground Fault Detection System The carbon brushes should be checked at regular intervals. the cause of the ground fault alarm must be investigated at once. the useful length of each carbon brush can be determined without removing the brush holder by inserting a gauge stick of insulating material into the bore of the brush holder. During operation. On occurrence of a ground fault between the winding and ground an alarm is activated and indicated on the danger alarm panel.4-4990-0500/1 0709 E . Caution: If. handle sliprings and brush gear with extreme care since at the worst the full field voltage may be applied to the slipring connected to the exciter circuit. operation of the generator should be continued only after consultation with the manufacturer to avoid major consequential damage. 5. Grinding of the new brushes to the required contour should be done using a model of the ring contour or by grinding to size at the slipring when the unit is at rest. To do this. Carbon brush wear depends on several factors.

According to the conventional interpretation. Endangered parts of the turbogenerator are. Provided that commercial tools can be used and that no special skills are required for the dismantling and erection work. During an inspection.5-1003 BHEL. however. This latent hazard can only be positively avoided by taking all preventive measures required to fully protect those components of the turbogenerator which may be affected by stress corrosion against the effects of moisture [1]. special attention should be given to avoiding the effects of moisture on austenitic retaining ring materials as a preventive measure against stress corrosion. In hightensile steel. It should be noted in particular that the hydrogen must be removed from the generator housing with carbon dioxide only. The estimated duration of the inspection or overhaul should also be stated. Following each inspection or overhaul. it is recommended to notify the manufacturer well in advance. the next inspection should be scheduled. Also refer to the following information [1] 2. the conditions for stress corrosion to occur are given by the combination of sufficiently high tensile stresses and a sensitive material/corrosion medium system. In all other cases.Turbogenerators Inspection Reliable operation of the turbogenerator will be ensured only if inspections and overhauls are carried out at regular intervals so that any faults can be detected and corrected before they result in costly failures. Components packed in plastic sheeting mostly contain a desiccant which must be replaced or reactivated from time to time. The shutdown of a turbogenerator for inspection should be made in exactly the reverse order as during commissioning. such as for the inspection of the shaft seals and their auxiliaries.5-0010-0500/1 0709 E . Haridwar Measures to Prevent Corrosion During Inspections 2. Extended storage until startup and extended shutdown or stand-by Introduction periods of turbogenerators may thus result in a latent hazard to components which are made of a material sensitive to stress corrosion. the inspections can be performed by skilled power station staff. the services of the manufacturer’s product service personnel will be required. this sensitive system already develops when the material is exposed to the moisture in the air. The spare parts stored for repairs and overhauls should be checked at regular intervals. the rotor retaining rings which consist of high-tensile austenitic steel. for instance. Should opening of the gas system or of the generator proper be required during an inspection. In the event the manufacturer’s personnel are required for a scheduled inspection or overhaul. it is required to replace the carbon dioxide with air.

5-0019-0500/1 0709 E . corresponding to an absolute humidity of 8.Turbogenerators Inspection Determination of Dewpoint Temperature Relative humidity in % Example: Relative humidity of ambient air = 50 % and room temperature = +20oC result in a dew point temperature (DT) of + 9oC. Haridwar 2.6 g/m3 BHEL.

Turbogenerators Inspection Note Generator rotors are high-grade components which are sensitive to moisture. This enclosure must be removed prior to each transshipment to hitch the rotor with a lath grid in place at the middle of the rotor body. Any deviations from the standard packing due to special circumstances shall be subject to the approval of BHEL. a third plastic sheeting cover is provided for the rotor retaining rings and the rotor body. This type of packing also ensures sufficient protection during subsequent storage in a covered hall. For protection against the effects of moisture. The packing precautions and the organizational measures for protection during transport and storage are described below and summarized in [1]. Skid and Outer Protection 5. powerhouse.1 Organizational Measures 6.4 Desiccant 5. Sealed Packing 4. The hitch should then be taken directly at the skid. The pressure can be read on a permanently installed pressure gauge. This cover forms a second additional barrier against the diffusion of moisture into the innermost plastic sheeting cover. The metallically bright shaft ends (shaft journals and couplings) are protected with a hard wax coating.2 Land Transport or Sea Transport or Longer Duration 6. Rotors with water-cooled windings are protected against corrosion by filling the water passages with pure nitrogen after drying to a gauge pressure of 0. This sealed packing is protected with a second plastic sheeting cover. if necessary. the enclosure forms an integral part of the skid. Protection of Packing During Transit 6. the rotor retaining rings and the rotor body are packed in sealed plastic sheeting covers. For land transport not exceeding one month.2 Sea Transport The packing provided for this mode of shipment 2.1 Production Appliances and Packing Materials 4. This provides a reliable protection for short-distance transport (from BHEL. In the case of sea transport. This description contains all details required for restoring the standard packing provided by BHEL for delivery of the rotor. this unit is protected against external influences by a wooden enclosure resting on the bottom frame of the skid. Contents 1. Haridwar to destinations in India ).2 Checks During Storage Period 7. adding materials for moisture absorption. the insulation resistance of the rotor winding and the condition of the desiccant should be checked at intervals of one month and the desiccant reactivated. e. Storage 7. If a rotor is to be returned to the manufacturer’s works for overhaul or in the case of a prolonged outage of the generator involving a separate storage of the rotor. Following the receiving inspection. Basic Makeup of Packing 2. Basic Makeup of Packing The packing precautions and organizational measures during transport and storage are intended for reliably preventing the effects of moisture on the rotor and especially on the rotor retaining rings which may be BHEL. Transport and Storage of Generator Rotors endangered by stress corrosion and for protection against mechanical damage during transport and transshipment procedures. 2 Definitions 2. The rotor is then placed on a skid with closed bottom and secured in position for protection against mechanical damage. The complete cargo is covered with tarpaulins for protection from the elements. In the case of land transport exceeding one month and with sea transport.2 Loading 6.3 Receiving Inspection 7.1 Land Transport (Less Than One Month) 5.1 Land Transport The packing provided for this mode of shipment affords sufficient protection for land transport under moderate climatic conditions and for a scheduled transit period of not more than one month.5-0030-0500/1 0709 E . 2. Definitions 3. the requirements specified in the following must be met for protection of the rotor.g. For this reason.3 Removal From Storage 1.1 Storage Area 7. Haridwar Packing.3 Providing the Plastic Sheeting Covers 4.5 to 1 bar via a cover at the exciter end. Summary of Rotor Packing Requirements 4. they must be protected against corrosion and mechanical damage during transport and storage.2 Protection of Metallically Bright Shaft Ends 4.

3 mm thick. A detailed description is given in the following section. Air dryer for any required drying of rotor end windings prior to packing.g. preferably in a hall. such as scissors..g. 4. consisting of: heat – impulse generator and heat – sealing tongs for a minimum seam length of 200 mm.affords protection during shipment by sea. etc. 2. 100 mm wide (e. as compared to land transport. In addition. 4. knife. the rotor and especially the rotor retaining rings and end winding portions should be dried with dry air by means of an air dryer (e. Munters dryer). endless Steel band. The inspections required during storage are the same as specified for land transport under item 2. The basic prerequisites are: Q The following packing materials are used. Tectyl 506) of sufficient thickness (dark-brown). HARIDWAR on request: Q Q Q Dry Condition of Rotor Prior to Packing The rotor must be dried if it is expected to be in a wet condition due to operational faults. 5 to 10 mm thick (e. 4 Sealed Packing The obtain a reliable and long-lasting corrosion protection. special appliances are required for obtaining a packing affording corrosion protection. Blower with small delivery rating for checking the plastic sheeting cover for tightness and for extracting the test air (e. both suitable production appliances and materials and appropriate methods of packing are required. 30 mm wide. Q Q 3 Summary of Rotor Packing Requirements · This summary [1] contains information on the makeup of the packing and on the procedures required to maintain the packing in sealed condition.2 Protection of Metallically Bright Shaft Ends The metallically bright shaft ends should be cleaned and degreased and protected with a hard wax coating (e. nailed to 5mm thick fabric mat. seaworthy outer packing. vacuum cleaner). heating the winding with direct current to approximately 60 to 70°C. 1 mm thick. Following this.g. consists of a third plastic sheeting cover and a closed.5-0030-0500/2 Heat-impulse fixture for heat sealing of polyethylene plastic sheeting. with turnbuckle and tensioning device Lath grid for taking a hitch at the rotor body consisting of hardwood laths 50x80x3000mm. The mechanical data required for the procurement of the equipment are available from the manufacturer on request. but for not more than six months. which does not absorb water.g. for attaching desiccant pouches Fabric tape. the rotor winding should be filled with pure nitrogen to a gauge pressure of 0.1. Weather-Protected Packing Area Packing and unpacking is only permissible in a weatherprotected area. 20 mm.1. Q Q Q Q Q Q Q Q Polyethylene sheeting.2 mm thick. All other areas contacting the skid should also be covered with 3 mm thick rubber board. Heated plate to melt wax-coated sheeting for bonding (e. To do this. Denso binding) Hard wax for application by brush (e. preferred width 6000 mm Rubber board with canvas reinforcement. Drying can be terminated when a pressure of less than 5 torr has been maintained on the hot rotor for a period of five hours. The additional packing. The desiccant included in the plastic sheeting covers is sufficient for the scheduled transport period. which are available from BHEL. Q Q Q Q Q Q Q Q Water-Cooled Rotor Winding Drying the cooling water circuit of the rotor winding should be performed with a vacuum pump. polyurethane) Silica gel in linen pouches as desiccant Moisture indicators for functional checking of desiccant (color indicators for 30%. Packing the rotor should therefore be performed immediately after withdrawal of the rotor and any required drying in order to minimise any uncontrolled phases.g. minimum width 1000 mm Wax-coated linen binding with 1 mm wax coating. electric iron).1 Production Appliances and Packing Material In addition to the standard tools. Denso binding) and a 3 mm thick canvas-reinforced rubber mat. endless. 40% and 50% relative humidity) Hemp rope. Tectyl 506) Cold degreasing agent Wax-coated aluminum foil Adhesive for plastic sheeting Adhesive tape for plastic sheeting Foam material. No Delays in Packing Procedure Care must be taken to ensure that after its removal the rotor will not suffer any moisture condensation or accidental wetting.g. 2 mm thick. the areas of support in the skid should be wrapped with two layers of wax-coated bindings (e. during unavoidable outdoor storage and for transport periods and under conditions exceeding those under item 2.g.5 bar via the end cover at the exciter end. 4.3 Providing the Plastic Sheeting Covers The polyethylene sheeting covers are made directly .g. 0.. The equipment and power sources required for vacuum drying should be obtained by the user in due time.

Following this check. Seams and overlapping portions should be sealed airtight by melting the wax coating with an electric iron. This rubber mat consists of individual sections. To protect the aluminum foil from being damaged by the handling ropes. If the cover remains inflated during the following two hours. After the rotor has been supported on the skid. 80x40 mm. Edges should be padded with layers of Inspection rubber board or foam rubber.3 Third Plastic Sheeting Cover For sea transport and outdoor storage as defined under Item 2.4. the polyethylene sheeting should be inserted between two rubber boards of sufficient size for protection against damage. a canvas-reinforced rubber mat. 4. which is then closed by heat-sealing. To protect the plastic Turbogenerators sheeting cover from damage. To do this. corrugated cardboard. Two plastic sheeting covers are required for land transport and storage as defined under Item 2. The desiccant must be placed so that it can 2. The grid should cover not less than the lower half twothirds of the rotor body circumference and be adequately secured with steel bands. sealing of the rubber mat at the middle of the rotor body will not be required for short-distance transport. each plastic sheeting cover is provided with a 500 mm dia. Axial overlap seams are additionally secured with steel bands. The range between the free shaft portion protected with hard wax and the end of the rotor body should then be wrapped with polyethylene sheeting which is to be sealed tightly with wax-coated canvas bindings at the rotor body and free shaft portion. the desiccant is added via this hose. All overlap seams are sealed with wax-coated canvas bindings. its upper half portion (rotor body and retaining rings) should be covered with a 5 to 10 mm thick layer of foam material outside the lath grid area. each plastic sheeting cover should be checked for tight sealing. 4. Care should be taken to ensure that the plastic sheeting cover remains intact during the subsequent packing procedures. 4. Within the range of rotor support in the skid and of other contact points (upper shipping saddles). the cover is properly sealed.3. Experience has shown that in the case of larger rotor body diameters (>1300 mm). with the wax coating facing the rotor body. It should be inserted into each plastic sheeting cover via the plastic sheeting hoses at the end windings.1 provide for the minimum packing requirements and are sufficient for land transport not exceeding 20 hours. Haridwar approximately 150 mm wider at each end of the rotor. The use of excelsior.2. the entire rotor body should be wrapped with wax-coated aluminum foil with 50 to 70 mm overlap. The wooden laths must be on the outside and arranged so that the rubber mat is BHEL. which is also held in place with steel bands. a second polyethylene sheeting cover of the same type should be provided between the shaft ends and the rubber mat at the middle of the rotor body. Even pinpricks and minute tears in the plastic sheeting will render tight sealing ineffective. At the end winding. felt or other hygroscopic materials is not permissible. To separate the two plastic sheeting covers. a 5 to 10 mm thick layer of foam material should be placed over the top half circumference of the rotor retaining rings and rotor body.3.2 to 4.3. opening for connection of a plastic sheeting hose having the same diameter and a length of approximately 1m.3.4 Desiccant 4. Finally. any contact with sharp edges must be avoided.2 Second Plastic Sheeting Cover In addition to the first plastic sheeting cover described under Item 4.on the components to be protected. one corner of the plastic sheeting hose should be cut for insertion of a vacuum cleaner hose (discharge end) and tightly sealed with a binding. a lath grid (hardwood laths attached to fabric mat or fabric tape) should be placed in position for hitching.4) is added to each plastic sheeting cover. This third polyethylene sheeting cover protects the entire range of the rotor between the shaft journals at either end.1 Type and Application The desiccant consists of silica gel in dust-free and air-permeable pouches.1. an additional diffusion barrier is provided. To maintain the sealed range in a dry condition desiccant (see Item 4. The overlap seam at the top on the circumference is secured in axial direction by wooden lath.3. In such cases.1 First Plastic Sheeting Cover As a first step.3. Within the range of rotor support the plastic sheeting is inserted between two rubber mats of 3 mm thickness each. 4.3. the above mentioned polyethylene sheeting should extend beyond the rubber mat at the middle of the rotor body and should be sealed tightly with wax-coated canvas bindings at these points. The plastic sheeting is placed over the rotor before the rotor is supported on the skid. It is placed over the plastic sheeting covers according to Items 4.1. After heat-sealing and tight wrapping with waxcoated bindings.2 and is to be made in the same manner. The precautionary measures specified under Items 4. and then the plastic sheeting cover should be heat-sealed. each having a length corresponding to the rotor body diameter + 100 mm and arranged with an overlap of not less than 100 mm. In the case of rotors provided with aluminum foil within the range of the rotor body. the aluminum foil cannot be wrapped around the rotor with sufficient tightness and may thus be omitted. the air should be drawn off. 3 mm thick and approximately 2500 to 3000 mm wide (dependent on overall length of rotor) should be placed around the center of gravity of the rotor.1 and 4. After checking the cover for tight sealing.5-0030-0500/3 .

5-0030-0500/4 .2.

The maximum quantity is sufficient for a shipping time not exceeding six-month. selfsupporting container. It is recommended to keep this shipping container for future needs. the desiccant must be removed and replaced or reactivated by drying. all circles are blue. Figs. Haridwar 5 Skid and Outer Protection 5. unless an adjustable universal skid is used for land transport which is available from BHEL. 4. the rotor should be protected against external influences by a wooden enclosure resting on the bottom frame of the skid.5-0030-0500/5 .4.2 Land Transport or Sea Transport of Longer Duration For land transport exceeding one month and for sea transport. if requested in due time. The information given in the following relates to the remounting of the rotor in sealed packing on the skid and to the provision of the outer protection. The opening in the plastic sheeting cover should then be resealed with a heat-sealing unit. During transit. A change in color to pink in the respective circle indicates the relative humidity in percent. absolutely dry condition are to be closed and reinserted into the plastic sheeting covers as quickly as possible. To do this. The container lid should be covered with tar board sanded on one side 2. i. The complete cargo should be covered with a lashed tarpaulin. The moisture indicators are marked with their respective location identifications as illustrated in Fig.e. Prior to closing the container. If a drying oven is not available. after interruptions in transit involving a storage period of more than one month and during normal storage at the site (see Item 7. the hitch should be taken either at the middle of the rotor body (lath grid) or at the rotor ends. the rotor should be packed in a closed. For loading operations. If necessary. spread out in a thin layer on a metal plate and dried at 110 to 130°C for several hours until the weight of the desiccant remains constant. when used. the rotor should be attached to the skid by means of upper saddles and secured in axial direction.4. At the shaft ends. they must be in an active. 2. The desiccant should then be filled back into the pouches which BHEL. All circles pink: danger of corrosion Two circles pink: replace desiccant One circle pink: Fig.2). The container bottom should have openings with perforated–plate covers for ventilation and to prevent the accumulation of water. The setup for two-pole rotors corresponds to Fig. HARIDWAR. but must not be left in this condition for more than 20 hours. All pouches must be tied together with a hemp rope. With the packing in dry condition. the plastic sheeting cover should be provisionally resealed. Care should be taken to ensure that the pouches do not come into contact with metal parts. 4. 2 and show the relative humidity inside the cover in three ranges (>30%. Both long sides of this protective enclosure should be clearly stencil-marked with the following note. use the moisture indicators (Fig. the rotor should be covered with 3 mm thick pressboard panels and polyethylene sheeting. >40% and >50%). 4. BHEL. An inspection opening at the exciter end should provide access to the contact pins on the exciter-end end cover of the rotor for measurement of the insulation resistance of the rotor winding. For reactivation.3 Checking and Reactivation The moisture absorption capacity of the desiccant must be checked after completion of shipment. cover Inspection contact area with polyethylene or rubber sheeting. The points of support should be padded with rubber mats for protection of the plastic sheeting covers. 4 and 5 depict typical examples. After opening.1 Land Transport (Less Than One Month) For land Transport.2 Desiccant Quantities The desiccant quantities [1] are proportioned to accommodate highly adverse climatic conditions. taking care to avoid the formation of troughs in which water might accumulate. the desiccant should be removed from the pouch. 5. 3) inserted in the plastic sheeting covers at a distance of not less than 5 cm from the sheeting. In addition.be easily replaced when this becomes necessary and that Turbogenerators it does not come into contact with steel or winding components (danger of corrosion). Caution: Remove protective enclosure for rotor transshipment. consisting of a skid and an enclosure. inspection openings with covers should be provided on the long sides for access to the desiccant pouches via the plastic sheeting hoses. the rotor should be supported on a skid similar to Fig. As soon as the 40% indicator changes to the pink color. 3 warning 50 40 30 Moisture Indicator Make sure that sufficient replacement desiccant or the necessary drying facility for reactivation is available. the pouches should be dried in a drying oven at a temperature of 110°C for 12 hours. HARIDWAR generator rotors are delivered in box type shipping containers. and.

3 Receiving Inspection After arrival of the rotor. In addition. the car must never be allowed to pass over a hump. Planks .4. there will be no need for raising the temperature of the rotor to the level of the ambient temperature. approximately 50 mm thick. steps must be taken to ensure that the rotor temperature will be 5 degC (safety margin) higher than the dew point temperature of the ambient air [4]. The total weight and the dimensions of the cargo should be marked on the container.e. These measures include : On the Cargo: Q Q Q Q Instructions for correct handling. This should be avoided by suitable precautions. If the nitrogen pressure has dropped to zero. In the Accompanying Documents: Q Reference to “Sealed Packing”. To this end. 7 Storage The preventive measures during storage provide for maintaining the dry condition of the rotor in the sealed packing without any interruptions until commencement of the installation. In addition the hitching range should be color-marked. it should be resealed as soon as possible. 7. the cargo should be loaded so that it can slide on the car. should be nailed to the long sides adjacent to the battens. 6. The condition of the desiccant can be ascertained at the moisture indicators. If the moisture absorption capacity of the desiccant is no longer sufficient (40 % indicator is pink).. As long as the nitrogen pressure is still slightly above atmosphere. certain minimum requirements must be observed. Reference to “Sealed Packing” on shipping container. If the rotor temperature is equal to or higher than the room temperature. copies of which should be forwarded to the consignor. it may become necessary to bring it to ambient temperature level for protection against moisture condensation.1 Organizational Measures : Proper packing of the rotor will prevent both the ingress and the condensation of moisture during transit. If a deep well wagon is used for transport. the desiccant should be removed from the plastic sheeting cover. The date of the receiving inspection should be entered in the respective section on the inspection hole covers. A corresponding note should be included in the waybill and affixed to the car in a well visible location.5m at either end. In the case of a water-cooled rotor winding the pressure of the nitrogen blanket should also be checked. the condition of the packing and of the desiccant contained in the packing must be checked at regular intervals. Q Reference to arrangements for customs clearance at place of installation. The results of the receiving inspection should be recorded in the check lists [2].and folding down over the edges not less than 200 mm. If the packing is found in damaged condition. and reactivated (see Item 4.2 Loading If a flatcar is used for transport. the skid must not be secured in position and must be free to move in both directions of running.5-0030-0500/6 should be checked. Q Check list relating to condition of desiccant [2]. which are dependent on the condition of the storage area. If the rotor temperature is lower than the ambient temperature. In addition. the insulation resistance of the rotor winding 2. During shunting operations. [3]. The same requirement applies if the seals were opened by the customs authorities. enabling a quick restoration of the dry condition of any damaged sealed packing. the winding should be filled with pure nitrogen to a gauge pressure of 0. Indication of desiccant quantity inserted into each individual plastic sheeting cover behind inspection hole cover. the rotor installation phase should be timed so that the unpacked rotor will not be exposed to extreme changes in temperature as this will involve the risk of moisture condensation.5 bar from the nitrogen bottle permanently installed in the shipping container. In the case of outdoor units. the skidmounted rotor should be secured in position at both ends of the loading bridge. i. Provision should be made for a sliding distance of approximately 1. The bridge through should be sealed with boards for protection against stones.3). it will normally not be necessary to recharge a water-cooled rotor winding with nitrogen. 6. The complete cargo should be covered with a tarpaulin for protection against the elements. the consignee should examine the packing for external damage. If outdoor storage . The rotor temperature can be measured at the accessible rotor ends using a temperature measuring instrument. the insulation resistance of the rotor winding should be measured. Attaching this instruction 2.5 – 0030. If the rotor is unpacked immediately after delivery.1 Storage Area Sufficiently ventilated and dry storage rooms for stable support of the parts in a fully accessible location are favorable preconditions for storage. Q Request for immediate drying in case of transport damage with moisture penetration. Q Checklist relating to insulation resistance of rotor winding [3]. with the shipping container protected from the environment. unless the sealed packing is damaged by improper loading procedures or customs inspections. 6 Protection of Packing During Transit : 6. To obtain additional verification.

5-0032 Checking Desiccant in Generator Rotor Packing BHEL. The dates of the repeat checks should be recorded on the outer packing below the date of the receiving inspection and in the check lists [2]. The checks required are the same as specified for the receiving inspection under Item 6.5-0030-0500/7 . a heavy-duty outer packing of the Turbogenerators seaworthy type must be provided. The outdoor storage facility must beInspection set up in such a way that the stored item is protected against rainfall and moisture from the ground. In addition. the stored item should be blocked up on the solid ground for protection against moisture. Enough space must be left between the boxes to permit inspections and checks. Also refer to the following information [1] 2.3 Removal from Storage If the storage area and the place of installation are not located in the same room (power house or workshop).3. the rotor temperature may be below the dew point level on transfer of the rotor from a cold storage area to a warm power house. Haridwar [3] 2.cannot be avoided.5-0031 Preventive Measures for Transport and Storage of Generator Rotors (Summary) [2] 2. 7. This would include placing a waterproof shelter over the shipping container which affords sufficient ventilation. surveillance of the equipment should be conducted by repeat checks at intervals of four weeks.2 Checks During Storage Period Following the receiving inspection. it should be left in its sealed packing for several days and allowed to assume the ambient temperature prior to removing the packing for immediate installation.5-0019 Determination of Dewpoint Temperature 2.5-0033 Insulation Resistance Measurements on Rotor and Exciter Windings During Storage (Test Report) [4] 2. To protect the rotor from moisture condensation.[3]. 7.

Add desiccant as under 8 . Plus 280 g for each Kg of wood and 35 g for each Kg of foam material within plastic cover. about 300 mm narrower than 4 . Watercooled rotor winding 2 Fill dried rotor winding with pure nitrogen to a gauge pressure of 0. respectively. Measure Inspection Protective Materials and Setup Land Transport Short-Distance Transport Period Less Than One Month Sea Transport Shipment by Sea or Transport Period More Than One Month Shaft journals 1 Couplings Hard wax coating (e. due to difficult handling) 4 5 Retaining 6 rings Fans (water boxes) 7 Rotor body and retaining rings Rotor body and retaining rings BHEL. insert plastic sheeting between 3mm rubber boards. Additionally protect areas of support in skid with two layers of wax-coated bindings and one layer of 3 mm canvas-reinforced rubber mat. > 40%. Haridwar Place 3 mm canvas-reinforced rubber mat. around two-thirds of rotor circumference and secure at top.2 mm polythene sheeting between shaft ends 1 and body ends 3 and rubber mat 4 . seal overlap seams with wax-coated bindings and steel bands. 12 Not required for land transport.g. up to 6 months: 1500 g. Place lath grid on fabric mat. Rotor Body 3 Place wax-coated aluminum foil over entire range of rotor body (only for rotor body diameters < 1300 mm. 9 Place 0. foam mat and cover entire rotor between shaft ends as under 9 . Moisture indicators for relative humidity > 30%. 2. heat-seal seams Check plastic sheeting cover for tight sealing by inflation with air and recheck after two hours.3 to 0. Check for tight sealing as under 7 .5 bar through cover at exciter end. 8 Add desiccant per m2 of sheeting surface shipping time up to 1 month: 500 g.5-0031-0500/1 0709 E . Place 0.Preventive Measures for Transport and Storage of Generator Rotors Summary Turbogenerators Purpose/ Phase A Corrosion Protection of shaft ends B Corrosion Protection of rotor winding C First packing of rotor retaining rings and rotor body in plastic sheeting cover (sufficient for shortdistance transport up to 20 hours and immediate installation) D Protection of first packing C by second plastic sheeting cover E Protection of packings C and D by third plastic sheeting cover Component Prev. Tectyl 506) of sufficient thickness (dark-brown color). secure axial overlap seam with wooden lath. seal joints with wax-coated bindings at both ends. With four-pole rotors. up to 3 months : 1000 g. 10 Check heat-sealed and tightly wrapped plastic cover 9 for tight sealing as under 7 11 Add desiccant and moisture indicators as under 8 . > 50%.2 mm polythene sheeting between shaft ends 1 and rubber mat 4 over a 5 to 10 mm foam mat around top half circumference of rotor retaining rings and rotor body. foam mat is split within range of lath grid. 2500 to 3600 mm wide (dependent on length of rotor) around center of gravity.

Complete cargo 14 Hitch point on rotor at lath grid in center of gravity after removal of enclosure. in the case of four-pole rotors on Steel sleeve at mid-length of skid. insulation resistance of rotor winding and. Replace desiccant when relative humidity is higher than 40 %. Hitch point on shipping container. 16 Prior to unpacking the rotor in a weather-protected location. Complete packing and rotor winding 15 Check outer packing and relative humidity inside plastic sheeting at moisture indicators. For outdoor storage. Protection against condensation hazard by preventive measure 16 2. nitrogen blanket at intervals of four weeks. if applicable. check outer packing for damage and tight sealing.Component One Month F Transit protection G Loading H Receiving of cargo J Storage K Removal from storage Prev. Rotor 19 Maintain tight sealing of packing as long as possible until rotor is installed. seaworthy packing plus additional precautions are required: storage on well tamped and suitably reinforced ground and set on blocks for protection against moisture.5-0031-0500/2 . Measure Purpose/ Phase Protective Materials and Setup Land Transport Short-Distance Transport Period Less Than One Month Sea Transport Shipment by Sea or Transport Period More Than One Month Tightly sealed rotor 13 Tightly sealed rotor 1 to 11 on skid with closed bottom under enclosure and tarpaulin Tightly sealed rotor 1 to 11 in closed self-supporting shipping container Under tarpaulin. Return check list with details on condition of packing and insulation resistances of rotor winding to consignor. Storage area 17 With packing for land transport. a cold rotor must have ambient or dewpoint temperature plus 5 K safety margin to prevent moisture condensation. case under protective roof. Complete packing and rotor winding 18 During storage (including interruptions in transit). only in a hall kept at a moderate temperature.

The desiccant must be removed and replaced or reactivated by drying when a change in the color of the 40% moisture indicator is observed.: Date Job name: The results should be recorded in the table below. Prior to shipment Condition of outer packing Storage area of compotent Location identification of moisture indicator Company Shipping or storage phase Name Sl.Checking Desiccant in Packing of Components Turbogenerators Inspection Desiccant Checking Requirements The absorbent capacity of the desiccant must be checked after shipment has been completed and at intervals of one month during any subsequent storage period.5-0032-0500/1 0709 E . Type: Moisture indicator blue or pink? Bottom Center Top circle circle circle (30%) (40%) (50%) Weight of desiccant in packing in Kg Replacement or reactivation of desiccant TE 1 TE 2 TE 3 EE 1 EE 2 EE 3 TE 1 TE 2 TE 3 EE 1 EE 2 EE 3 TE 1 TE 2 TE 3 EE 1 EE 2 EE 3 TE 1 TE 2 TE 3 EE 1 EE 2 EE 3 TE 1 TE 2 TE 3 EE 1 EE 2 EE 3 BHEL. Haridwar 2. No.

Haridwar 3 4 5 The connection to the rotor winding should be made at a specially identified bolt on the exciter-end end cover.: Shipping or storage phase Type : Component : Prior to shipment Date Name Company Storage area Temperature in Storage area in °C Rel. 2 Prior to each measurement. The connection to the rotor body should be made at a specially identified bolt on the exciter-end end cover. any static charges should be removed by short-circuiting the winding through the rotor body (not less than 20 minutes).5-0033-0500/1 0709 E . applying a voltage of 100 V. any static charges should be removed by grounding the windings as a precautionary measure (10 minutes). BHEL. 2. Rotor temperature in °C Moisture Indicator in packing blue or pink? TE1 TE1 50 40 30 50 40 30 Pressure of Nitrogen blanket in bar Inaulation Resistance in M ohm Applied voltage in V 15 s 30 s 45 s 1 min 2 min 3 min 4 min 5 min 6 min 7 min 8 min 9 min 10 min Notes: 1 The insulation resistance should be measured with an insulation measuring device. The results should be recorded in the table below.Insulation Resistance Measurements on Rotor and Exciter Windings Test Report Turbogenerators Inspection Checking the Insulation Resistances of Rotor Windings in Sealed Packing The insulation resistance of the rotor winding should Job name : be checked after shipment has been completed and at intervals of one month during any subsequent storage period. but not more than 250 V. After each measurement. Sl No. humidity of ambient Air in storage area in %.

Caution: Burrs and compression marks on bearing metal surfaces should only be removed by means of a spoon scraper or flat scraper. etc. the cleaned surfaces should be carefully dried and afterwards a thin oil film should be applied. The cleaned screws should then be dipped into a solvent and immediately afterwards be screwed into the holes for thread cleaning. all machined surfaces are provided with a protective coating. The dimensions of the external and internal threads may be taken from the respective drawings. If required. unless certain portions must be protected during transport against corrosion or damage. Cleaning of internal and external threads should be done by chasing. using suitable taps or cutting dies. The machinery parts and the fixing and locating elements should be checked for burrs and compression marks. Non-observance of this requirement implies the danger of corrosion.. Caution: Never use scrapers. 2 Removal of Protective Coating The protective coating applied at the manufacturer’s works should be carefully removed prior to assembly. e. complete assemblies are sealed in plastic sheeting. Make sure that the sleeves and bolts of the DC. Fine –finished surfaces should only be polished by means of an oilstone.g. 2. all sensitive portions of the machinery parts. In case of orders for delivery to other countries. When using trichlorethylene. Where no taps are available cleaning of the tapped holes may also be carried out with the aid of the original screws. are provided with a protective coating and protected against damage.Turbogenerators Preparation of Machinery Parts Inspection 1 General The machinery parts to be assembled are delivered ready for mounting. Particularly thick layers of protective coating should be softened by applying one of the above-mentioned cleaning agents and then be removed by means of a hardwood board (approximately 10 cm x 10 cm x 1 cm). In case of orders for delivery to overseas countries. the screws should be cleaned by means of solvent and a brush. 3 Remedying Minor Damage Damaged machinery parts should be reconditioned as dictated by the extent of the damage and the operational requirements unless the nature of the damage does not warrant such remedying. Use dry compressed air to blow out the re-tapped holes. finishing trowels or sheet metal strips for removing the protective coating from highly sensitive machinery parts (journals. At first. BHEL. journals.5-0200-0500/1 0709 E .) The covers protecting the components of the DC plugin contact assembly should be removed shortly before coupling the rotors. Seriously damaged parts should be returned to the manufacturer’s works together with a damage or failure report. In addition. Haridwar plug-in contact assembly of the exciter rotor will not come into contact with any solvent. this procedure should be repeated several times until the threads are free from protective coating. The surfaces to be cleaned should be washed with petroleum or a similar agent. and such imperfections should be removed by means of a smooth-cut file.

2 Inner and Outer Labyrinth Rings Inner and outer labyrinth rings are insulated from other components. the insulation should be dried at 80°C maximum. If a sufficiently high resistance value is measured (five megohms) proceed with fitting of the next pipe. 2. It is also be expected that BHEL. the measuring circuit covers in parallel. the components coming into contact with the shaft are separated from the shaft by an oil film. the insulation resistance of the built-in bearing saddle should be measured separately by means of a 100 V megger applied between the bearing saddle and the lower part of the stator frame. With the generator running. which has insulating properties. To check the insulation resistance. the total resistance will be slightly lower than the lowest individual resistance value measured before. Useful results are. The insulation resistance of each individual labyrinth ring should be measured after installation in order to preclude any lengthy search for faulty mounting on measurement of a poor insulation resistance. For reasons of interchangeability. Due to contact with the shaft. bolt the associated oil pipe to the bearing pedestal being careful to insulate it. all stator components coming into contact with the generator rotor are insulated. It is also recommended to repeat the insulation resistance measurement after fitting of each individual pipe. Caution: With this measurement and the following checks both rotor bearings must be insulated. Proceed with mounting of the next component only after having identified and removed the cause of a poor insulation resistance. the insulating parts should be checked for moisture. Since. Following this. TE/EE bearings TE/EE shaft seals Exciter bearing pedestal with pipe work 3 Checking the Shaft Seal and Bearing Insulation of the Assembled Unit Checking the shaft seal and bearing insulation during operation may be done by way of the shaft voltage prevailing with the generator running in an excited condition. After installation of all insulated components the total resistance will be slightly lower than the lowest individual resistance value measured before. the potential of the insulated shaft seals and bearings is accessible external to the generator. 2. however. 2 Checking the Shaft Seal and Bearing Insulation During Installation 2. Consequently. The values measured should be recorded. 3. With satisfactory insulation. all individual resistances measured previously are now in parallel in the measuring circuit. to prevent the generator rotor from being grounded. For this purpose.1 Checking the Insulation with the Generator in an Excited Condition 2. a value in excess of 10 megohms is to be expected.3 Shaft Seals Both shaft seals are mounted such they are insulated. Grounding must be maintained to discharge to ground any static charges occurring continuously during operation due to steam and oil film friction. voltages are set up along the rotor due to magnetic unbalances and ring excitation. The following method permits the insulation to be checked without disassembly of components being required. a final insulation check should be performed. If an insulation resistance value below three megohms is measured. If this value is higher than three megohms .1 Bearing Saddle Prior to inserting the rotor and supporting it on the bearings. with the rotor inserted. 2.4 Pedestal Bearing of Exciter The insulation resistance between the bearing pedestal and base frame should be measured immediately after mounting of the pedestal. proceed with mounting of the exciter rotor. a value in excess of 10 megohms is to be expected. Finally. This shaft voltage would cause a destructive current to flow through the bearing.5 Final Checking After the exciter rotor has been coupled to the generator rotor and insulated from the bearing pedestal. shaft seal and other components if the rotor were not insulated from ground at least at the exciter end. With satisfactory insulation. a non-defined resistance value is set up at the potential measuring points of the shaft seals and bearing sleeves which is dictated by the magnitude of the resistances of the oil film and insulating parts. If required. Haridwar the total resistance will likewise be lower than the lowest individual resistance measured before. and the generator rotor must not come into contact with the turbine shaft through measuring devices or similar parts. follow the same procedure as outlined for the labyrinth rings. to be expected only if the turbine end of generator rotor and the turbine shaft are grounded properly as defined during the measurements. measure the insulation resistance to the base frame of the bearing pedestal with the connected pipe work. At the exciter. contamination or metallic contacts. all bearings or the complete exciter are insulated. The measurement should be repeated immediately after the rotor has been supported on the bearings. 2.5-0300-0500/1 0709 E . The total insulation resistance must not be less than one megohm.Turbogenerators Checking the Bearing and Seal Insulation Inspection 1 General During operation of a generator.

the instrument will continue to indicate a shaft voltage of the original magnitude. In the event of insufficient insulation resistance. The voltage should be picked off the shaft through a sliding contact with an insulated handle. the bridge instrument should be connected between this component and ground. (Contact the manufacturer). Bridging of the oil film results in a 2.33 to 6. it must be assumed that the insulation is defective. 2 Measurement of Shaft Voltage at Exciter End With the Generator in Exciter Condition readings are not identical.2. 3 Measurement of Shaft Current With the Generator in Excited Condition 1 Voltmeter (AC range) Fig. The oil film of the component is thus bridged. To measure the resistance of the insulated component with respect to the shaft and ground. since a stable oil film providing for full insulation can be formed above a speed of approximately 3. 1 Voltmeter (AC range) Fig. on the function of the rotor grounding system (carbon brush sliding on shaft). this will be an AC voltage of a few volts on which a small dc component is superimposed. If the shaft voltage can be exactly measured according to Fig. with the component assuming the shaft potential. the rotor grounding system should be rectified first before taking any further readings to check the insulation for shaft currents. This measurement is not practicable with the generator at standstill. which is connected to the meter by a circle.1 Measurement of Shaft Voltage Generator in Excited Condition With the Measurement should be performed by means of an AVOmeter in the AC range. Since the result depends. If the two 1 Voltmeter (AC range) Fig. reduction of the original shaft voltage or in its complete collapse. however.5-0300-0500/2 2 Ammeter The resulting current can be measured for a brief moment by means of an ammeter connected into the circuit between the measuring brush and the potential measuring terminal.2 Checking the Insulation With the Generator in NonExcited Condition If the previous tests are inconclusive. In case of a low insulation resistance. which may be read at the ammeter connected into the circuit. 4 Measurement of Insulation Resistance With the Unit in Non-Excited Condition to locate insulation defects with the generator running and in non-excited condition.Due to the rotor grounding arrangement at the turbine end. the measuring brush on the shaft should first be connected to the potential measuring terminal of the insulated component (bearing sleeve or shaft seal) at the exciter end by means of a cable. 2. With satisfactory insulation. additional tests may be performed in consultation with the manufacturer 1 Measuring Bridge Fig. . the shaft voltage should first be measured according to Fig. Normally.1 with the generator running and excited. a current will flow through the insulation. 3. the shaft voltage should be measured at the exciter end. A bridge instrument must be used.66 s-1. The resistance (Roil and Rins in series) of the parts in contact with the shaft are then connected in parallel with the measuring voltage. The shaft voltage measured in this way should then be compared with the voltage according to Fig. requiring detailed checking of the insulating parts.

6 bar for 6 hrs.C. (By 500V megger) Min. 6 bar for 30 mts 8 Hydraulic test of seal oil cooler i) Shell side ii) Tube side (No leakage is allowed) 10 Kg for 30 mts 10 Kg for 30 mts Hydraulic test of stator water coolers i) Shell side ii) Tube side (No leakage is allowed) 10 Kg for 30 mts 10 Kg for 30 mts 9 10 Test on diodes for reverse blocking capability (by 1KV megger with two diodes in parallel circuit) IR > 5 Mega ohms 11 Measurement of fuse resistance on the diode wheel by passing 10 Amps regulated D. current (Fuse Type 800V/800Amp) 155+6% Micro ohm at 20 deg. (No visual leakage is allowed.5-0305-0500/1 0709 E . (No visual leakage is allowed) 6 bar for 48 hours by N 2 cushion 6 Hydraulic test pressure for seal oil and ring relief oil inlet pipeline in the end shield (No leakage and pressure drop is allowed) 10 bar for 15 mts 7 Pneumatic test for seal oil and ring relief oil inlet pipeline. C 12 IR measurement of heat sinks. 3 above) ——do——- 5 Hydraulic test for stator winding and primary water system. (No leakage & pressure drop is allowed).5 bar 4 Gas tightness test of exciter rotor. (Condition of testing same as a Sl. Press. Haridwar 2. drop not more than 0.Turbogenerators Test Norms During Overhaul Inspection 1 Hydraulic pressure test of hydrogen gas coolers. The test is to be conducted either with nitrogen or helium). 10 Mega ohms. BHEL. (No leakage is allowed) 8 bar for 30 mts 2 Hydraulic pressure test for brushless exciter coolers (No leakage is allowed) 8 bar for 30 mts 3 Gas tightness test of TG Rotor.

as an exception. 2 Leakage Test of H2 Gas System Using Air After assembling the generator and placing the seal oil system into operation. etc. a leakage test using hydrogen is performed. If a satisfactory tightness is established the generator may be filled with CO2. safe and accepted practice. the leakage rate may be four times as high as during a leakage using air.. including the connected gas system. °C If an air loss higher than 2. A nitrogen cushion at a gauge pressure of 6 bar is to be provided on the water level in the primary water tank and maintained for a test period of not less than 48 hours. Suspected areas should be brushed with Diprol or other foaming solution. must be leak tested using compressed air.t. Should a pressure increase be observed in the primary water tank.)*/24 hrs results. permitting even small pressure increases to be measured. The duration of the leakage test should be at least 48 hours. mbar = barometer reading at beginning of leakage test. 3 Leakage Control of H 2 System During Actual Operation During operation. Haridwar Leakage Tests of Generator and Gas System z VG p1 p2 p B1 p B2 t1 t2 = duration of leakage test. bushings. joints.)* per 24 hour periods 0.t.t. a search for the leak must be made.p.p.5-0310-0500/1 0709 E . mbar = temperature of the gaseous atmosphere at beginning of leakage test. mbar = gauge pressure within the system at end of leakage test. mbar = barometer reading at end of leakage test. Losses such as the steady controlled gas loss occurring at the electrical purity meter system and the gas removed from the generator through the seal oil should not be counted. The H2 gas system may be considered sufficiently tight if the loss of air is below 1. the entire circuit should be carefully checked for leakage.p. Leak detection during this test should be performed by means of a gas leak detection.6 precision pressure gauge should be used for pressure measurement. 2. For this purpose. and the leakage test repeated. the generator.2694 x 24 p1 + pB1 p2 + pB2 V = ——————— . A class 0. The test pressure should be equal to the generator operating pressure. welds. °C = temperature of the gaseous atmosphere at end of leakage test. Though the primary water circuit has already been leak tested.Turbogenerators Inspection To ensure trouble free operation. the internal primary water circuit should be included in the leakage test of H2 gas system. the pressure gauge in the waste gas pipe of the primary water tank should be replaced by a U-tube gauge. should be examined thoroughly. all systems should be checked and operated strictly in accordance with sound.t. The quantity of hydrogen leaking uncontrolled may amount to 12 m3 (s. m3 (see Mechanical Data) = gauge pressure within the system at beginning of leakage test. The pressure gauge in the waste gas pipe should be replaced for the duration of the test with a pressure gauge having a range of not less than 6 bar.4 m3 (s. During the test. a leak of the primary water system within the generator would be expected and must be located and repaired.————— ) 273 + t2 Z 273 + t1 Where V = loss of air in m 3 (s. During this test the stator winding should be filled with water.2694 = 273°K ——————— 1013. Any leaks detected should be repaired.p.5 m3/24 hrs = 100 dm 3/hr (s.25 mbar BHEL. If. A special connection is provided for this purpose. such as Q Q Q Q Q flange connections. The likely location of leaks. 1 Leakage Test of Primary Water Circuit The primary water circuit must be filled with water for leakage testing. screw couplings.)*/24 hrs.)* at this test. Note that only the quantity of gas leaving uncontrolled should be used for evaluating the tightness. The primary water tank should be at atmosphere pressure and the waste gas pipes closed. The loss of air is determined as follows : 0. The formation of bubbles (foam) indicates a leak. and subsequently with H2. the loss of H2 gas must be monitored continuously on the basis of H2 consumption. hrs = generator volume. VG ( ————— .

4

Leak Detection by Means of a Gas Leak Detector

If an undue loss of gas occurs on the unit, the
location of the leak must be determined. To do this, we
recommend a leak detector of the Handy-Tector type
with battery charger (product of Edwards Hochvacuum
GmbH, Frankfurt/Main, West Germany).
4.1 Description of the Handy-Tector
The equipment consists of a battery driven manually
operated leak detector with two sniffler probes (made
of stainless steel and plastic) and a battery charger.
The Handy-Tector is accommodated in a handy
case and is provided with a pistol grip. It weighs about
0.5 Kg and enable access to all components of the unit
even when locations are obstructed. Equipped with a
thermistor bridge as a sensing element it detects leaks
from which, for instance, H2 gas escapes by initiating
the difference in thermal conductivity of the gas and
the ambient atmosphere (normally air). The sensing
element is not subject to wear and cannot be overloaded,
damaged or contaminated by too high a gas
accumulation. All operating elements, e.g. indicators
(measuring range 0 to 5 with adjustment mark for battery
testing), switch for polarity reversal, On-Off switch,
key for battery voltage testing, and a potentiometer by
zero setting, are arranged in an easily surveyed and

practical manner. The pistol form allows one-hand
operation. The overall dimensions of the equipment are
150 x 160 x 65 mm. The Handy-Tector is supplied in a
portable leather case.
4.2 Handling the Handy-Tector
The sniffer probe of the Handy-Tector should be
led over the surface of the test object as slowly as
possible. Note that with a leakage gas lighter than air
the leak detection should be carried out above the object,
and with gases heavier than air underneath of the test
object.

Fig.1

Handy-Tector

* s.t.p. = Standard temperature and pressure, 0oC and
1.013 bar
2.5-0310-0500/2

Turbogenerators

Flushing the Oil Piping

Inspection
1

Measures to be Taken at Inspections, Repairs
or Checks

When opening parts of the oil systems for inspection,
repair or checking, make sure that no dirt is introduced into
the oil circuits. In the event of a contamination being
unavoidable due to the work to be performed, take care to
reduce such contamination to a minimum and perform a
thorough cleaning afterwards.
In case of more extensive inspections, it is
recommended to drain the oil, to clean the oil coolers, the
oil tank and the bearing compartments in the same way as
for initial operation of new plant, and refill the oil via filters.
After each inspection, the oil system should be subjected
to a short flush. It is recommended to install screens in the
throttle valves and to perform flushing for 12 hours. On
completion of this flushing procedure, all filters and screens
should be cleaned again.
If the oil piping must be flushed the following procedure
should be used.
2

Preparation of Bearing Compartments

1
1
2
3
4

3

Q

Q

4

Flushing Oil
The oil used for flushing must be provided by the user

BHEL, Haridwar

4

Oil Drain at Generator Bearing

and oil supplier as laid down in the generator manufacturer’s
oil specification. In this connection, it may become necessary
to consult the turbine manufacturer too.
The following methods are possible :

Preparing the Lube Oil System for Flushing

During flushing, the highest possible oil velocity is to
be maintained in the pipes.
When the bearings are installed, make sure that no
contaminated oil is introduced between shaft and babbit.
To do this, remove the upper half bearing sleeves and fit
temporary oil drain pipes to the inlet openings of the lower
half sleeves. Remove the valve cones from the permanently
adjustable throttle valves before the bearings and insert
the flushing screens supplied with the throttle valves. Make
sure that the hoses of the shaft lift oil system are not
connected to the bearings, as otherwise contaminated oil
will be admitted to the bearing journal.

3

Oil drain
Bearing saddle
Seal
Bearing sleeve

Fig. 1

Prior to commencement of the flushing procedure, the
bearing compartments should be cleaned carefully. If any
reworking has been done in the bearing compartments
(e.g. drilling), the chips should be removed by means of a
magnet. In addition, the bearing compartments should be
cleaned with lint-free rags (never use cotton waste). The
cleaning agents used should leave no residue. After
cleaning, the bearing compartments should be subjected
to a thorough visual inspection.

2

5

Use of the same oil grade for both flushing and
operation. On completion of the flushing procedure, oil
samples should be taken and analyzed to decide
whether the flushing oil charge can be used as service
oil change after treatment by the oil supplier.
Use of an oil grade intended for use as flushing oil
only. Its properties, particularly its viscosity, are
matched to the special application. The oil charge is
completely drained on completion of the flushing
procedure and replaced by a new service oil charge.
The properties of the service oil and flushing oil must
be suitably matched.
Flushing Procedure

Flushing all bearing oil lines and all shaft lift oil pipes
of the generator should be performed in conjunction
with the turbine according to the instructions issued for
the turbine.
During flushing, the oil lines should be hammered
regularly to remove dirt particles from the walls. During
the last third of the entire flushing period, the screens
2.5-0320-0500/1
0709 E

should be temporarily installed in the throttle valves
upstream of the bearings for checking the dirt
accumulation.
After draining of the flushing oil, remove any left dirt
deposits from the bearing compartments. Remove all
bypasses, orifice plates or blank flanges as well as the
additionally installed filters. Refit the valve cones in the
throttle valves before the bearings. Assemble the
bearings ready for operation. The hoses of the shaft lift
oil system should be connected to the bearings and

2.5-0320-0500/2

checked for tightness.
6

Supervision of Oil Circuits

After recommissioning, all screens and filters should
be replaced and/or cleaned as frequently as possible.
During commissioning, the oil should be checked for
contamination, e.g. via vent ports. In case of an extremely
high dirt content due to carbon dust, construction work,
etc., special precautionary measures should be taken.

Turbogenerators
Inspection
The high strength austenitic material used for the rotor
retaining rings, etc. is susceptible to stress corrosion if it
is simultaneously subjected to high tensile stresses and
moisture (e.g. moisture condensing from the ambient air).
If persisting for a sufficiently long period, stress corrosion
will lead to crack initiation and crack growth. Since tensile
stresses are due to the shrink fit of these components and
thus unavoidable, any prolonged exposure to moisture must
be positively prevented.
During an inspection, the individual components of the
generator are exposed to the ambient conditions which
may result in hazards to these components. It is therefore
strongly recommended to take suitable measures for
preventing any exposure to moisture, especially rain, snow,
liquids of any kind and condensation., Covering the
components will not afford sufficient protection.
To avoid the above-mentioned hazards, the assembly
work during an inspection should be accomplished under
protection from weather conditions. The generator should
only be opened if an uninterrupted execution of the work
will be ensured and provided that the necessary protective
measures can be taken. After opening of the unit and
withdrawal of the rotor, the stator openings should be
promptly reclosed. The stator should be dried by means of
a portable air dryer or fan-forced heater and kept above
ambient temperature level. The air dryer or fan-forced
heater should be arranged so that the air will circulate
through the stator interior in a closed circuit for ventilation

BHEL, Haridwar

Measures to Prevent Corrosion
During Inspections

of the entire internal space .
The rotor should be protected in such a manner that
especially the retaining ring area can be kept dry and above
ambient temperature level. The air dryer or fan forced
heater should be arranged so that the air will circulate in a
closed circuit.
Primary water circulation should be maintained also
during the inspection work, as far as practicable. The heat
loss of the pump is sufficient to keep the temperature of
the primary water and thus of the stator winding above
ambient temperature level.
The cooling water should be drained from the coolers.
The coolers should be cleaned, dried and maintained in dry
condition by suitable measures.
During inspection work on the exciter unit , it should be
observed that the devices installed as a precautionary
measure, such as anticondensation heating system and
air dryer will no longer be effective after removal of the
exciter enclosure. The required protection should be
restored by suitable measures (covers, etc.) and portable
dryers or hot-air blowers.
Normally, a condensation hazard can be recognized
with the help of dewpoint measuring device. In case of
doubt, however, it is recommended to dry the components
on a continuous basis in order to achieve a markedly low
dewpoint temperature on these components, i.e. to maintain
their temperature above ambient temperature level.

2.5-1003-0500/1
0709 E

Turbogenerators
Inspection

Preventive Measures to Avoid Stress
Corrosion
Survey

Phase

Keyword

Transport

Packing:

1

Dry rotor retaining rings and RR* wheels by blowing dry air into rotor end
windings and RR * wheels portable air dryersshortly before packing. Multiple dry
packing in sheetings with desiccant added:

Accompanying
documents:

2

Reference to special packing and request for restoration after opening due to
customs or in-transit damage.

Damage to
Packing:

3

Restore proper condition of dry packing immediately. For details, see description
accompanying the cargo.

Receiving:

4

Check effectiveness of dry packing and desiccant. Record condition in checklist.
Request for repeat checks according to checklist during subsequent storage.

Condition:

5

Maintain dry packing until immediately before assembly.

Check:

6

Monthly functional check of dry packing and desiccant according to checklist.

Storage area:

7

Indoor storage in dry building; outdoor storage in seaworthy packing, under shelter
protected against precipitation/ground moisture.

Outdoor
installation:

8

Transport to job site in dry packing. Acclimatization in dry packing to avoid condensation after unpacking.

9

Installation under shelter. Removal of dry packing from retaining rings (1 st layer) as
late as possible.

Storage

Installation

Open generator
rotor installed:
Ready for
Operation
(standstill
or turning
gear
operation)
Sched.
mainten.
Without
removal
Sched.
mainten.
with
rotor
removal

Precautionary Measure and Checks

10 With danger of condensation (outdoor installations and open power house), blow
dry air from portable air dryers into rotor end windings and RR * wheels

Generator closed, 11
filled with
H2 gas:
Exciter unit
in enclosure

Outdoor
installation:

H2 –cooled generators:
Pass small cooling water flow through H2 cooler to ensure that cooler is coldest
component in the generator (condensation hazard!).

12 RR* exciter units:
Drying process with stationary or mobile air dryer.
13 Generator closed: Measures as under “Ready for operation”
14 Generator open: Shelters must prevent precipitation from entering the generator;
the retaining ring areas must be covered and kept dry by supplying dry air.rotor

Indoor
installation:

15 If rotor is set down in dry power house with even temperature, it is sufficient if the
entire rotor is covered against dirt and wetness. If danger of condensation, the rotor
areas between the bearing journals must be provided with dry packing.

Outdoor
installation:

16 Set down rotor under shelter and provide rotor areas between bearing journals with
dry packing

* RR = Rotating rectifier

BHEL, Haridwar

2.5-1005-0500/1
0709 E

Turbogenerators

Inspection Schedule
Foreword

Inspection
Preventive maintenance of generators serves to
avoid major problems or damage while the unit is in
service.
Apart from its scope, the timing of an inspection is
important. To account for the deterioration and stresses
due to different modes of operation, both the number of
operating hours and the number of starts are used as
criteria determining the intervals between the
inspections.
The intervals recommended in the following are the
same as those indicated in the VDEW Recommendations
for intervals between Generator Inspections (published
by Vereinigung Deutscher Elektrizitatswerke – VDEW
– e.V. in 1980). This Foreword contains a large number
of extracts from the VDE Recommendations.
The guiding values given in the VDEW
Recommendations are to assist the power plant owners/
operators in scheduling inspections, taking into account
also own experience on the performance of their
generators and that of sister machines.
1

Types of Inspections

Depending on the scope of work, a differentiation is
made between initial inspection, minor inspection and
major inspection.
Type

Feature

Duration

where
Tequiv
Tact
ns
Ts

=
=
=
=

equivalent operating hours
actual operating hours
number of starts
additional number of operating hours to be
considered for one start. According to the
present state of knowledge 20 hours
account for one start of a turbogenerator.

The recommendations given in the following apply to
normal operation without major disturbances. Abnormal
disturbances, such as close-in system faults, faulty
synchronizing, asynchronous running and inadmissibly high
unbalanced load, may necessitate shortening of the
respective inspection interval or an immediate check.
When scheduling inspections, also consider the
following factors :
Wear and deterioration of components.
Deterioration of running behaviour.
Q Frequency of load rejections associated with overspeed.
Q Earth faults or interturn faults in generator field circuit.
Q Hydrogen, water or cooler leaks.
Q Change in coolant flow rates.
Q Fouling of air-cooled generators.
Q Deterioration of shaft insulation.
Q Inherent fault (recognized deficiency in comparable
machines or components).
Q
Q

Initial
Inspection

Extensive checks, incl.
removal of rotor

Approx.
6 to 9 weeks

Minor
Inspection

Specific checks and
maintenance without
removal of rotor

Approx.
1 to 3 weeks

With proper performance of the generator and provided
that the inspection findings obtained by the preceeding
inspection(s) have been favourable, the intervals between
inspections may be lengthened within reasonable limits.

Major
Inspection

Removal of rotor

Approx.
6 to 9 weeks

3

Table 1

Recommendations for Scheduling Inspections
It is recommended to perform the initial inspection after

Types of Inspection

The initial inspection is the first major inspection of the
generator involving the removal of the rotor and is an
essential prerequisite for assuring high reliability on a longterm basis. The scope of work and checks to be performed
should be agreed upon with the manufacturer in good time.
The date of the initial inspection should be determined under
due consideration of changes that are likely to occur after
a relatively short service period.
The time periods given are guiding values. Depending
on the scope of the planned work of inspection findings,
the inspection period is either shortened or lengthened.
2

Influences
Scheduling of the initial inspection and of the
subsequent inspections mainly depends on the number of
operating hours and on the number of starts. Both
influences are considered in the parameter equivalent
operating hours.
Tequiv = Tact + ns . Ts

BHEL, Haridwar

10,000 h < Tequiv < 20,000 h
equivalent operating hours and to observe an interval of
40,000 h < Tequiv < 60,000 h
equivalent operating hours between two major inspections.
It is recommended to perform minor inspections, i.e.
specific brief checks and maintenance work, during the
service period between major inspections. When
scheduling minor inspections consideration has to be given
not only to the technical requirements of the generator but
also to those outage periods of the unit that are not
attributable to the generator.
Scheduling of the initial inspection is primarily dictated
by the state of the art embodied in the end winding and
stator slot support systems. The synthetic and insulating
materials used in generator manufacturing tend to develop
plastic flow (creep) under the influence of pressure and
temperature, especially during the initial period after

2.5-1010-0500/1
0709 E

Operating duty

Tact

ns

ns. Ts

Tequiv

hours

Starts/year

hours

hours

A Continuous/base load

7000

10

200

7200

B Continuous/occasional peak load

4000

100

2000

6000

C Peak load (abt. 1 start/day)

2000

300

6000

8000

D Peak load (abt. 2 starts/day)

1000

500

10000

11000

Table 2 Equivalent Operating Hours T equiv for One-Year Operation With Different Operating Duties

commissioning. The resulting setting and looseness can
be corrected during the initial inspection. Any deficiencies
due to manufacture, assembly or new design can thus be
identified and eliminated at an early date.
The specified interval between major inspections is in
accordance with the present state of the art in generator
engineering.
The special stresses attributable to each start or
shutdown of the unit are considered in the equivalent
operating hours Tequiv of the generator which account for
the number of starts (n s). These stresses include :
— effects of expansion and friction on winding and
insulation due to thermal and centrifugal force cycles.
— special vibratory forces arising when passing through
natural frequencies of various generator components.
— material fatigue, especially of rotating parts, resulting

from the centrifugal force cycle.
The additional number of 20 operating hours to be
considered for one start (Ts) has been determined by an
agreement reflecting the present state of knowledge.
4

Inspection Schedule
All important maintenance activities required for
maintaining the generator and its auxiliaries in proper
condition are listed on the following Inspection Schedule
pages.
If the work required in each case is performed at the
specified intervals, major financial losses and prolonged
outages can be minimized, the result being a high availability
of the generator.

Actual operating hours Tact (103 Hr)
Fig.1 Typical equivalent operating hours of Turbogenerators
2.5-1010-0500/2

Turbogenerators
Inspection

0

2000

4000

6000

8000 Hrs

Fig.2 Graph for Determining the Equivalent Operating Hours of Turbogenerators

BHEL, Haridwar

2.5-1010-0500/3
0709 E

BHEL.Turbogenerators Initial inspection Minor Inspection Major inspection Inspection Inspection Schedule Stator Measure insulation resistance of stator winding x x x Stator winding insulation x x Dismantle stator end shield and replace gaskets x x work required Dismantle bushing compartment and replace all gaskets x* Dismantle bushings and replace gaskets x* Check condition of stator core x x Check slot wedging system and end winding support structure x x Check coil connections (preloading.5-1020-0500/1 0709 E . voltage drop) x x* Replace all generator flange gaskets x x Replace all gaskets on water-carrying parts x* Replace seals on teflon hoses of primary water system x* Replace all gaskets of casing penetrations x* Check teflon expansion joints x Clean filters in primary water circuit x x x x Check balancing orifices in phase connector x* Check strainers at phase connector flanges x* Leakage test of primary water system x x x Leakage test of H2 system x x x * Normally required only at every second major overhaul 1) Dissipation factor measurement. charging and leakage current measurement. Haridwar 2. and. high potential test. in particular cases.

5-1030-0500/1 0709 E .Major inspection Work required Minor Inspection Inspection Inspection Schedule Rotor First Inspection Turbogenerators Perform runout check x x Withdraw and check rotor x x Perform ultrasonic testing of rotor retaining rings x x Check rotor wedges and retaining rings x x Check end windings and gas outlet ducts x x Measure insulation resistance of rotor winding x Check bearing surfaces x x Check shaft seal contact faces x x Check rotor fan x x Check coupling flanges x x Check rotor alignment x x BHEL. Haridwar x x 2.

check and clean water and air sides. if required. if required. if required. check water and oil sides. recondition exciter cooler water channels x x x Dismantle exciter coolers. replace gaskets and perform pressure tests x Seal oil Cooler Clean seal oil coolers on water side x x x Check condition and. if required. clean. recondition water channels of primary water coolers x x x Dismantle primary water coolers. BHEL. Haridwar 2. vent pipes. replace gaskets and perform pressure tests x Exciter Cooler Clean exciter water coolers on water side x x x Check condition and. recondition H 2 cooler water channels x x x Work required General Hydrogen Cooler Dismantle H2 cooler. replace gaskets and perform pressure tests x Primary Water Cooler Clean primary water coolers on secondary water side x x x Check condition and.5-1040-0500/1 0709 E .Turbogenerators Initial inspection Minor Inspection Major inspection Inspection Inspection Schedule Coolers Check cooling water inlet and outlet pipes. check and clean primary and secondary water sides. if required. replace gaskets and perform pressure tests x Note: No cleaning on water side is required on coolers supplied with condensate. if required. recondition seal oil cooler water channels x x x Dismantle seal oil coolers. clean. drain pipes and mounting of all coolers x x x Check condition and performance of temperature and pressure measuring devices at all coolers x x x Clean H2 on water side x x x Check condition and. check water and oil sides.

replace bearing insulation x x Check bearing surfaces and babbitt bonding x x Check bearing clearances x x Check seating of bearing sleeves on bearing saddles x x Check labyrinth rings and. if required. replace seal strips x x Check condition and performance of bearing temperature monitoring system x x Check condition and performance of shaft lift oil system x x BHEL. Haridwar 2. if required.5-1050-0500/1 0709 E .Major inspection Work required Minor Inspection Inspection Inspection Schedule Bearings First Inspection Turbogenerators Check and .

Major inspection Work required Minor Inspection Inspection Inspection Schedule Shaft Seals First Inspection Turbogenerators Check shaft seal insulation x x Replace shaft seal insulation and gaskets x x Check sliding contact faces of seal rings and seal ring carriers x x Check contact faces of seal rings x x Check seal rings clearances x x Check inner labyrinth rings and.5-1060-0500/1 0709 E . Haridwar 2. if required. replace seal strips x x BHEL.

replace gaskets x x x Check condition and performance of measuring devices x x x Check condition and performance of level monitoring system (oil level).Turbogenerators Work required Seal oil pumps and Perform functional check × × × Check coupling × × × × × Regrease bearings of drive motors drive motors Major inspection Initial inspection Inspection Minor Inspection Inspection Schedule Seal Oil System (1) Replace bearing of drive motors × Replace gaskets of seal oil pumps × Replace antivibration pads ×* Check control and safety valves (including float valves) x x x Replace control valve bellows x x x Check all valves x x x Replace valve inserts x Replace gaskets in and at valves x Replace complete flange gaskets ×* Check and clean seal oil filters.5-1071-0500/1 0709 E . Haridwar 2. check sight glasses x x x Perform functional check of complete seal oil system x x x Check seal oil flows of individual shaft seals (at rated gas pressure and n=50 s-1 and n=0 s-1) x x x Perform functional test of bearing vapour exhausters x x x Check drain in vent gas line of bearing vapour exhausters x x x * (1) Normally required only at every second major inspection Regrease bearings after 8000 operating hours at the least BHEL.

Haridwar 2. heater and fan) x x x Replace gas dryer desiccant (replace cover gaskets) x Replace PTFE sleeves in multi-way valves x* Replace flange gaskets of gas dryer x Replace gaskets and coating of CO 2 flash evaporator x Check condition and performance of CO 2 flash evaporator x x Replace dust filter in gas purity meter system Check complete gas system for leakages * x x x x x Normally required only at every second major inspection BHEL.5-1072-0500/1 0709 E . operation) x x x Work required Replace valve gaskets and inserts x Replace flange gaskets x* Check condition and performance of measuring devices x x x Perform functional check of gas dryer (leakages.Turbogenerators First Inspection Minor Inspection Major inspection Inspection Inspection Schedule Gas System Check condition and performance of all pressure reducers x x x Check performance of all valves (leakage.

Haridwar 2. if required) x x x Perform functional check of fine filter x x x Replace Micro-Clean cartridges in fine filter x x x Check shutoff valves and non-return flaps for leakage x x x Perform functional test of valves and. clean NaOH tank in alkalizer unit x x x Check feed valve in alkalizer unit for tight shutoff x x x Check cable and pipe conduits in NaOH tank for firm attachment x x x Replace diaphragm pump * 1) 2) x Normally required only at every second major inspection Change Bearing oil in pump casing at intervals of 3000 operating hours Regrease antifriction bearings of drive motors at intervals of 8000 operating hours BHEL.Work required Primary water pumps Major inspection Initial inspection Inspection Inspection Schedule Primary Water System Minor Inspection Turbogenerators Functional check × × × Check coupling × × × Change bearing oil in pump casings 1) × × × Regrease bearing of drive motor 2) × × Check and.5-1073-0500/1 0709 E . if required. if required. if required. replace wearing parts x Replace valve stuffing boxes x* Check condition and performance of all measuring and supervisory devices x x Replace all flange gaskets x x* Check complete primary water system for leakage x x x Inspect and. replace bearing of drive motors and pumps × × Replace bearings and oil seal rings of drive motors and pumps × Replace sliding-ring glands of pumps x x Check and clean main filter x x Perform functional check of ion exchangers (replace resins.

Haridwar 2.Check condition and performance of temperature gauges and alarms x x Replace gaskets at temperature measuring points Major inspection Work required Minor Inspection Inspection Inspection Schedule Generator Suppervisory Equipment First Inspection Turbogenerators x x* Check condition and performance of level meter system (liquid level alarm switches) x x x Check condition and performance of grounding brush x x x * Normally required only at every second major inspection BHEL.5-1080-0500/1 0709 E .

g. replace x x Replace Multicontact-strip x* Check alignment x x Check bearing and pipe insulation x x Replace bearing and pipe insulation x* Check bearing surface and babbitt bonding x x Check bearing clearances x x Clean seating of spherical portions of bearings x x Check labyrinth rings and. Haridwar 2. using liquid leak indicators (e.Turbogenerators Initial inspection Minor Inspection Major inspection Inspection Inspection Schedule Excitation System Check radial bolts for H2 leakage 1) x x x Dismantle exciter x Check insulation resistances of windings x Work required x x Replace fuses x x Check condition and performance of rectifier wheels. if required. DIPROL) is not permitted.5-1090-0500/1 0709 E . BHEL. To be performed before H2 removal. replace seal strips x x Check air filter x x x Check condition and performance of measuring devices x x x Check condition and performance of ground fault detection system x x x Clean prefilter for exciter dryer and replace if required x x x Perform functional test of emergency cooling flaps x x x Check emergency cooling flaps for tight closing by in-service pressure measurement x x x * 1) Normally required only at every second major inspection. if required. check stator and rotor windings x x Check coupling flange x x Check contact pin and Multicontact-strip and.

the insulation resistances of the stator and rotor windings should be measured and the windings dried. and the exciter drying system should be kept in operation continuously. The stator and rotor windings should then be protected against moisture by maintaining the generator interior at a moderate temperature or in dry condition by suitable means. High relative humidity in combination with severe temperature changes involves the risk that the temperature of certain surfaces in the generator may drop below the dew point. special measures may be required for preservation of the rotor retaining rings and rectifier wheels [1]. However.5-1100-0500/1 0709 E . 1 Generator Interior The hydrogen gas should be removed from the generator. For cooler drying. on the overall conditions in the vicinity of the unit and on the extent to which checks and inspections are possible during such period. resulting in the possible formation of a moisture film due to condensation on these generator components. with monitoring and maintenance to be performed in accordance with the information given in the turbogenerator manual. During the weekly activation of the seal oil system for turning the shaft. 5 Bright Components All accessible bright components. the shaft should be operated on the turning gear for approximately three to four hours. should be protected with a suitable corrosion inhibiting oil or grease. the primary water system should be placed into operation or kept in service. hot air or dry ambient air may be used which should be admitted by means of blowers via the cooling water inlet/outlet flanges. the cooler should be drained. In such a case. During the outage. No additional measures are required. The supply of water to the bearing oil and seal oil coolers is not required during this period. All valves in the gas system should be closed. dried and maintained in a dry condition. 7 Primary Water System After completion of the assembly or following a prolonged shutdown of the unit.g. The preservation measures recommended in the following are sufficient under normal conditions. Haridwar Packing Transport and Storage of Generator Rotors 2.Turbogenerators Inspection Preservation measures will have to be taken when a water-cooled generator is to be shut down. 2 Bearing and Shaft Seals No preservation measures are required on the bearings of the turbogenerator and exciter and on the H2 shaft seals. e. for instance. the air should be admitted and discharged via branches at the exciter and turbine end manhole covers Prior to recommissioning the generator. Measures for Preservation of Generator During Standstill 3 Coolers All coolers should be drained on their water sides and dried by suitable measures. After activation of the oil systems. Also refer to the following information [1] 2. no preservation measures are required on the coolers of the seal oil system. the system should be inspected for proper functioning by checking all operating values. exposed shaft portions. be achieved by the provision of a hot air blower or dryer. Caution : Never leave water-filled coolers standing idle for several weeks.g. The carbon brushes should be lifted off and the sliprings covered with oiled paper. This may. Tectyl. If additional blowers are used for drying. The generator interior can also be maintained in a sufficiently dry condition by keeping the primary water system in operation as mentioned under Item 7 with activated primary water heating system.5 – 0030 BHEL. e. the drains and vents should be kept open. 4 Exciter The exciter should be protected against the formation of a moisture film due to condensation To do this. if provided. if required. 6 Seal Oil and Gas Systems Except for the work already mentioned. The scope of the preservation work required depends on the duration of the shutdown. No additional blowers are then required. A fan-forced heater with a rating of 1-2 kW has proved satisfactory for this purpose. the bearing and seal oil systems should be placed into operation once a week and the entire system adequately flushed with water free oil.

Depending on the scope of the inspection. This should include both the electrical metering connections and the pipe connections to the measuring instruments. the interior should always be inspected for contamination of any kind. Prior to recommissioning. The generator interior should be cleaned thoroughly. All primary water hoses and pipes should be checked.5 – 2310 BHEL. improved.5 – 2300 [2] 2. its cause should be determined and corrected in order to preclude any new contamination. the insulation resistance of the stator winding should be measured and. if necessary. the slot wedges should be checked for proper seating. [2]. After opening the generator. The seating of the end windings should also be checked. The bushings and expansion joints should be inspected to ensure a proper connection between the bushings and the phase connectors. if possible. The stator should be checked for tight anchoring to the foundation. Also refer to the following information [1] 2. When dismantling of the hydrogen cooler is required for inspection. the insulation resistances should be measured prior to carrying out the inspection [1]. If contamination is detected.5-2000-0500/1 0709 E . leaving the generator filled with primary water.5 – 3300 [3] 2.Turbogenerators Stator Inspection After each shutdown. The bushings should also be checked for proper connection to the bus bars arranged external to the generator. All stator flanges should be checked for proper alignment and seating. All metering connections should be checked for proper mounting and condition as far as practicable. Haridwar Insulation Resistance Measurement on Stator Winding Insulation Resistance Measurement on Rotor and Exciter Windings Drying the windings 2. [3]. the cooler wells in the stator frame should be checked for cleanliness.

3 Breaking the Cemented Joints Cemented joints which are to be broken should be placed in a bath of either dimethyl-formamide for a brief period or ethylacetate for a longer time. The maximum storage time at room temperature is six months. Defrost Sicomet prior to use and bring to room temperature. 2 Preparatory Work and Application of Adhesive 2.2 Pattex Pattex cannot be used for cementing together gaskets because of its low temperature stability (50°C max. 1 Cementing of a Profiled Gasket BHEL. Repeated freezing and defrosting does not affect the bonding properties.1 Sicomet 50 Profiled gaskets should preferably be cemented together by means of Sicomet one-component adhesive.) and insufficient oil resistance.2 Cementing the Joint The adhesive should be applied in drops on the joint areas to be cemented together. To prevent an increase in viscosity and discoloring of the adhesive Sicomet is best stored at a temperature of –10°C. Warning : Sicomet should only be used in well ventilated work areas. rinse immediately with ample amounts of distilled or potable water to dilute the adhesive. The eye should then be treated to sooth any inflammation and a physician immediately consulted. its only disadvantage being the difficulties encountered in storage. any cement residue should be removed from the outer surface of the bonded joint by means of emery paper. In the event of contact with the eye. 2. resulting in swelling. If stored under these conditions. The joint faces could be cut so that the overlapping portion to be cemented is approximately 30 to 40 mm long. When cutting take care that the profiles does not suffer any visible distortion and that the pressure applied after pulling together the part to be mounted is exerted on the area of cut (see arrow in Fig. heat and sunlight and should therefore be stored in a dry.Turbogenerators Cementing the Joints of Profiled Gaskets Inspection 1 Survey of Adhesives 1. 30 to 40 mm Fig. Care must be taken to avoid body contact. Because of the short curing time of 10 to 30 sec. cool and dark place.1 Preparatory Work The exact length of profiled gasket is determined by inserting it in the center of the sealing groove. 1. rubber cement.5-2120-0500/1 0709 E . allowing 30 to 40 mm in length for overlapping at the joint. The use of other adhesives. The faces to be cemented together should be well roughened. is likewise not permissible. 1). After curing. Sicomet should be protected from moisture. 2. using a plastic or metal spreader for obtaining a thin film Immediately afterwards the joint faces should be assembled and located in position. as. This adhesive meets all requirements. any readjustment will be almost impossible. Sicomet has an unlimited working life. The adhesive not used up must be stored at a temperature of –10°C immediately. Haridwar 2. for instance.

Wipe the mating flange surface of the generator frame with bonding agent too. the sealing compound starts to thicken and will have completely solidified after 3 to 4 hours. the prepared mixture is usable for about 1 to 1½ hours. Following this period. Immediately before mounting the respective lower half end shield. The lower half end shield should then be carefully mounted. Haridwar 2. These should be mixed in a ratio of 100 g silicone compound S to 3g hardener TL. At a temperature of +20°C. 2 Sealing Compound The recommended sealing compound is silicone compound S with hardener TL. lint free cloth.1 Preparing the Sealing Compound Mixing of silicone compound S and hardener TL in the above-mentioned ratio should be done in a clean and completely dry container.5-2160-0500/1 0709 E . the surfaces to be sealed should be wiped with a bonding agent using a clean.Turbogenerators Inspection 1 General The joints of the end shields and their flange surfaces toward the generator frame are sealed gastight with profiled gaskets. 5 Mounting the Upper Half End Shield Suspend the upper half end shield from the crane and wipe its flange surface with bonding agent within the range Mounting the Upper Half End shield BHEL. 2. 4 Mounting the Lower Half End Shield Prior to attaching the lower half end shield to the generator frame. A thick coating of the compound should be brushed on the surfaces previously treated with bonding agent. Experience has shown that an additional sealing compound must be applied in order to obtain a gastight seal at the Tee-joints of these packings and at the flange surface of the seal ring carrier. wipe the flange surface with bounding agent over a width of 100 mm at the location of the agent. any surplus seating compound should be removed with of a knife. paying particular attention to the gasket. 1 Sealing Generator End Shield Joints 3 Bonding Agent Prior to applying the sealing compound. scraper or similar device. silicone compound S and hardener TL should be thoroughly mixed using the ratio mentioned earlier. After curing. Fig.

2.of the joint over a width of 100mm at the location of the gasket. The gasket projecting slightly from the joint in this plane as a result of the contact pressure established by bolting the end shield halves together as well as any surplus sealing compound should be cut flush with the flange surface with a sharp knife.5-2160-0500/2 Caution : Any spaces coming into contact with turbine oil must not be contaminated with silicone compound. 3 Gasket in Lower Half Stator End Shield With Retaining Device Note : Detaching the flat iron bar and cutting flush the gasket should be done immediately prior to mounting the respective seal ring carrier. After lowering the upper half end shield. 2 Upper Half End Shield Lowered in Position 1 2 1 1 2 3 4 5 6 2 3 4 5 6 Inner labyrinth ring Gasket Shim. . 4 Retaining Device for Gasket Fig. Should this happen. Following this. Wipe the mating flange surface of the generator frame with bonding agent too. Upper half end shield Retaining device for gasket Joint bolt Lower half bearing Rotor shaft Fig.The upper half end shield should then be carefully mounted. 2. Apply a thick layer of ready mixed sealing compound on the surfaces previously treated with bonding agent. but prior to bolting the end shield joint. the joint 1 2 3 4 5 1 2 3 4 5 surfaces of the lower and upper half end shields should be wiped with bonding agent within the range of the Tee joint and within the range of the flange surface for the seal ring carrier over a width of 100 mm. the area should be cleaned with extreme care after the sealing compound has cured. paying particular attention to the flange and joint gaskets.3 and 4). secure the gasket in place with a flat iron bar to be attached with a 3 mm shim for spacing. Experience has shown that the gasket will be forced out if seal ring carrier is not mounted immediately. 3 mm Flat iron bar for gasket Mounting screw for retaining device Lower half end shield 1 2 3 4 5 6 3 4 5 6 Lower half end shield Gasket Mounting screw for retaining device Flat iron bar for gasket Lower half bearing Rotor shaft Fig. If this is not done the gasket will be forced out too far at the mounting face of the seal ring carrier during bolting of the end shield joint (see Figs.

e. 1 Diagram for Correction of insulation Resistance Measured to a Temperature of 40 o C BHEL.g. drying of the windings will be indispensable. The windings should also be grounded after each measurement for the duration of the recharging period. Haridwar The water manifolds for the cooling water are insulated for 5 kV against the frame and connected outside the generator via cables to the insulated contacts. During the test. insulators at bus duct or terminal bushings. Prior to primary water filling. The insulation resistance of the stator is measured between the winding copper and the stator core. If the insulation resistances of the individual phases are likewise lower than the required limit value.Turbogenerators Insulation Resistance Measurements on Stator Winding Inspection During manufacture and transport. If required. To enable. the neutral connections must be separated and the insulation resistances of the individual winding phases measured. a measurement of the insulation resistance. 2. the required conductivity being < 1 µmho/cm. 2 Measurement of Insulation Resistance Prior to each measurement. the other two phases which are not involved should be grounded. 1 Required Insulation Resistance of Stator Winding The insulation resistance measured is dependent on the temperature. nevertheless. it is recommended to obtain the services of a specialist from the manufacturer’s work. a correction to an agreed reference temperature (formerly 75oC) must be made. During measurements. the primary cooling water must be flowing. the generator should be dried until a sufficient insulation resistance is obtained. To permit a proper assessment. the winding bars are electrically connected to the grounded cooling water manifolds through the water in the water inlet and outlet hoses. The bushing hoses are provided with contact sleeves. a determination of the insulation resistance according to the known methods is no longer practicable. the insulation resistances of the individual stator winding phases with respect to the steel part should be measured by means of a 2. additional connections should be separated. During normal operation. New international standards specify an insulation resistance of not less than 1 megohm per each kilovolt of rated generator voltage at 40oC.5 to 5 kV megger. the insulation of the stator winding may have been exposed to moisture which would reduce the insulation resistance of the windings. During normal operation. the generator must be deexcited and any static charges removed by grounding the windings. and thus grounded. these contacts are connected to the frame. An insulation resistance of 1 megohm per each kilovolt of rated voltage at 75oC is normally attainable without any difficulties. A correction of the insulation resistance measured at 10000 5000 3000 2000 Insulation Resistance R in megohm 1000 500 300 200 100 50 30 20 10 5 3 2 the winding temperature prevailing during the measurement to the above reference temperature can be made using the diagram in Fig.5-2300-0500/1 0709 E . If the insulation resistance measured is lower than the specified minimum value. If practicable. this turbogenerator with water| design cooled stator winding incorporates the following features: Q 1 0 20 40 60 80 100 120 140 160 Temperature in oC Q Fig. The insulation resistance should therefore be measured prior to initial startup. after prolonged shutdowns and after work on the windings. If this measure does not result in an improvement. Great differences in the insulation resistance values are indicative of local contaminations. Because of the considerably lower resistance in the hoses.1.

Q After measurement. Stator winding connection and terminal arrangement as shown in the diagram are schematic only and may not match exactly with the machine. joined to the contact sleeves and connected to the same power source as the windings. the water manifolds should be grounded again via the ground contacts. Individual phases can be tested by a similar procedure. the power source is now required to supply the possibly very high partial currents via the cooling water connections. observing the negative sign. U (kV) Ω R10 = ————— = 103 MΩ I (mA) Note : When the generator is filled with hydrogen. the metering leads should be disconnected at the generator terminal strip (at stator frame) during the above test. the insulation resistance of the complete winding should first be measured by applying a positive voltage.To measure the leakage current according to Fig. During measurement. To protect the connected metering leads and measuring instruments. the water manifolds should be disconnected from ground. the measurement should be repeated with a negative voltage. in addition to the very low leakage current. For this reason. Fig. the movement of ammeter A N is connected to the positive pole of the stabilized power supply (approximately 1000V to ground).5-2300-0500/2 . the ammeter should be changed over and the current read and recorded. batteries are not suitable for this purpose. The dc voltage should therefore be obtained from a stabilized power supply. A micro ammeter should be inserted in the connection to the windings. After completion of the measurements the measuring circuit should be removed. The recharging current is the mean value of the tests performed with positive and negative voltage. make sure that the rotor shaft ends are properly grounded during measurement and discharging. In such a case. The measuring circuit is shown in Fig.2. Note : Current may pass through zero. The insulation resistance (R10) is calculated from the applied voltage and the 10 minute recharging current. the currents due to any cells resulting from the cooling water in the hoses between the winding copper and the water manifolds of steel must be taken into consideration. After discharging. To determine the insulation resistance of water-cooled windings. 2.2. Since. 2 Circuit Arrangement for Measuring the insulation Resistance R 10 1 = 2 = 3 = 4 = 5 = 6 = 7 = G1 = G2 = G3 = B = UB = AN = IUVW= S = Stator Rotor Terminal Bushing Water manifold ground contact Generator ground connection Hose with contact sleeve Ground connection for manifolds Grounding of generator frame Grounding of TE shaft end Grounding of EE shaft end Stabilized power supply Voltmeter Ammeter Current to winding Switch Note: Q The primary water must flow through the winding during the measurement. Temperature detectors may be installed in the ringshaped water manifold.

5-2310-0500/1 0709 E . after operation of the differential or ground fault detection system the insulation resistance should be checked for a lowresistance ground fault with a megger. In the event of a prolonged shutdown of the generator it is preferred that the hydrogen be retained in the generator. thereby eliminating surface moisture on the windings. The resultant temperature prevents condensation of new moisture of the windings. Any reduction of the insulation resistance during transport. e. Should it become necessary to check the insulation resistance of the stator windings. the primary water pump should be kept in service and the winding temperature maintained at a value above ambient temperature. Haridwar Drying the Windings the stator winding. The circulation of the water with closed primary water coolers will result in a slight temperature rise of the primary water and also of BHEL. erection or a prolonged shutdown is mostly caused by the formation of a moisture film on the surface of the insulation. This should eliminate moisture problems. 2. Such a moisture film can be prevented or removed by inserting one forced air heater (approximately 2 kW) into each of the two end shield compartments of the open machine via the respective manhole covers.Turbogenerators Inspection The epoxy resin insulation used for the stator windings absorbs practically no moisture. The generator interior can thus be heated to a temperature slightly above the ambient temperature. This will provide for adequate drying of the stator and rotor windings. The primary water pump should also be kept in operation when the generator is at rest in order to maintain low conductivity of the primary water. When the generator is again sealed.g. the windings will normally remain dry. If the hydrogen has to be removed from the generator for any reason.

1 Measuring Points To permit an assessment of the preloading.3 Permissible Slot Wedge Movements To account for the very high electromagnetic forces on generators. limits are specified for the permissible slot wedge movement which should normally not be exceeded. inserted between the slot material and the slot wedge- results in preloading forces far in excess of the pulsating electromagnetic forces.9 mm 18 bar x NB in cm x KL in cm 2 x 0.Turbogenerators Inspection 1 Function of Slot Support System The slot wedging system serves to ensure that the bars are. The measuring points should be distributed over the slot length so that a helical configuration is obtained on the stator bore circumference. 1 7 F = Test pressure a = Spring deflection N B = Slot width (equated with TRS width) KL = Length of slot wedge (equated with TRS length) Stator Slot Support System Using Top Ripple Spring BHEL. however. The required preloading force is obtained during wedging by compressing the springs. To achieve this. 1 Test Instruction for Stator Slot Support System With Top Ripple Springs - compensates for shrinkage (setting) of the slot material by providing for resilience. They include adequate safety margins for preloading and resilience to ensure 2. Haridwar Test Pressure F Per Wedge 1 x 0.5-2340-0500/1 0709 E . 3 Top Ripple Springs Number x Thickness 4 1 2 3 4 5 6 7 5 6 Stator core Slot wedge Driving strip Filler strip Compression strip Top ripple spring (TRS) Stator bar Fig. This means that at least every fifth slot wedge must be checked. Bar vibrations are thus permanently suppressed. However. The force which the preloaded spring exerts on the slot material can be determined by depressing the slot wedge from outside [1]. A slot wedging system using a preloaded corrugated spring of epoxy-glass-laminate. the permissible slot wedge movements specified below are very small. filler strips of the required thickness are used. 2 3 4-5 6 7 1 2 2.8 mm 10 bar x NB in cm x KL in cm 1 x 0. not less than five wedges must be checked in each slot. excluding the bonded end wedges. The following versions are possible. with the measuring points not being located side by side but staggered from slot to slot. the check should cover not less than 20 % of the total number of slot wedges. To simplify this evaluation in practice . The actual preloading of the TRS can be accurately determined from the spring characteristic by way of the spring compression measured. tight in the slots and that they are permanently protected from possible vibrations in order to avoid damage to the insulation and the bars. 2 Test Procedure 2. the so-called top ripple spring (TRS). Such forced vibration of loose bars can be caused by the pulsating electromagnetic forces. it will normally not be necessary to check all slot wedges. and remain.9 mm 30 bar x NB in cm x KL in cm 2. except for a small residual amount of the normal spring deflection of approximately 2 mm.2 Test Pressure The test pressure to be applied to a particular slot wedge depends on the thickness. The test pressure to be applied for checking must be higher than the preloading force. number and compressed area of the springs (approximately slot width x length of slot wedge).

The test record with the results of the depression check should be forwarded to BHEL for evaluation in each case.4 P e r m i s s i b l e S l o t W e d g e M o v e m e n t s A f t e r Rewedging During a rewedging operation [2].75 mm. 2. If two wedges in any slot exhibit movements of more than 0.1 mm but not more than 0. Slot wedge movement at remaining 40 % of measuring points shall not exceed 0. For test pressure to be applied. If the actual slot wedge movements measured during the next major overhaul are larger than the above guiding values. The remaining deflection determined by depressing the slot wedges permits the actual condition of the spring to be readily derived from the known stress-strain characteristic of the top ripple spring.5 – 2345 Rewedging of Stator Winding .75 mm. The individual assessment of the preloading conditions relies on a comparison of the actual spring Note : New top ripples springs must only be fitted if the existing springs are found damaged. all wedges of this particular slot shall be checked (except for end wedges) to ensure that not more than two excursions per slot exist. Q Q Q Q Slot wedge movement shall not exceed 0. Haridwar who will then issue recommendations regarding the need for rewedging under due consideration of : Q Q Q Q the specific electromagnetic forces and preloading forces the specific relaxation due to setting the statistical experience with comparable units customer’s specific requirements in respect of future inspection intervals. Slot wedge movement at remaining 25 % of measuring points shall not exceed 0.5-2340-0500/2 Also refer to following information [1] 2. If one slot wedge movement of more than 0.55 mm for not less than 60 % of all measuring points.75 mm is measured in any slot.2. 2.45 mm. the number of measuring points for this particular slot should be doubled. A residual spring deflection is required for elastic compensation of the thermal expansion of the bars in the slots. see table under item 2.5 – 2342 Test equipment for Stator Slot Support System [2] 2. the preloading of the spring is restored by inserting filler strips of the required thickness. an additional slot wedge movement of 0. the following slot wedge movements are permissible : Q Q Slot wedge movement shall not be less than 0. To enable an easier and more reliable determination of the thickness of the filler strips.3 mm for not less than 75 % of all measuring points. For slot widths of more than 60 mm. it is recommended to measure the movements of all wedges prior to rewedging.reliable bar support during the subsequent service period.1 mm is permissible to account for the elastic spring action of the slot wedges. loading with the electromagnetic force arising in the particular generator. the condition of the slot support system will be separately investigated by BHEL. After rewedging of the complete winding.

. . . bar Mean value of radial wedge movement in 1/100 mm derived from readings of two dial indicators ar thrust piece Slot No. (bar) . . . . . . . .(cm2) p = . . .5-2342 Test Equipment for Stator Slot Support System) Slot no 1 = end of phase A top bar at EE. No of springs fitted . . . 3 4 BHEL. .5-2340 Test Instruction for Slot Support System With Top Ripple Springs) Piston area AK (see 2. (cm) . . .5-2341-0500/1 0709 E . . . Test pressure F. . (cm) . . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 TE 1 2 Slot wedge No. Haridwar 5 6 7 8 EE 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 2. . .Stator Slot Support System Radial Wedge Movements Test Record Turbogenerators Inspection Project name: Sl No: Generator type No of slots * * Date of test Checked by: Deptt: Signature Radial movement of slot wedges at major overhaul Radial movement of slot wedges after rewedging mm. mm. . . . . . . Length of slot wedge KL mm Slot width NB TRS thickness . counting to be continued in counterclockwise direction) Pump pressure p = p= test pressure F Piston area AK . (see 2. .

Slot No. 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 TE 1 2 Slot wedge No.5-2341-0500/2 4 5 6 7 8 EE 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 . 3 2.

x 5 mm (part 2). BHEL. To prevent compression marks on the stator core. taking care that this size matches the radius of the stator core (part 1). Rigid pipe connections are not advisable. 1 Hydraulic System The hydraulic system consists of an oil-hydraulic jack with hand-operated pump. a mating thrust shim of fabric base laminate measuring approximately 100 x 100 mm should be provided. since the equipment must be suitable for use in the stator bore. Precision pressure gauge Dial indicator Magnetic stand Stator core Slot wedge BA AK NB KL = = = = Stator bore Effective piston area Effective slot width Length of slot wedge Fig. Haridwar 2. Place dial indicator stud to thrust piece. The connections between the pump and jack should consist of hydraulic hoses. The equipment should be of moderate size and weight for convenient use in the stator bore. 2 Mechanical System The mechanical system consists of a light metal tube of approximately 50 mm dia. 1 2 3 4 5 6 Mating thrust shim (fabric base laminate) Tube Aluminium Hydraulic jack Thrust piece Hydraulic pump Hydraulic hose 7 8 9 10 11 For exact setting of the jack pressure. 1 Test equipment * Select range depending of pressure ** Attach magnetic stand to stator core in bore. a precision pressure gauge must be provided between the jack and the pump.Test Equipment for Stator Slot Support System Turbogenerators Inspection The test equipment consists of two principal assemblies: Q Q Hydraulic system Mechanical system The test equipment was designed for use on generators of any size without any significant modifications being required and can normally be assembled from locally available standard components.5-2342-0500/1 0709 E .

see [1]. 2 Checking the Stator Slot Support System Fig. The thrust piece should match the slot width (NB) and the length of the slot wedge (KL) and must be approximately 70 mm high to ensure a sufficient resistance to bending (part 4).5 – 2340 Test Instruction for Stator Slot Support System With Top Ripple Springs [2] 2. Take the mean of the two readings and enter this value in the test record [2].The thrust piece and jack should be connected to the tube with intermediate fittings to obtain a single unit for case of handling.5 – 2341 Stator Slot Support System radial Wedge Movements – Test Record 2.5-2342-0500/2 . The hydraulic pressure is transmitted to the slot wedge through a thrust piece. Fig. The resulting radial movement of the slot wedge is measured with the dial indicators located at both ends of the thrust piece. 3 Pump Pressure The necessary pump pressure P for the check depends on test pressure F and the effective piston area Ak (in cm2) of the available jack (also see rating plate). It is calculated according to the following formula: F P = ——— [bar] Ak For test pressure. 4 Measurement of Radial Movement of Slot Wedge The device described transmits test pressure F to the slot wedge via the thrust piece. thrust pieces and jack (part 3) should be dimensioned so that the length of the device corresponds to the stator bore diameter. 3 Arrangement of dial indicators Also refer to the following information [1] 2. Tube.

18….14…..0.9… mm* …….mm ……. the number of measuring points in this slot should be doubled.1…….1. Note: If the above guiding values are exceeded. mm ….10.10…. Haridwar for advice.) If a wedge movement of more than …1...143…N/mm2 3 Specific Test Pressure PF = ……. mm is measured in one slot.5-2343-0500/1 0709 E .bar 4 Permissible Radial Wedge Movement ≤ ≤ …. If the value is exceeded at two points... who will then issue recommendations regarding the need for rewedging under due consideration of : Q Q the specific relaxation due to setting the statistical experience with comparable units BHEL. Haridwar for evaluation in any case. Haridwar in case of deviations. consult BHEL.mm* Check thickness on site. Magnetically Induced Slot Forces PB = …. Q customer’s specific requirements in respect of the future inspection intervals..90…. 2. Inform BHEL.0..Instructions for Checking the Stator Slot Support System Turbogenerators Inspection 1 Stator Slot Support System Configuration Number x thickness of top ripple springs : Slot width Slot wedge thickness * 2 (NB): (KD) …….x……. The test record with the results of the spring deflection check should be forwarded to BHEL. mm for not less than 60 % of measuring points for remaining measuring points (40 % max. Haridwar all wedges in this slot (except for end wedges) should be checked to ensure that not more than two excursions per slot exist.0.48…..

A spring replacement will be indispensable on fracture of glass cloth laminations which can be easily checked with the fingernails. Be careful to avoid damage when driving out the slot closing elements. Prior to rewedging.Nominal Value = Nominal radial movement of slot wedge = Thickness of filler strip Example : 0. 1 2 3 All parts of the slot support system. For this reason. using a felt pen. This will enable an economical and fast implementation of the rewedging work. BHEL. these being indicative of separations between the individual glass cloth laminations. the thickness of the filler strip can be separately determined for each slot wedges : Actual Value Radial movement of slot wedges measured . The permissible values specified in the test instruction [1] include considerable safety margins to ensure reliable operation during the service period until the next scheduled major overhaul. Marking should be done in accordance with the scheme specified in the test record [2]. Rewedging is done by inserting filler strips between the top ripple spring (TRS) and the compression strip to restore the preloading of the top ripple spring. can normally be reused. compression and driving strips (tied together with adhesive tape). Set down each slot wedge removed together with the associated top ripple spring and the filler. This effect has. however.85 . As a first step. Before proceeding with the removal of the remaining wedges.6 mm and more across their broad side should be replaced. lock slot material in first half by inserting auxiliary wedges with a spacing of 500 mm. and wedge No. rewedging is done by inserting additional filler strips. The results of this check are contained in the test record [2]. Wear of the top ripple spring is revealed by light discolorations at the peaks and valleys of the corrugations. Slot wedges found with a permanent deformation of 0. on its top.7 mm) 2. The TRS should only be replaced in case of very serious separations extending over its entire width and length. start at one end of the stator core and remove wedges up to mid-length of core.65 mm = (radial movement of slot wedge measured) (mean of upper and lower limit of nominal value) (approximate thickness of filler strip = 0.20 = 0. The holes for the ventilating slots in the flanks of the end wedge should preferably be provided during the actual rewedging procedure. the radial movement of all slot wedges should be measured as recommended in [1].0. The thickness of the filter strips depends on the difference between the radial movement of the slot wedge measured prior to its removal as recorded in the test record [2] and the radial movement required after rewedging as specified in [1].5-2345-0500/1 0709 E . the decision on any major rewedging should only be taken after consultation with the BHEL specialists. Haridwar Checking the Slot Closing Elements Removed Rewedging Procedure Provided that the slot closing elements removed can be reused. including the top ripple springs. In the case of units where all slot wedges were checked. In order to remove the slot wedges.Turbogenerators Inspection 1 Rewedging of Stator Winding 3 Note The need for rewedging may arise from the results of a check[1]. Replacing such a TRS will normally not be required. It is recommended to have this work performed by BHEL specialists or under their supervision. 4 4 5 6 1 Stator core 2 Slot wedge 3 Driving strip 4 Filler strip Fig. 1 2 7 5 Compression strip 6 Top ripple spring (TRS) 7 Stator bar Stator Slot Support System Removal of Slot Closing Elements It is advisable to adopt a slot-wise approach for rewedging. each slot wedge should be marked with the slot No. hardly any influence on the stress-strain characteristics of the TRS. Any end wedges found damaged should be replaced by new wedges made with the same dimensions and geometry as the original end wedges. The cemented end wedges require particular attention.

adherence to the specified radial movement may not be ensured. it is recommended to check the radial movement of the slot wedges according to [1]. Such information will be particularly useful on units where not all slot wedges were checked. After rewedging of both halves of one slot has been completed. The results will be helpful in optimizing the rewedging procedure. remove the auxiliary wedges from one half slot section between midlength of core end and then refit original slot wedges in the correct locations as marked. Then proceed with rewedging of the remaining slots. Rewedging should be started at mid-length of the core in direction towards the core ends.5-2345-0500/2 [1] 2. Proceed with the second half section by following the same procedure. This check should include not less than 20 % of the total number of slot wedges. A final check [1] should be performed after rewedging of all slots has been completed.5 – 2346 Cementing Stator Slot End Wedges . The thickness of the filler strip should preferably be determined on the basis of the mean value of the radial wedge movement in the respective slot. It is known from experience that a comparison between the force required for driving in the slot wedge and the radial movement of the slot wedge after rewedging provides information enabling the fitter to make a correct assessment of the necessary thickness of the filler strips.5 – 2340 Text Instruction for Stator Slot Support System With Top Ripple Springs [2] 2. Provided that sufficient experience is available checking the radial movement of the slot wedges will not be required after rewedging of each slot. To do this.5 – 2341 Stator Slot Support System Radial Wedge Movements– Test Record [3] 2. The filler strips corresponding to BHEL specifications. Proceed with cementing of end wedges [3] after completion of this check.If only a restricted number of slot wedges is checked (not less than 20 %). Also refer to the following Information 2.

Turbogenerators Cementing Stator Slot End Wedges at Trubine and Exciter Ends Inspection 1 General The procedure described in the following presupposes that the end wedges removed can be reused or that new end wedges have been made after the pattern of any damaged wedges.5-2346-0500/1 0709 E . Remove surplus Metallon prior to curing. or equivalent available from BHEL Haridwar.5 mm to provide reservoirs for the adhesive. make sure that no Metallon is left in ventilating slots. The resulting space should be packed with filter strips which must be cemented together and to the end wedge and compression strip for protection against displacement. Drive in end wedge. 2 5 Cementing the End Wedges Prior to driving in the end wedge (part 2) roughen surfaces of compression strip (part 7) with abrasive cloth over a length of not less than 50 mm from core end. the material is not brittle but similar to rubber. If the wedge end coincides with a ventilating slot in the core. Insert driving strip and top ripple spring. Roughen driving strip (part 3) with abrasive cloth over a length of 50 mm and brush driving strip surfaces with adhesive. When checking the installation of the end wedges. Roughen filler strips (parts 5 and 6) with abrasive cloth over a length of 50 mm on both surfaces. the end wedge should be shortened by 5 mm. Haridwar 5 6 7 8 Filler Filler strip Compression strip Top bar C D 5 6 7 8 Notes A End wedges are positioned on supporting keyway of core B Metallon bon. make sure that the end of the end wedge is positioned on the supporting keyway of the core. except for surface in contact with the stator bar. After curing. compression springmust be 10 mm longer than wedge C Cementing lower surface of compression stripto bar is not permissible D Thickness of filler (part 5) when using one top ripple spring : 1mm. leaving a clearance of approximately 3m between the end wedge and the adjacent slot wedge. brush both surfaces with a thin coat of adhesive and then insert filler strips. the adhesive has a cure time of one to two days. and apply a thin coat of adhesive. These portions of the end wedge flanks are recessed by 0. The prepared mixture is usable for approximately one hour at room temperature. 4 Preparatory Work The end wedges should be cemented to the core on both flanks over a length of not less than 50 mm as referred to the core end. The top ripple spring pertaining to the End of core Caution: If bond extends over a length of two or three core packets. Cementing the top ripple spring is not permissible. when using two top ripple springs: 2 mm 2. end wedge must be 60 mm shorter than the end wedge. Place a suitably shaped piece of Metallon on the compression strip ahead of the filler strips and the end wedge and smoothen Metallon surface. 3 Preparing the Adhesive Press equal lengths of adhesive and hardener on to a suitable base and mix to a uniform grey color. 50 mm 1 2 3 4 3 mm A B 10 mm 1 2 3 4 Stator core End wedge Driving strip Top ripple spring BHEL. Roughen recessed portion of end wedge with abrasive cloth and apply a thin coat of adhesive prior to driving in the end wedge with a mallet and hammer. Adhesive Metallon E 2082. At room temperature.

Contact grease has a grease-like. 2. pasty consistency.5-2350-0500/1 0709 E . Haridwar a cloth wetted with solvent. these should be cleaned and greased anew. 2 Treatment of Bolted Contact Surfaces Application Degrease silver-plated contact surfaces by means of BHEL. it is chemically inert and water-repellent. After this preparatory treatment. In the case of the terminal bushing make sure that the insulators never come into contact with the solvent. the contact grease improves the electrical conductivity of the contact surfaces. If greased surfaces are soiled prior to making the bolted connection. it cleans oxidized contact surfaces and protects them against corrosion. Copper surfaces without silver coating should be cleaned and degreased by means of solvent after emerypolishing. Excess contact grease should be wiped off with a clean rag.Turbogenerators Inspection 1 General The silver plated contact surfaces and the bright copper surfaces of the contact faces should be treated with contact grease primarily to fill up the gaps remaining after bolting. apply the contact grease to the contact surfaces with clean fingers in such a quantity that a little excess grease is pressed out all around on bolting of the contact faces. it does not dry up. In addition.

Careful cleaning is important so as not to damage any of the numerous insulated parts. 7 Insulation Resistance Measurement Prior to recommissioning. The coupling bolts should be inspected for proper condition. The exciter rotor should be uncoupled from the generator and a new leakage test of the central field connection performed.5-3000-0500/1 0709 E . If no H 2 gas leak is detected. use a leak detector and check coupling flange between generator and exciter rotors and field studs at rectifier wheels for gas leakage. examine it carefully. 2 Rotor Wedges and Retaining Rings If the rotor is removed. reconditioning should be carried out according to instructions from our service personnel. improved. Details are given elsewhere in this manual [1]. the insulation resistance of the rotor winding should be measured and. 3 Shaft Journals and Shaft Seal Contact Faces The shaft journals and shaft seal contact faces should be checked for grooves. The hydrogen should be purged from the generator only after completion of the leakage test. 5 Contact Pins and Plug-in Socket Strips The contact pins and plug-in socket strips should be checked for arc erosion and proper contact resistances. therefore. To do this. even if the visual inspection did not reveal any contamination.5 – 2310 Drying the Windings BHEL. Any inexpert use of compressed air involves the risk of cooling duct clogging and of damage to insulated parts. Also refer to the following information [1] 2. the exciter should be dismantled. 6 Coupling The coupling flange at the rotor should be checked both at the guide flanges and at the fitting bolt holes. the rotor should be cleaned Rotor thoroughly. recommended to make use of the services of our experienced product service personnel who will carefully remove any dirt accumulations below the retaining rings and within the range of the end windings by means of a special vacuum cleaner. Haridwar 2. Proper seating of the contact pins on the plug-in socket strips can be verified by visual examination. The wedges and retaining rings should be inspected for proper condition. If a leak is detected during this leakage test. the manufacturer must be notified.Turbogenerators Inspection 1 Leakage Test of Field Current Lead Before starting overhaul work and H2 purging. It is. if necessary. check H2 seals at the field current lead for leakage. [2]. 4 Cleaning the Rotor After each withdrawal. If any irregularities are detected.5 – 3300 Insulation Resistance Measurements on Rotor and Exciter Windings [2] 2.

1 2 Note: When the generator is filled with hydrogen.1 0 10 20 30 40 50 60 70 80 90 o Slot Temperature in C Fig. This voltage will present no danger to any of the devices in the excitation circuit. after prolonged shutdowns and after work on the winding. 1 Correction curve for Insulation resistance Measured (Rmeas) to a temperature of 40oC 2. 1 100 K Required Insulation Resistance of Rotor Winding The insulation resistance should amount to ≥ 1 megohm at 40oC. a correction can be made using the curve shown in Fig.Turbogenerators Insulation Resistance Measurements on Rotor and Exciter Windings Inspection During manufacture and transport. the insulation of the rotor winding may have been exposed to moisture which would reduce the insulation resistance of the winding. the winding capacitance should be discharged for not less than two minutes. The measurement should be performed with the measuring brushes for the ground fault detection system lifted off the sliprings. The duration of the test should be approximately two minutes.5-3300-0500/1 0709 E . the generator should be dried until a sufficient insulation resistance is obtained. make sure that the rotor shaft ends are properly grounded during measurement and discharging 10 R 40oC = R m eas x K Measurement of Insulation Resistance Prior to each measurement. At winding temperatures other than 40 oC. using a megger with a maximum voltage of 250V. Haridwar 1 0. If required. The insulation resistance should therefore be measured prior to initial startup. BHEL. the generator must be deexcited and any static charges removed by grounding the winding The insulation resistance should be measured between a slipring which is electrically connected to the rotor winding and a second slipring in contact with the shaft. After each measurement.

the BHEL specialists are in a position to determine with a high degree of probability the flaw size from the indications obtained. stress corrosion may lead to crack initiation and crack growth.Turbogenerators Inspection Austenitic retaining rings manufactured from X55MnCr(N)18k steel are sensitive to stress corrosion. Care should be taken to ensure that the winding and insulating parts do not come into contact with the paint remover. According to experience so far available. operation or outages. including repainting of the retaining rings. In addition. Approximately three days are required for preparations and execution of the examination. After completion of the examination. if persisting sufficiently long in an unfavourable environment during storage.5-3357-0500/1 0709 E . In the following the use of the ultrasonic inspection method for non-destructive examination is outlined and recommendation are given on the test procedure. Haridwar Ultrasonic Examination of Rotor Retaining Rings at Power Plant echoes. The examination can only be performed with the rotor withdrawn. the detectable flaw size is far below the critical flaw size that may result in a sudden forced rupture. The intervals at which the examination should be repeated can be the same as the scheduled inspection intervals but should be determined on the basis of the inspection facts. It is therefore recommended to subject the retaining rings to such an examination during a major overhaul involving the withdrawal of the rotor. it is recommended to repeat this examination at regular intervals. The coating of the retaining ring should be stripped with a paint remover. Openings in the pole areas and the gaps between the retaining ring and rotor body should be sealed. it is advisable to arrange for examination of the retaining rings at the power plant. In addition to preventive measures to avoid stress corrosion. 1 Purpose and Scope of Ultrasonic Examination Ultrasonic examination of the shrink-fitted retaining rings serves to detect incipient cracks and particularly those which have already grown to a dangerous size. i t i s recommended to pull of the respective retaining ring for further examination. 3 Execution of Ultrasonic Examination To perform the examination. the oil-wetted portions of the retaining ring should be degreased with a solvent. resulting in the difficulties in the interpretation of the ultrasonic indications. particularly within the range of the shrink fits and on shapes deviating from the smooth cylindrical outline. If the echoes reflected by a flaw are markedly above the spurious echo level of the inner periphery and can be interrupted as incipient c r a c k s w i t h a h i g h d e g r e e o f p r o b a b i l i t y. Based on previous experience and using special probe heads and reference blocks. When performing cleaning work care should be taken to ensure that the winding and insulating parts do not come into contact with the solvent. 2 Flaw Detection Ultrasonic examination of the shrink fitted retaining rings inevitably also involves the generation of spurious BHEL. The retaining ring should then be repainted and the rotor reinserted. Any changes detected when comparing the test results with the previous results provide useful information for assessing the integrity of the retaining rings. Such an examination is urgently required after disturbance during which the retaining rings are exposed to moisture. the rotor must be removed and supported so that an inspection is practicable on the entire circumference of the retaining ring. 2.

It is advisable. the gas side should be cleaned by means of dry and clean compressed air. The coolers should be withdrawn from their wells when more extensive inspection work is required. the hydrogen coolers should be cleaned thoroughly both on the gas and water sides. On detection of any contaminations. The cooler cleaning interval depends on the cooling water condition and is indicated when a substantial reduction of the cooling capacity is observed at the coolers. using new gaskets for reassembly. be definitely fixed only after several years of operation. The vent pipe connection in the inlet/outlet water channel should be detached for brushing of the cooler vent pipe.Turbogenerators Inspection Depending on the extent of the inspection. to have such chemical cleaning work be performed by specialist firms. The return water channel can be removed after the inlet and outlet valves at the coolers are closed. For this purpose. Whereby the tube bundle is flushed with cooling water. any dirt should be drawn off through the drain connection in the inlet/outlet water channel. This should be followed by reopening the inlet and outlet valves. the coolers should be thoroughly inspected on the gas side. the return water channel and inlet/outlet water channel of the hydrogen cooler sections should be removed. a 10% solution with the usual picking additives left in the tubes for several hours will be sufficient. Brushing of the tubes normally suffices for cleaning. the water channels and gaskets can be installed observing of the aligning marks. Haridwar 2. During a less extensive inspection. the tubes should be cleaned on the water side only. Any damage detected on the protective coast must be properly remedied prior to reassembly of the cooler. The date at which Hydrogen Cooler the next cleaning will be required can be determined at that time. The tubes are cleaned by special brushes. It is recommended to perform the first cleaning operation two months after initial commissioning. It may be possible. The water channels should then be cleaned thoroughly. After withdrawal. The smallest trace of contaminations should be removed. The intervals for cleaning can. a new flat gasket should be fitted and the return water channel tightly bolted to the upper tubesheet of the cooler section. which are moved up and down in the individual tubes of the tube bundle. For this purpose. in the event of sufficient experience not being available.5-4000-0500/1 0709 E . however. Also refer to the following information [1] TWA 57 905 Measures to prevent Corrosion damage BHEL. however. At every generators inspection. The coolers should then be installed in the generator housing. It is advisable for wet cleaning to slightly lower than the cooler water level by opening the outlet valve for a short time. After cleaning. For additional details. Care should be taken in this work so that the water channels and gaskets are not damaged and that their location is sufficiently marked for easy reassembly. no withdrawal of the coolers will be necessary. After all tubes are well brushed. that the interval between one cleaning and the next amount to several years. Any scale deposits which cannot be removed by brushing should be dissolved with a hydrochloric acid solution. After all tubes are brushed. see separate instruction [1]. when the hydrogen is left in the generator. A repetition of the tube cleaning every two months may be necessary when the cooling water is heavily contaminated.

2. which are resiliently mounted to the side walls of the cooler section. the cooler section against expands in downward direction. The flange and sealing faces and the groove for insertion of the round-cord packing should be cleaned. The cooler section should be slowly inserted into the cooler well. the lower wire rope should be removed and the section positioned over the respective cooler well opening. Gastight sealing of this tubesheet is done by a round cord packing. the compression ring should not be tightened excessively. The upper tubesheet should then be firmly bolted. requiring a gastight sliding contact between the tubesheet and the Vee gasket over the distance due to thermal expansion. For this reason. To do this. A second wire rope should be attached to the nozzles of the inlet/ outlet water channel and suspended from a second crane hook The cooler section should be brought in an upright position. serve to seal the gap between the cooler section and the cooler well.5-4100-0500/1 0709 E . 5 Sealing the Cooler Section at the Lower Tubesheet After alignment of the cooler section in the cooler well and tightening of the flange bolts at the upper tubesheet. the wire ropes should be removed and an alignment check performed at the lower tubesheet. In case these seal strips fail to perform their function. the upper and lower tubesheets and the inlet/outlet and return water channels. After the cooler section has been lowered into position. the seal strips should be thoroughly checked for proper functioning. For this section. the sections should be raised by means of one crane hoist only. since the compressed air will only raise the dirt and carry it to inaccessible locations. and then inserted into the groove. 4 Inserting the Coolers The cooler section to be inserted should be cleaned and suspended from the crane hook using the suspension device of the return water channel. the hydrogen gasket should be inserted. exercising utmost care. hydrogen can flow past the cooler section without being cooled. 3 Sealing the Cooler Section at the Upper Half Stator End Shield The round-cord packing should be cemented together in accordance with the instructions given elsewhere in this Manual [1]. Never use compressed air for this purpose. suitable wooden supports should be placed on the operating floor in order to protect the cooler sections against damage at the tilting edge and to ensure a firm footing of the section on the floor during tilting. The seal strips. as otherwise the sliding motion will be impaired and/or excessive contact.Turbogenerators Inspection 1 General Each cooler section consists of a tube bundle. 2 Checking the Generator Prior to inserting a cooler section. Gastight sealing of the lower tubesheet is done by a packing–type seal. All compartments and surfaces in the well should be subjected to a vacuum cleaner treatment. The upper tubesheet is larger than the cooler well opening and used to fix the cooler. taking care that the resilient seal strips bed against the gas baffle and that the round-cord packing is correctly positioned in the groove. the cooler well should be thoroughly checked for dirt or other foreign matter. With the cooler section in vertical BHEL. Note: During operation. The lower tubesheet is sealed but is freely movable and capable of following the differential movement of the cooler due to the different thermal expansions. Haridwar Insertion and Removal of Hydrogen Coolers position. If no second crane is available for bringing the cooler section in vertical position. Any burrs or compression marks should be removed with a smooth-cut file. There must be a uniform spacing between the tubesheet and the cooler well opening on all sides.

Bearing sleeves and shaft journals should be checked for proper condition. 2.Turbogenerators Inspection The insulation resistance of insulated bearings should be measured prior to each inspection.5-5000-0500/1 0709 E . If a low insulation resistance has been previously measured. The inspection procedure described above should be performed at all sleeve bearings of the turbine generator. If grooves are detected the manufacture should be asked for advice whether BHEL. The bearings should then be dismantled and cleaned thoroughly. the respective bearing should be inspected thoroughly for any damage by cathodic action. Haridwar Bearings the bearing may be used further.

Haridwar Shaft Seal be carefully and thoroughly cleaned. A minor inspection includes measurement of clearances and a visual examination. After dismantling.5-6000-0500/1 0709 E . A medium or full-scale inspection is automatically assumed if withdrawal of the rotor is required for which purpose the entire shaft seals will have to be dismantled and should be subjected to a close inspection. All points subjects to natural wear should be inspected closely. a medium and a full-scale inspection. all shaft seal components should BHEL. Reassembly of the shaft seals should be performed with utmost care. 2.Turbogenerators Inspection A differentiation is made between a minor. a check should be made to ensure that the seal rings are still sufficiently insulated from the stator frame. During each inspection.

All checking. Reassemble using new gaskets. be sure that all status indications and alarms function properly. When recommissioning the seal oil system. drive out cotter pin and unscrew knurled unit. signal and pressure sensing pipes should be carefully vented at operating pressure. If the performance of a float valve is unsatisfactory. Check all sliding surfaces and valve cones for damage or wear. cleaning and reconditioning work should be performed with utmost care to ensure reliable operation of the entire seal oil equipment for a prolonged period of time. 8 Thermostats and Contacts Check thermostats. Remove the main bellows and the upper and lower sealing bellows. This work should be performed with utmost care so as to avoid damage to the sliding surfaces. The scope of this work depends on what defects were detected from the date of the last inspection. The following inspection work should normally be performed : 1 Seal Oil System for damage or wear. If damage or wear is detected on the sliding surfaces. unload the compression springs. Seal Oil Filters 5 The filter to be cleaned should be taken out of service by changeover to the standby filter. Haridwar Shutoff Valves and Check Valves Inspect shutoff valves and check valves for proper operation. If necessary. disconnect the signal pipes and drain the oil. Check safety valves for proper performance on pressure gauge panel prior to installation. Clean screen inserts with a solvent. replace the valve inserts. the bushings should be replaced. Remove cover of seal oil filter and complete screen inserts. Rinse the screen inserts with clean turbine oil to thoroughly remove any solvent residue. To do this.5-7100-0500/1 0709 E . Drain the seal oil from the signal pipes. All control gear. The operating log should be checked to determine which deficiencies should be corrected at the inspection. coolers. filters. Check the sliding surfaces BHEL. 2. unload the compression spring. Base.Turbogenerators Inspection The work to be performed at an inspection is very difficult to determine in advance. contacts of pressure gauges and pressure switches for proper operation. fabric-lined supporting cylinder and screen ring can now be pulled off the magnetic strainer unit. Replace the seals if they are worm or damaged. 7 Seal Oil Tank and Float Valves Remove the seal oil tank cover and check the float valve for free movement. If sludge has accumulated. safety equipment. 2 Differential Pressure Regulating Valves Disconnect the signal pipes from the pressure regulating valves. the valve should be removed and replaced. Before removing the valve yoke. Disassemble the valve head and valve yoke. 3 Safety Valves Pressure Equalizing Valves Prior to disassembly of the pressure equalizing valves. Replace the main bellows and the upper and lower sealing bellows. 4 The safety valves should be removed and cleaned with turbine oil. 6 Pressure Measuring Points The signal pipes to the pressure gauges should be drained and flushed with clean turbine oil. the seal oil tank should be cleaned.

a thorough cleaning of the bearing interior and an inspection for wear will be required. This work necessitates a withdrawal of the armature. 2. until the grease is completely removed. The bearings should then be packed with grease of the same grade. Remove the old grease from the regreasing device and check the packing washer and seals for wear. add a small quantity of turbine oil via the oil filling plugs on the seal oil pumps to ensure proper lubrication of the shaft seal and the necessary sealing of the screws for suction. After approximately 8000 operating hours. The period will be shorter under onerous service conditions or at high ambient temperatures. the bearing vapor exhausters should be thoroughly examined. For this purpose. If the brushes are heavily worn. taking care that both sides of the cages are covered with grease so that an effective seal is obtained against the ingress of foreign matter. a grease on lithium-soap base with a drop point above 160°C is used. BHEL. the antifriction bearings of the seal oil pump motors are packed with grease sufficient to give troublefree service for a period of two to three years. Prior to recommissioning the seal oil system. Check whether the dummy pistons. Haridwar Seal Oil Pumps and Bearing Vapour Exhausters 2 Seal Oil Pumps Disassemble the seal oil pumps. replace the packing washer and seals. The motor should be disassembled and the bearings cleaned and packed with new high melting point grease or replaced by new bearings. Be sure to observe the specified order of the spring washers and spacers when reassembling the unit.5-7120-0500/1 0709 E . Measure the carbon brush wear on dc motors. the screws or the deep-groove ball bearing are worm. new carbon brushes should be installed. if required. 3 Bearing Vapor Exhausters The antifriction bearings of the exhauster motors normally require no maintenance. the motors should be dried in an oven at approximately 70°C for several hours.Turbogenerators Inspection 1 Electrical Motors of Seal Oil Pumps At the manufacturer’s works. If the insulation resistances does not comply with the related equipment manuals. followed by washing the bearing shield bore. The passages in the casing insert and the sliding rings should also be checked. The unit can then be reassembled. Measure the insulation resistances between the windings and ground with a 500 V megger. On recommissioning of the unit. measure the vacuum in the bearing compartments. After reassembly. If necessary. the bearings and the bearing covers with light petroleum to which a small quantity of oil was added. a check should be made whether the shaft turns properly in the bearings. The seal rings and gaskets should be examined for tight sealing and replaced. On expiry of this period.

The drain and vent holes in the water channels should be checked for freedom from deposits and dirt. Haridwar 2. see separate instruction [1].Turbogenerators Seal Oil Coolers Inspection After isolation of the cooling water inlet and outlet. as this would promote corrosion. Use only new gaskets when reassembling the seal oil coolers. Use tube cleaning brushes to clean the tube interior.5-7130-0500/1 0709 E . Take care that the protective coating on the tube surfaces is not damaged during cleaning. the tube bundle should be well rinsed with turbine oil inside and around the tubes to remove the last traces of the solvent. the tube bundle should be placed into a bath with a suitable cleaning fluid Cleaning by means of steam using solvents is also possible. Also refre to the following sections [1] TWA 57 905 Measures to Prevent Corrosion Damage BHEL. For additional details. the upper water channels should be removed and their position marked. The vent and drain cocks should be thoroughly cleaned and checked for proper operation. If cleaning of the tube exterior should be required. After each cleaning procedure. Make sure that all deposits in the tubes and water channels are fully removed.

Check and. Haridwar 2.Turbogenerators Gas System Inspection The work to be performed at an inspection is very difficult to determine in advance. Fill the CO 2 vaporiser with heat transfer liquid until the liquid level is observable in the riser of the expansion vessel. Disassemble the CO 2vaporiser. the following work should normally be performed. The waste gas valves should then be closed. if required. In addition. It should be noted.5-7200-0500/1 0709 E . After completion of all inspection work on the gas system. Check the gas dryer for leaks at the changeover valve assembly and.5 – 0310 Leakage Tests BHEL. including the connected equipment. The scope of this work depends on what defects were detected from the date of the last inspection. the gas system and generator should be leak tested. A check by means of a leak detector should be performed when higher pressure drops are observed at the leakage test. The gas system can be considered sufficiently tight when the pressure drop during a 24 hour test with compressed air does not exceed 0. that these values exclusively apply to the gas valve rack and the connected pipes up to the next shutoff valve. however. the scope of inspection work depends on the intervals between inspections. Replace old gaskets with new ones and reassemble the CO 2 vaporiser. All pipe connections of the gas system should be checked for leaks [1] before the unit is shut down. The main purpose of an inspection of the gas system is to restore a satisfactory gastightness. During the filling procedure. the main gas and measuring gas pipes at the generator should be closed. the valves at the gas valve rack (except for the waste gas valves) should be open continuously to ensure that all components are included in the leakage test. The test pressure should correspond to the rated gas pressure of the generator. with hydrogen or air. On completion of the inspection work. Drain the heat transfer liquid from the CO 2 vaporiser. The operating log should be checked to determine which deficiencies should be corrected at the inspection. the electrical purity meter system should be calibrated with pure CO 2 and H2.15 bar. During a full-scale inspection the parts listed under items a. The throttle element should be unscrewed. if required. All leaks should be marked and corrected during the inspection. Subsequently. followed by filling the gas system. On sealing of the leaks. a) Remove and clean the dust filters in the CO 2/H2 purity b) c) d) e) transmitter. the scope of the work performed during the preceding inspection and on the time available. the pressure drop in the system should be monitored for a period of 24 hours. Also refer to the following information [1] 2. the leakage test should be repeated until satisfactory results are obtained.57 bar. Check all valves of the gas system for leaks. For this test. Perform functional check of the fan and heater. Replace the absorbent material of the dryer. replace the gaskets. cleaned and reinserted. b and c should always be replaced. If required. insert a new sintered bronze filter. If required. Then functionally check the CO 2 vaporiser. Depending on the inspection conditions. replace the pressure reducer diaphragms. the permissible pressure drop is 0. The air of gas supply should be shut off when the test pressure has been reached. When this test is performed with hydrogen filling. replace the diaphragms and valve inserts.

Turbogenerators Primary Water System Inspection The work to be performed at an inspection is very difficult to determine in advance.2 Fine Filter The cartridge in the filter should be replaced at each overhaul[1].3 – 9782 Conductivity in Primary Water System BHEL. The operating log should be checked to determine what faults need to be corrected. 2 Ion Exchanger Depending on the condition of the ion exchanger resins. cleaning and reconditioning work should be performed with utmost care to ensure reliable operation of the entire primary water system for a prolonged period of time. During a large-scale inspection. After cleaning of the individual components of the filter insert and filter housing. Haridwar 2. since these cleaners will not contaminate the primary water. Also refer to the following information [1] 2. After recommissioning of the primary water system. install the insert with new seals and insert the magnet bars. 3 Valves Inspect all valves for proper operation. only fully demineralized water. they should be replaced by new or reactivated resins. the packings of the valves should be replaced.1 Main Filter Open the filter housing and remove the insert. 5 Conductivity Meter System At each inspection. All checking. Reinstall the filter cover.4 – 4740 Primary Water Filters [2] 2. 1. using a brush of medium hardness. The following inspection work should normally be performed after draining of the primary water circuit : 1 Primary Water Filters 1. As filter cleaning agent. the transmitters of the conductivity meter system should be removed. blow out the strainer with compressed air from the clean side for removal of the dirt retained in the filter cloth. After cleaning. The filter insert should be brushed and rinsed with a suitable cleaning agent. condensate or air should be used. cleaned and reinstalled using new seals. making sure that the filter insert is tightly seated and that the cover gasket is properly positioned. all control and alarm equipment should be subjected to a functional test.5-7300-0500/1 0709 E . 6 Controllers and Contacts Check the thermostats and pressure switches for proper operation. The replacement of the resins should be done in accordance with a separate instruction [2]. The magnet bars should be taken out of the filter insert. 4 Level Monitoring System The probe rods in the primary water tank should be removed. cleaned according to a separate instruction [2] and reinstalled using new seals.

Measure the installation resistance between the windings and ground with a 500 V megger. 2. BHEL. the bearings of the electric motors should be removed. Haridwar 2 Primary Water Pumps 2. 3000 hours of operation.0004 in. Worn bearing should be replaced by new ones.000 operating hours. During intermediate inspections. For this purpose.2 Sliding Ring Gland During minor and major inspections. When replacing the bearings. 70°C (160°F). the motors should be dried for several hours in an oven at approx. Check the coupling between motor and pump and replace worn parts. For this purpose. After approx.1 Bearings The primary water pumps are equipped with lubricated bearings. the oil should be changed. The oil level in the bearings can be checked at an oil slight glass. Worn out bearings should be replaced. the pump impeller must be pulled off. the sliding ring gland should be replaced. thick). 2. cleaned and packed with high melting point grease. only a good quality oil (SAE 20/30) should be used. the seal rings should also be replaced. the bearings should be checked.Turbogenerators Primary Water Pumps Inspection 1 Electric Motors for Primary Water Pumps After 8.1 mm = 0. If the insulation resistances do not comply with the related equipment manuals.5-7320-0500/1 0709 E . The bearing caps should be remounted using new gaskets (0.

Haridwar Hints for Cooler Operation 2. Also refer to the following information [1] 2. the tube bundle should be immersed in a suitable cleaning agent.5-7330-0500/1 0709 E . The vent and drain should be cleaned thoroughly and checked for operation. Only new gaskets and packings should be used for reassembly.3 – 5003 BHEL. as this would promote corrosion. The tube interior and exterior should be well rinsed with water and dried after each cleaning. with solvent added. Cleaning by means of steam. If corrosion or damage to the protective coating is detected. For reassembling the tube exterior. The drain and vent ports in the water channels should be inspected for freedom from deposits and dirt. The tube bundles should be withdrawn and the tubes cleaned internally using special brushes [1]. the effected area should be cleaned and protective coating reconditioned or replaced. Deposits on the primary water side of the tubes should be removed with a water jet. Take care that the protective coating on the tubes is not damaged during cleaning. is also possible. Care should be taken that all deposits on the tubes and water channels are completely removed.Turbogenerators Primary Water Cooler Inspection The upper water channels should be removed and their location marked after the cooling water inlet and outlet valves are closed.

too. using argon (99. Use only brushes of corrosion resistant chrome-nickel steel for such mechanical cleaning work. For grinding work use only new grinding wheels or wheels that have been in contact with corrosion-resistant materials only. Prior to assembly. the welds should be treated as follows: Q Q Fusion check (surface penetrant test) The fusion check to be carried out on each weld according to the surface penetrant method. Mechanical treatment or cleaning of pipes tarnished by welding. Following this. Even when using a shielding gas. Q 2 Treatment of welds After welding. Any required pipe bends should be made only by cold bending on the pipe bending machine or pipe elbows should be welded in. All pipe lines not required for immediate service should be closed at the ends. 2. on the inside. the pipes tarnish BHEL. On completion of the welding work. Flushing the pipes welded at the power plant.9 %) as shielding gas. Haridwar 3 up to 20 mm from the weld.5-7381-0500/1 0709 E . all parts should be dried by blowing them out with water and oil-free compressed air.Turbogenerators Inspection 1 Treatment and Cleaning of Pipes in Primary Water Circuit General The pipes of corrosion-resistant resistant chromenickel steel used in the primary water circuit of watercooled generators are welded according to the TIG method with SAS 2/G. the tarnished portions of the pipes should be cleaned mechanically on the outside and as far as accessible. all pipes welded at the power plant should be flushed with hot water at 80°C or with Chlorothene NU at ambient temperature. Flushing the Complete Piping System Prior to commissioning the complete piping system should be flushed in completely assembled condition.

generator main circuit breaker (if provided). BHEL. Ensure that tank MKF60BB001 is not filled with resins and has been drained. Remove bypass pipes.5 – 7384 Leakage Test of External Primary Water Circuit. Haridwar 2. Fill system with cold or hot deionate (up to 50°C) via the filler valve in accordance with the instructions for filling the primary water circuit. Remove filter element from filters MKF60BT001. Close above components by fitting closure discs. the complete piping system should be flushed. clean and reassemble main filter.5 – 7381 Treatment and Cleaning of Pipes in Primary Water Circuit [2] 2. generator main leads (if provided). 4 Close all equalizing valve assemblies upstream of volume flow measuring devices. 2 Q Q Q Q Q Q 3 Check to ensure that primary water pumps are ready for operation. Flushing the Complete Piping System stator winding terminal bushings. keep drain valve MKF91AA505 open during filling and flushing procedures and adjust the filling rate accordingly. Reinstall orifices and screens prior to performing the leakage test. all filters should be reassembled using new gaskets. Any dirty and dust particles in the system in spite of the extreme care taken in the installation will thus be retained in the main filter. It is assumed that all pipework is in clean condition and that all pipe sections replaced during the inspection have been subjected to the treatments and checks specified elsewhere in this manual [1]. if provided. Open. Repeat flushing procedure until no dirt particles are collected in the filter. For this reason.5-7382-0500/1 0709 E . Perform leakage test according to the instructions given in the turbogenerator manual [2]. the following work should be performed: Q Flushing External Part of Primary Water Circuit Install bypass pipes between inlet and outlet of Preparing Primary Water Circuit for Leakage Te s t Also refer to the following information [1] 2. Initial flushing should be performed for 8 to 12 hours at a water temperature of 45 to 50°C. Isolate N 2 supply line and vent gas line by closing shutoff valves MKF91AA502 and MKF91AA506. Vibrate all piping and welds to facilitate removal of dirt. Then drain all flushing water from the circuit. Heat water by simultaneously placing both primary water pumps in operation after filling of primary water circuit.Turbogenerators Inspection 1 General Prior to startup of the turbine-generator. Remove all orifices and screens. After the last flushing procedure and filter check. Preparatory Work Prior to flushing. Ensure that pressure in primary water tank does not exceed the full-scale value of pressure gauges (MKF91CP001 and MKF91CP501.

Drain external primary water circuit after completion of the leakage test. the stator winding and the terminal bushings with the phase connectors should be and must remain isolated from the external primary water circuit by means of closure discs. Before applying the test pressure. remove all closure discs and promptly reasonable the primary water circuit. The test pressure is to be applied from a nitrogen bottle connected to the gas pipe to the primary water tank via a pressure reducer. BHEL. Pressure rise in circuit can be read at pressure gauge MKF91CP501. Water level in primary water tank should be approximately 300 mm. Close shutoff valve MKF91AA502 when gauge pressure in circuit amounts to 10 bar. pressure gauge MKF91CP501 in the waste gas pipe should be replaced by a pressure gauge of accuracy class 0.5 – 7382 Flushing External Primary Water Circuit.5-7384-0500/1 0709 E . 4 Applying the Test Pressure Admit nitrogen at a gauge pressure of 10 bar to provide a gas cushion above the water level in the primary water tank. Observe water level I the primary water tank during the filling procedure. Repair any leaks detected and repeat the leakage test. bottle and welded joints in primary water circuit as well as the respective shutoff valves for leaks while maintaining constant pressure. close shutoff valve MKF91AA508 and open shutoff valve MKF91AA502. 2 Preparatory Work The external primary water circuit is normally cleaned before the leakage test is performed [1]. All other pressure gauges and pressure transmitters with a range of less than 10 bar should be isolated from the primary water circuit by cleaning the respective valves.6 with a range of not less than 10 bar. 5 Leak Detection Inspect all flanged. Ensure that all water lines connecting to the primary water tank are filled Leakage Test of External Primary Water Circuit with water. Place primary water system in operation immediately after the system has been restored to its previous condition. making sure that all drain valves have been closed prior to filling. 3 Filling the Circuit The circuit should be filled with deionate via the filler line (shutoff valve MKF60AA504) and properly vented. This test serves to inspect all components of the system for leaks. 6 Terminating the Leakage Test The primary water circuit may be considered as sufficiently tight when no leaks are detected by visual examination and when no pressure drop is observed at pressure gauge MKF91CP501 during a test period of 10 minutes (after thermal equilibrium has been reached).Turbogenerators Inspection 1 General A leakage test of the external primary water circuit is required after a major overhaul of the unit. Since the test is restricted to the external circuit. All shutoff and gas valves in the primary water circuit should be opened. Also refer to the following information [1] 2. Haridwar 2. During the leakage test.

see the respective instruction [3]. To do this. Check coupling bolts for proper condition and take dimensions. make sure that the air inlet side points downward. the filter mats should be rinsed with clean water. In accordance with the inspection schedule [1]. Haridwar For details.Turbogenerators Inspection 1 General The scope of work to be performed during an inspection depends mainly on the equipment on which defects have been detected since the last inspection. The coupling flange at the rotor should be checked both at the guide flange and at the coupling bolt holes. Cleaning should be done very carefully to avoid damage to the numerous insulated parts. 5 Drying the Windings After a prolonged shutdown of the exciter. Particular care should be exercised when cleaning the porcelain bodies of the diodes. Such a moisture film can be removed by drying the main exciter rotor. slightly contaminated filter mats should be beaten out. labyrinth rings. Perform the maintenance work in accordance with manufacturer’s special instructions. Otherwise. It is. To do this. no pressure drop is permissible within a period of about six hours. The space inside the cover should then be pressurized at a gauge pressure of 6 bar via the compressed air connection. The drive motors of the actuators for the emergency cooling flaps should be subjected to a thorough functional test. at the diodes. Check field connection for gas tightness. The filter mats of the makeup air filters should be cleaned or replaced. the following inspection work should be performed. This should be done by placing an air dryer into operation. BHEL. 9 Checking the Contact Pins and Plug-In Socket Strips The contact pins and plug-in socket strips should be checked for proper mechanical condition. check the coupling between the generator and exciter and the terminal bolts between the rectifier wheels with a potable leak detector. When placing the filter mats in the suds. For details see the respective instruction [4]. Remove measuring brushes of ground fault detection system from slip rings. For details. 7 8 Emergency Cooling and Makeup Air Filters Bearing and Labyrinth Rings Check the insulation of the bearing. if required. Any accumulations of dirt in the ventilating air ducts of the rotor.g. the dc field connections should be leak tested. With gas tight lead. If the silver 2.5-9000-0500/1 0709 E . a cover with top-mounted pressure gauge should be attached to the coupling flange and sealed gas tight. the filter mats should be washed in cold to lukewarm (30°C maximum) suds (e. fuses and heat sinks must be removed. The strips of the labyrinth rings should be checked for proper condition and replaced. If the bearing babbitt is found grooved. Prior to removing the hydrogen gas from the generator casing. recommended to remove these contaminations with a brush. Fuses and Rectifier Wheels 3 The drive motors of the actuators for the emergency cooling flaps should be subjected to a thorough functional test. 2 Hydrogen Leakage Test Excitation System Exciter see the respective instructions [2]. 6 Checking the Diodes. cloth (non-linting) and a vacuum cleaner. our erection engineer should be consulted regarding further use of the bearing. The insulation resistances to ground of the individual windings should be measured with a megger. a reduction of the insulation resistance may be caused by the formation of a moisture film on the surface of the winding. therefore. After washing. It will therefore be necessary to extract from the operating log all deficiencies to be corrected during the inspection. which was installed as additional precaution against corrosion. 4 Measuring the Insulation Resistances of the Windings Disconnect cables at stator terminal boards of the pilot and main exciters. Pril). Dismantling and Cleaning the Exciter Remove exciter rotor. pipe connections and. To enable their reuse.

1 2 3 Insulation Contact sleeve Plug-in contact strip Fig. Ensure to insert the carbon brushes of the specified grade which match the slip ring contour.plating of the contact pins shows signs of arc erosion. the complete ground fault detection system should be subjected to a functional test. After complete assembly of the exciter.5-9000-0500/2 [1] 2.5 – 9010 Checking the Rectifier Bridge Circuit [4] 2. A check should be made to ensure that the projecting contacts of the plug-in socket strips are spirally distributed on the entire circumference of the contact sleeve. 3 Section Through Contact Sleeve Also refer to the Following Information 2. the contact pins require reconditioning and re-plating.5 – 0300 Checking the Bearing and Shaft Seal Insulation . 11 Cleaning the Exciter Coolers Remove the coolers and perform the same cleaning procedure as described for the hydrogen cooler.5 – 3300 Insulation Resistance Measure-ments on Rotor and Exciter Windings [3] 2.5 – 1090 Inspection Schedule – Excitation System [2] 2. 10 Checking the Condition and Performance of the Ground Fault Detection System It is recommended to replace the carbon brushes of the ground fault detection system at each inspection.

Turbogenerators Inspection Regular inspection work should include checking the insulating sections.5 – 9011 Checking the Insulation at Rectifier Wheels BHEL. In the event of a diode losing its blocking capability. Leakage paths may be formed at these points as a result of dirt deposits. rendering the fuses connected after the diodes ineffective in the event of a failure. between the diode heat sinks and rectifier wheels [1]. Also refer to the following information [1] 2. resulting in a phaseto-phase fault in the main exciter circuit. an interruption of the respective bridge arm by the fuse Excitation System Checking the Insulation Resistance of Heat Sink Insulation would then no longer be ensured.5-9010-0500/1 0709 E . The insulation resistance between the heat sink and rectifier wheel should not be less than 10 M(. the insulation resistance between points a and b or a 1 and b 1 respectively. can be measured by means of a megger. Haridwar 2. applying a voltage of 500 to 1000V. After removal of the fuses.

8 2 BHEL.5-9011-0500/1 0709 E . Haridwar 2.Turbogenerators Excitation System Checking the Insulation at Rectifier Wheels Inspection 10 1 2 3 4 5 6 7 8 9 Current path 1 2 3 4 5 6 7 8 9 10 Fuse Heat sink Diode Rectifier wheel (-ve polarity) Terminal bolt Tension bolt Hot air outlet Rectifier wheel (+ve polarity) AC lead DC lead 3 1 9 Detail X 4.