GENERATOR AUXILIARY SYSTEM

Synchronous Generator
• Auxiliary System
– Seal oil system
– Gas system
– Stator water cooling system

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 Generator Cooling System
• Hydrogen cooling (compared to air as coolant)
– 1/14 of the density, reduces windage loss & noise
– 14 times the specific heat
– 7 times the thermal conductivity thus coolers can be
smaller also reduces temperature gradients
– 1.5 times the heat transfer, more readily taking up and
giving up heat hence reduction in size of machine
– Reduces insulation corona (during corona, ozone and
nitric acid are formed which attacks the insulation)
– Degradation of insulation by oxidation can not occur in
hydrogen atmosphere (free from dust and moisture)

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 Hydrogen Cooling System
• Hydrogen cooling disadvantages
– concentration of 4 to 76 % of hydrogen in air
are explosive and Hydrogen will not support
combustion if purity is maintained above 95%
– Casing and end shields have to be leak proof
and rugged in construction
– Rotor shaft and outgoing connections have to
be perfectly sealed
– Rotor sealing require sophisticated sealing
system
– A comprehensive gas control system is
required (pressure, temperature, purity, feeding
and purging) PMI Revision 01 4
 Hydrogen Cooling System

• Gas System
– Safely putting H2 into or taking out of machine
– to maintain gas press in the machine at desired
value
– CO2 used as buffer between the H2 and air in the
process of Gassing-up and Degassing (Scavenging)
• Components
– H2 and CO2 cylinders
– Pressure regulator
– Gas dryer
– Purity meter
– Compressed air PMI Revision 01 5
 Hydrogen Cooling System
• Fans
– Circulate hydrogen through stator and cooler
– Two single stage, axial flow propeller type shrink fitted at
each end of shaft
• Pipe connection
– For filling H2, perforated manifold at top of stator body
– For filling & venting of CO2 & air, feed pipe is provided
at the bottom of stator body
– Manhole at bottom to inspect inside of generator
• Liquid Leakage Detector (LLD)
– 3 no. drains for any oil or water in bottom of casing
• Gas cooler
– Four no. mounted longitudinally inside stator body
– Headers are accessible without degassing the casing
– Made of admirality brass/copper tubes 6
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7
 Hydrogen Cooling System
• Gas dryer
– Humidity affects IR of rotor and stator winding
– Corrosion of stator core, stress corrosion of retaining
rings and RR nuts can occur
– Sources: steam from turbine gland seals is source of
moisture in shaft seal oil system which is picked by
Hydrogen, water leakage from coolers or stator
windings
– Moisture measured by psycho-meter or by dew point
measurement of H2 gas
– Gas dryer keep the moisture content of casing
hydrogen low enough to prevent condensation
– use activated alumina or silica gel
– regeneration through blower and heater arrangement
– differential across rotor fans create flow through dryers
– Refrigeration type dryer 8
PMI Revision 01
 THDF: Ventilation Scheme
• Gas flow path 1 enters rotor on Turbine
end and cools rotor overhang and slots
• Gas flow path 2 cools stator core
• Gas flow 3 enters rotor on exciter end &
cools rotor overhang & slots, as well as
stator core end parts at both the ends
• Hot gas from all paths returns through air
gap to compressor, and to coolers

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 Hydrogen Cooling System
• Direct gas to copper contact
• ‘Gap pick up’ ventilation provides self ventilation
effect in slots
• Cooling by Gas Pick up method
• hydrogen is sucked through elliptical holes serving
as scoop on rotor wedges and is directed to flow
along lateral vent ducts on rotor copper coil to bottom
of coil due to press. created under scoop by rotation
• More than 35 cooling paths / slot
• Fans force gas flow in overhangs
• Maximum to average temperature ratio low
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Rotor Slot
Rotor Wedge

Top Slot Liner

Conductor

Inter turn Insulation

Slot Liner

Sub Slot

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PMI Revision 01 12
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 Hydrogen Cooling System
• Gas enters rotor ends into ducts
provided in copper conductors
• Hot gas comes out radially at barrel
centre from copper conductors
• Gas also enters into end winding at
barrel ends
• After cooling overhangs, it is
collected in special chambers and
then discharged into the air gap
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Rotor Slot Cooling

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THDF: VENTILATION SCHEME

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THW TG: VENTILATION SCHEME

SEC C-C SEC B-B

B C

B C

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 Main Parts of Turbo generator
Coolers

Foundation

Terminal bushing

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 Hydrogen Gas System

H2 DISTRIB
ANALYZER
CO2
TO SEALOIL
DP

LLD-3 H2 DRIER

FILTER DPI
VAPOURIZER
OP CO2

AIR

LLD-1 LLD-2

DRAIN HYDROGEN

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 THW-210: Unloading Schedule of
High Cold Gas Temp
9050 RATED CURRENT 9050 A
8600
STATOR CURRENT
8200 280
7800 260
RATED 247 MVA
7400 240
AMP MVA
7000 220 220
MVA
6600 200 200
6200 180 OPERATION AT >55°C
NOT ALLOWED 180
5800 160 44 COLD GAS °C 160
42 (NOMINAL) 46 48 50 52 5420 55
PMI Revision 01
 Operating Limits
 Generator hydrogen pressure: 3.4 to 3.5 kg/cm2
 H2 pressure – low: 3.3 kg/cm2 and high: 3.7 kg/cm2
 H2 purity – normal: 99 % and low: 97 %
 Generator gas volume: 56 m3
 Hydrogen consumption – 3 cylinders/day
 CO2 stock – 15 cylinder (minimum)
 Min. 5 cylinders of CO2 should always be connected
 Generator cold gas temp: 40oC (Normal)
 High - 45oC very high - 55oC Minimum – 20 oC
 Generator hot gas temp: < 65oC
 Very high - 75oC
 H2 cooler maximum water inlet temperature: 37oC
 Generator hydrogen dew point: 20oC lower than cold gas
temp.
 Moisture in H2 : 15 gm/m³ (RH <30%)
 Maximum oxygen content : 1.2% 21
PMI Revision 01
 Stator water Cooling System
• Stator water cooling system (Five main criteria)
– Conductivity must be very low, to prevent current flow
– Means used to transfer water into conductors must be
high integrity insulation material, not easily degraded
– Velocity of water must be low enough to prevent erosion,
& design must not allow corrosion
– Maximum water press must be lower than casing H2
press (no leakage from water to H2 side)
– Maximum temperature in water circuit must be low
enough to provide an adequate margin below boiling
point

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 Stator water Cooling System
• Losses in stator core & winding
• Core losses go to hydrogen gas and
winding losses to winding water
• There are 120 winding bars - two in
each slot
• They are made up of hollow and solid
‘ETP’ copper conductors that are Roebel
transposed to reduce losses
• Copper headers, brass / stainless steel
nipples, Teflon tubes for water feeding
23
PMI Revision 01
 Stator water Cooling System

• Stator water cooling system

– De-mineralized (DM) water is used
– all metal with which water is in contact is either non
ferrous or stainless steel
– Flexible hose of PTFE (Poly Tetra Flouro Ethylene)
used to transfer water
• Components
– Stator water pumps
– Stator water cooler and Magnetic filters
– Expansion tank and water jet ejector
– Polishing unit
– Gas Trap
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 Stator water Cooling System
• Stator water cooling is a closed loop system
• There are two full capacity single stage centrifugal
pumps with change over facility
• The stator water cooler is shell and tube type heat
exchanger
• There are two filters
• Filters are having wire mesh and permanent
magnet
• The expansion tank is a hermetically sealed (no
ingress of air) container made of S.S.
• Vacuum is maintained in expansion tank using
water jet ejectors
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 Stator water Cooling System
• Float valve is there in the expansion tank to maintain water
level in the tank which act as suction storage tank for
stator water pumps (suction is through perforated pipes)
• Polishing unit (mixed bed ion exchanger) is there to
maintain conductivity of stator water to desired level (30%
water flows through polishing unit)
• Ring type water header
– made of copper, separate for distillate inlet & outlet in the stator on
turbine side supported on insulators and isolated from stator body
– Individual bar connected by PTFE hoses (Teflon tubes)
– Vent pipes connected through GAS TRAP device (used for
detecting H2 gas in water)
• Resistance Temperature Detector (RTD)
– Embedded inside stator slots for measurement of core iron and
winding copper temperature
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PMI Revision 01 27
 Stator Water System
EXPANSION FLOW DIFF PRESS
TANK METERS SWITCH
GAS TRAP

FILTERS

FSI
DIFF PRESS. I

CONDUCTIVITY
POLISH UNIT
MAKE
UP
COOLERS

PUMPS
Ejector system

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STATOR WATER SYSTEM

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 Operating Limits
 Stator Water
 Flow: 30 m3/hr
 Alarm – 21 m3/hr
 Trip – 13 m3/hr (25 sec. time delay)
 Temp. of stator water at inlet to winding: 35 to 40oc
 Conductivity: < 5 micro mho/cm
 Alarm–13.3 micro mho/cm
 Trip-20 micro mho/cm (1 sec)
 Dissolved oxygen: 1.0 to 4.5 ppm (Analysis monthly)
 Copper pick up: max. 200 ppb
 Expansion Tank Level: 80 to 90 cm
 Level low alarm - 41 cm
 Stator water pump trip - 38 cm
 Expansion Tank Vacuum: 100 TO 150 mm of Hg
 Maximum DP across filter: 0.4 30
PMI Revision 01
 Operating Limits
• STATOR WATER PARAMETER TO BE
MAINTAINED
- pH : 6.5 to 8.5
- Conductivity : < 5.0 µs/cm preferably 1.0 µs/cm
- Dissolved CO2 : nil
- Dissolved/undissolved Cu : < 20 ppb
- Dissolved/undissolved Fe : < 20 ppb
- Ammonia and chloride should be minimum
- water should be free of any chemicals from
treatment process such as hydrazine etc.
- D.O. < 10 PPb in low D.O. regime
2.0 to 5.0 PPM in high D.O. regime
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 Low/High D.O. Regime

Limits - below 10 PPb

With low D.O. concentration, copper corrosion is
inhibited by a passive film of Cuprous Oxide
(Cu2O)

Limits - 2 to 5 PPM
With high D.O. concentration, copper corrosion is
inhibited by a passive film of Cupric Oxide (CuO)

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 Low/High D.O. Regime

Cuprous oxide Cupric oxide

Cu2O CuO

Corrosion

Cu2O+CuO

0.1 1.0 4.5

O2 in PPM

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 THW-210 : Unloading Schedule
DM Water Temperature
CURRENT
AMP 9000 RATED 9050 A
8900 STATOR CURRENT
8800
RATED 247 MVA
8700 248 8700
8600 244 MVA 8600
8500 240 8500
8400 236 236
OPERATION >48°C
8300 232 232
NOT ALLOWED
8200
43 44 45 46 47 48
DM WATER TEMP °C 34
PMI Revision 01
 Sealing System
• Seal oil system
– To prevent escape of hydrogen
– Seal oil is maintained at a higher level than the
gas pressure in the generator
– Type of shaft seal : Single flow ring type
– Seal oil - H2 DP : minimum 1.0 kg/cm², normal
1.5 kg/cm² and maximum 1.7 kg/cm²
– Quantity of seal oil
• Air side : 2/3 rd
• Hydrogen side : 1/3 rd
– Seal oil supply is from same turbine oil
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 Seal Oil System
• Components
– AC Seal oil pump / DC Seal oil pump
– Seal Oil Storage Tank (SOST)
– Intermediate Oil Tank (IOT)
– Seal Oil Tank (SOT)
– Pre-chamber (exciter end and turbine end)
– Seal oil coolers and Seal oil filters
– Governing oil filter
– Vacuum pump
– SOST vapor exhauster
– Differential pressure regulating valve - A
– Differential pressure regulating valve - B
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 Seal Oil System
• Both the seal oil pumps are 100% capacity screw
type pump
• A vacuum pump is provided to maintain vacuum
of 400 to 500 mmHg by evacuating gases in seal
oil tank (SOT) to prevent deterioration in H2
purity
• There is a additional facility to supply seal oil
from governing oil using DPRV-B
• The seal oil pressure to the seal is controlled by
DPRV-A which maintain specified DP between
oil and hydrogen
• Two seal oil coolers having 100% capacity is
provided to cool the oil
• Duplex filter is provided in the oil line
PMI Revision 01 37
 Seal Oil System
• Seal oil system
– On air side, pressure oil also called Ring Relief oil is supplied
laterally to the seal ring via annular groove to ensure free
movement of seal ring in radial direction
– Ring Relief oil holds the seal ring in position against gas pressure
– Ring relief oil pressure is 0.5 Kg/cm2 more than seal oil pressure
– Ring relief oil supply is from governing oil
– Upon failure of normal AC pump, standby DC pump takes over
automatically, Upon failure of both the pumps, seal oil is taking
over by governing oil system
– Oil from air side directly goes to SOT
– If SOT is full, air side oil goes to SOST and overflow of SOST
goes to MOT
– Oil drained from H2 side first flows into pre-chamber (one on each
side) & then to IOT before returning into SOT to block H2 draining
– Purpose of Pre-chamber is defoaming and calming of hydrogen
bubbles
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 Operating Limits
 H2/seal oil DP: 1.4 to 1.6 kg/cm2
 Normal: 1.5 kg/cm2
 Minimum: 1.0 kg/cm2
 Maximum: 1.7 kg/cm2
 Quantity of seal oil
• Air side : 2/3 rd
• Hydrogen side : 1/3 rd
 Quantity of seal oil per seal : 38.5 l/m
 Generator seal oil temp: 40oC (max - 45oC )
 DPRV-A setting: 1.5 kg/cm2 (1.8 - 0.3 kg/cm2 )
 DPRV-B setting: 1.2 kg/cm2 (1.5 - 0.3 kg/cm2 )
 Seal oil cooler
 Water inlet temperature: 40OC
 Water outlet temperature: 70OC
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 Seal Oil System
• Shaft Seals
– provided in both end shield to prevent escape of
hydrogen along the shaft
– Seal ring & shaft sealed with seal oil under press
maintains continuous oil film between seal ring and
rotor journal clearance such that to maintain oil film
without unnecessary large oil flow and with minimum
friction losses
– Seal rings are made of steel
– They are robust and free from distortions, having large
cross section, precision machined and babbited
– Rings have single flow system
– Ring relief oil for balancing the gas pressure on seal
ring
– Rings have small clearances with shaft
– Ring carrier is insulated from stator body
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 Shaft Seal Assembly
Hydrogen
Side
Air Side

1. OIL WIPER RING AIR SIDE 7. SEAL RING 13. INSULATION

2. SEAL RING CHAMBER 8. SEAL RING CARRIER 14. PACKING
3. PRESSURE OIL GROOVE 9. OIL WIPER RING H2 SIDE 15. SEAL OIL GROOVE
4. BABBIT 10. SEAL STRIP 16. END SHIELD
5. SEAL OIL INLET BORE 11. ROTOR SHAFT
6. SEAL OIL GROOVE 12. INNER LABYRINTH RING 41
 H2 Shaft Seal
END SHIELD
INSULATION
RING CARRIER

H2 PACKING
SEAL RING

PRESS OIL

SHAFT
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Seal Oil System

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 Seal Oil System With Three Pumps
EE
BEARING FROM GAS
FLOW METER PS PG
TE SYSTEM
BEARING TS ES
GAS DPRV
EXHAUST FR
TG
SOST BEARG
DRAINS

IOT FILTERS
DP
SW
VACCUM VACUUM
PUMP TANK OIL
SOP-3 COOLER
1 2 DC
SOP

CONSTANT PRESSURE REGULATORS

WITH ORFICE PLATES 44
THANK YOU 45