RTPP

OPERATION & MAINTENANCE
MANUAL
FOR
210 MW TOTALLY IMPREGNATED
TURBOGENERATOR
INDIRECT GAS COOLED STATOR WINDING
AND DIRECT GAS COOLED ROTOR WINDING
RAYALSEEMA TP,
STAGE-3
BHARAT HEAVY ELECTRICALS LIMITED

RANIPUR, HARIDWAR-249 403 (UA)
OPERATION & MAINTENANCE
MANUAL
FOR
210 MW TOTALLY IMPREGNATED

TURBOGENERATOR
INDIRECT GAS COOLED STATOR WINDING

AND DIRECT GAS COOLED ROTOR WINDING
RAYALSEEMA TP ,STAGE-3
BHARAT HEAVY ELECTRICALS LIMITED

RANIPUR, HARIDWAR-249 403 (UA)
Turbogenerators Manual Survey
General
This manual contains

information on operation
and maintenance of turbogenerator
and Its auxiliary systems
and is subdivided into
following main sections.
General
Description
Operation
Maintenance
Inspection
Appendix
BHEL, Haridwar 2.0-0005-0012/1

Turbogenerators Table of Contents
General
Title-Page 2.0-0001 Coil and End Winding Support System....... 2.1-2340

General Stator End Winding..................................... 2.1-2341
Manual-Survey........................................... 2.0-0005 Electrical Connection of Bars and
Table of Contents........................................ 2.0-0010 Phase Connectors................................ 2.1-2350
Preface....................................................... 2.0-0030 Terminals Bushings..................................... 2.1-2370
Notes on the Use of the Manual................... 2.0-0040 Construction and Cooling of Terminal
Operation Beyond Contract Commitment.. 2.0-0050 Bushings..................... 2.1-2371
General Safety Information for Hydrogen
Cooled Generators........................................... 2.0-0100 Rotor
2.0-0200 Rotor Shaft................................................. 2.1-3000
Safe Disposal of Turbogenerator Items......
Cooling or Rotor Winding............................ 2.1-3100
R-Cooling System of Rotor .......................... 2.1-3110
Description Rotor Winding............................................. 2.1-3300
Brief Description Rotor Slot.................................................... 2.1-3301
Rating Plate Data of Generator.................... 2.1-1001 2.1-3310
Rotor End Winding......................................
Generator Cross Section............................. 2.1-1020 Arrangement of Damper Bars
Generator & Exciter Outline Diagram............ 2.1-1026 in Rotor Body........................................ 2.1-3333
Design and Cooling System........................ 2.1-1100 Rotor Retaining Ring................................... 2.1-3350
Generator Cooling Gas Circuit.................... 2.1-1120 Field Connections........................................ 2.1-3370
Stator......................................................... 2.1-1210 Electrical and Mechanical Connection
Stator Winding............................................ 2.1-1230 of EE Coupling............................................ 2.1-3373
Rotor........................................................... 2.1-1300 Rotor Fan.................................................... 2.1-3600
Hydrogen Cooler......................................... 2.1-1440 Rotor Fan and Fan Baffle Ring..................... 2.1-3603
Bearings..................................................... 2.1-1450
Shaft Seals.................................................. 2.1-1460 Cooler
Oil Supply for Bearings and Shaft Seals.. 2.1-1510 Hydrogen Cooler ........................ 2.1-4000
Seal Oil System (Simplified Diagram)....... 2.1-1511 Hydrogen Cooler 2.1-4001
Gas System.............,......................................... 2.1-1520
Gas System (Simplified Diagram)................ 2.1-1521 Generator Bearings
Generator Bearings. .................. 2.1-5000
Technical Data Generator Bearing (Typical Arrangement) 2.1-5001
Measurement of Bearing Temperature. 2.1-5003
General and Electrical Data........................ 2.1-1810 Generator Bearings Insulation................. 2.1-5005
Mechanical Data......................................... 2.1-1820
2.1-1829 Shaft Seal
Excitation System........................................
2.1-1830 Shaft Seal .................................. 2.1-6000
Cooler Data...................................................
2.1-1850 Shaft Seal- Insulating and Sealing
Reactive Capability Curve............................ of Seal Ring Carrier. .................. 2.1-6005
Oil Specification........................................... 2.1-1880
Gas Specification........................................ 2.1-1883
Seal Oil System
Seal Oil System ......................... 2.1-7100
Stator Constant Pressure Controller. ... 2.1-7101
Stator Frame..................................................... 2.1-2100 Seal Oil Unit ............................... 2.1-7105
Core and Winding Assembly....................... 2.1-2110 Differential Pressure Valve ........ 2.1-7108
Stator Winding, Total Impregnation Process 2.1-2120 Regulator for Seal Ring Relief Oil.. 2.1-7109
Stator End Shield......................................... 2.1-2150 Seal Oil Diagram ....................... 2.1-7111
Hydraulic Testing and Anchoring Bearing Vapor Exhauster ........... 2.1-7120
of Stator Frame........................................... 2.1-2190 Seal Oil Pumps .......................... 2.1-7123
Anchoring of Generator to Foundation........ 2.1-2191 Vacuum Pumps., ....................... 2.1-7126
Stator Core.................................................. 2.1-2200 Seal Oil Cooler and Seal Oil Filter. 2.1-7130
Core Support System and Flat Springs......... 2.1-2201 Seal Oil Cooler ........................... 2.1-7131
Cooling of Stator End Portion........................ 2.1-2209 Seal Oil Filter ............................. 2.1-7132
Construction and High Voltage Insulation 2.1-2300 V acuum Regulating Valve............ 2.1-7133
Connection Diagram of Stator Winding......... 2.1-2301
Stator Slot................................................... 2.1-2303 Gas System
Micalastic High Voltage Insulation............... 2.1-2320 Gas System ............................... .... 2.1-7200
Construction of High Voltage Insulation......... 2.1-2321 Gas Diagram ............................. 2.1-7211
Corona Protection....................................... 2.1-2330 CO2 Flash Evaporator ................ 2.1-7230
CO2 Flash Evaporator Control Logic........... 2.1-7231

Refrigeration Hydrogen Dryer................................ 2.1-7260 Operation Log
General........................................................ 2.3-4100
Automatic Controls Generator Supervision................................. 2.3-4120
Coolant Temperature Control 2.1-8010 Seal Oil System.............................................. 2.3-4150
Gas System................................................ 2.3-4160
Protective Devices Exciter Supervision........................................ 2.3-4190
Safety Equipment for Hydrogen Operation..... 2.1-8310
Waste Gas System........................................... 2.1-8311 Start-up
Generator Waste Fluid System....................... 2.1-8315 Preparations for Starting-Introduction................. 2.3-5000
Generator Mechanical Equipment Protection 2.1-8320 Hints for Cooler Operation................................... 2.3-5003
Tripping Scheme for Generator Filling and Initial Operation of
Mechanical Equipment Protection 2.1-8321 Seal Oil System-Preparatory work...., 2.3-5100
Electrical Generator Protection ………………… 2.1-8330 Valve positions in Seal Oil System for
Tripping Scheme for Normal Operation.......................................... 2.3-5108
Electrical Generator Protection……… 2.1-8331 Filling and Initial Operation ofAir Side Seal Oil
Rotor Grounding System………………………… 2.1-8350 Circuit.................................................................. 2.3-5110
Arrangement of Brush Holders for Placing Vacuum Pump in Service.......................... 2.3-5113
Rotor Grounding System......... 2.1-8351 Venting of Seal Oil Circuit.................................... 2:3-5130
Setting of Seal Oil Pressures................................. 2.3-5150
Measuring Devices and Supervisory Equipment Setting of Operating Values for
Introduction.................................................... 2.1-8400 Seal Oil System.............................................. 2.3-5160
Temperature Transducers............................. 2.1-8410 Measurement of Seal Oil Volume Flows............... 2.3-5163
Pressure Transmitters for seal oil.................. 2.1-8412 Activating the Measuring Device
Bearing Vibration Pickup................................. 2.1-8414 for Vacuum in seal Oil Tank........................... 2.3-5165
Shaft Vibration Pick Up- Relative Vibration Meas. 2.1-8415 Functional Testing of Pumps and
Supervision of Generator.............................. 2.1-8420 Exhausters................................................. 2.3-5180
Generator Measuring Points.......................... 2.1-8422 Start-up of Seal Oil System................................... 2.3-5210
Supervision of Bearings................................ 2.1-8440 Activating the Level Detector System for
Supervision of Seal Oil System..................... 2.1-8450 Seal Oil and Generator Supervision............. 2.3-5510
Supervision of Gas System .......................... 2.1-8460 Positions of Multi-way Valves in Gas System..... 2.3-6107
Supervision of Exciter.................................... 2.1-8490 Valve Positions in Gas System for Gas Filling
Exciter Measuring Points............................... 2.1-8491 from CO2 and H2 bottle supply........................... 2.3-6307
Valve Positions in Gas System for
H2 Position..................................................... 2.3-6308
Gas Filling-Replacing Air with C02....................... 2.3-6310
Gas Filling-Replacing C0 with H2......................... 2.3-6320
2
Excitation System Duplex Hydrogen Drier....................................... 2.3-6710
Exciter............................................................. 2.1-9100 Turning Gear Operation and
Basic Arrangement of Excitement System Run up of Generator..................................... 2.3-8010
with Rotating Rectifiers.................................. 2.1-9101 Generator Startup Diagram................................... 2.3-8011
Permissible Synchronizing Criteria...................... 2.3-8081
Rectifier Wheels............................................. 2.1-9102
Rectifier Wheels and Coupling....................... 2.1-9103
On-Loading Running
Permanent-Magnet Point
Permissible Load Limits of Generator..................... 2.3-8170
Exciter Rotor and Fan............................ 2.1-9104
Exciter Cross Section.................................... 2.1-9110
Permissible Loading at Rated P.F. During 2.3-8181
Exciter Cooling Air Circuit................................ 2.1-9120
Voltage and Frequency Deviations...
Stroboscope for Fuse Monitoring................... 2.1-9140
Generator Capability with Hydrogen Coolers
Exciter Drying System.................................... 2.1-9150
Out of Service on Water Side........................ 2.3-8184
Ground Fault Detection System for
Generator Capability vs.
Exciter Field Circuit …………………….. 2.1-9180
Cooling Water Temperature......................... 2.3-8186
Arrangement of Brush Holders for
Unbalanced Load-Time Curve............................ 2.3-8187
Ground Fault Detection System............. 2.1-9181
Current Overload Capability................................ 2.3-8188
Bruch Holders for
Ground Fault Detection System............. 2.1-9182
Shutdown
Precautions Against Contamination
Shutdown of Generator........................................ 2.3-8310
of Exciter Unit......................................... 2.1-9187
Generator Shutdown Diagram. 2.3-8311
Ground Fault Detection System
Brush Dust Extractor............................. 2.1-9189
Standstill
General................................................................. 2.3-8400
Operation Coolers.................................................................. 2.3-8440
Operating and Setting Values-General.......... 2.3-4000 Seal Oil System................................................... 2.3-8500
Operation and Setting Values- Shutdown of Seal Oil System.............................. 2.3-8510
Gas Quantities........................................ 2.3-4010 Draining Seal Oil Circuit........................................ 2.3-8520
Stator Supervision.................................. 2.3-4020 Gas System........................................................ 2.3-8600
Seal Oil System...................................... 2.3-4050 Valve Positions in Gas System for
Gas System........................................... 2.3-4060 Gas Removal................................................ 2.3-8608
Exciter Supervision..........................................2.3-4900
2.0-0010-7500/2
Lowering Hydrogen Gas Pressure Preventive Measures to Avoid Moisture
in Generator........................................... 2.3-8610 Condensation............................................ 2.5-1005
Gas Removal - Replacing H2 with CO2........... 2.3-8620 inspection Schedule - Introduction.................... 2.5-1010
Gas Removal - Replacing CO2 with Air.......... 2.3-8630 Inspection Schedule - Stator............................. 2.5-1020
Exciter.............................................................. 2.3-8900 Inspection Schedule - Rotor.............................. 2.5-1030
Inspection Schedule - Coolers.......................... 2.5-1040
Fault Tracing Inspection Schedule - Bearings........................ 2.5-1050
General.......................................................... 2.3-9000 Inspection Schedule - Shaft Seals................... 2.5-1060
Stator and Generator Supervisory Inspection Schedule - Seal Oil system............. 2.5-1071
Equipment............................................... 2.3-9200 Inspection Schedule - Gas System................... 2.5-1072
Rotor................................................................ 2.3-9310 inspection Schedule - Generator
Hydrogen Coolers......................................... 2.3-9440 Supervisory Equipment............................. 2.5-1080
Bearings........................................................ 2.3-9450 Inspection Schedule - Excitation System.......... 2.5-1090
Bearing Vapor Exhausters............................ 2.3-9521 Measures for Preservation............................... 2.5-1100
Seal Oil Pumps............................................... 2.3-9523 Stator................................................................. 2.5-2000
Seal Oil Pressures and Temperatures.......... 2.3-9531 Check list on works on Generator............................2.5-2001
Oil Level in Seal Oil System........................... 2.3-9561 Cementing the Joints of Porfiled Gaskets......... 2.5-2120
CO2 Flash Evaporator and Gas Dryer-.......... 2.3-9630 Mounting of Inner Labyrinth Rings.................... 2.5-2126
Gas Pressure and Volumetric Flow Rates.... 2.3-9640 Generator Drying System................................. 2.5-2155
Gas Purity Meter System.............................. 2.3-9680 Fitting New Seal Strips to Labyrinth Rings........ 2.5-2163
Insulation Resistance Measurements
Fuses on Rectific Wheeles........................... 2.3-9901
on Stator Winding...................................... 2.5-2300
Exciter Temperatures.................................... 2.3-9911
Drying the Windings.......................................... 2.5-2310
Exciter Cooler................................................ 2.3-9914
Treatment of Bolted Contact Surface................ 2.5-2350
Storboscope.................................................. 2.3-9941
Rotor.................................................................. 2.5-3000
Exciter Drying System.................................... 2.3-9955
Insulation Resistance Measurements on
Exciter Fault Detection System in
Rotor and Exciter Winding......................... 2.5-3300
Exciter Field Circuit................................. 2.3-9980
Ultrasonic Examination of Rotor Retaining
Ring at Power Plant................................... 2.5-3367
Maintenance
Hydrogen Cooler................................................ 2.5-4000
Maintenance and Supervision-Introduction.... 2.4-4200
Bearings............................................................ 2.5-5000
Survey on Maintenance and Supervision...................2.4-4205 Shaft Seal.......................................................... 2.5-6000
Stator................................................................. 2.4-4210 Seal Oil System................................................. 2.5-7100
Hydrogen Coolers.......................................... 2.4-4240 Seal Oil Pumps and Bearing
Bearings........................................................ 2.4-4250 Vapor Exhausters..................................... 2.5-7120
Barton Cells(Vacuum Indication)...................... 2.4-4281 Vacuum Pumps.........................................................2.5-7121
Rotor.................................................................. 2.4-4310 Seal Oil Coolers................................................. 2.5-7130
Seal Oil Pumps and Bearing Vapor Exhausters.... 2.4-4520 Gas System....................................................... 2.5-7200
Seal Oil Coolers.............................................. 2.4-4540 Exciter................................................................ 2.5-9000
Seal Oil Filters................................................ 2.4-4550 Checking the Insulation Resistance of
Gas Consumption........................................... 2.4-4610 the Heat Sink Insulation.............................. 2.5-9010
Replacing Gas Dryer Desiccant..................... 2.4-4661 Checking the Insulation Rectifier Wheels..................2.5-9011
Fuses on Rectifier Wheels............................ 2.4-4910 Exciter Cooler.................................................... 2.5-9440
Emergency Ventilation and
Make-up Filter of Exciter................................. 2.4-4930 Appendix
Exciter Coolers............................................... 2.4-4940 Introduction........................................................ 2.9-0060
Ground Fault Detection System...................... 2.4-4990 Symbols for Supply Circuit and
Supervisory Equipment............................. 2.9-0210
Inspection Electrical Tests on Stator Winding
Introduction.................................................... 2.5-0010 with Vaccum Impregnated
Determination of Dewpoint Temperature....... 2.5-0019 Micalastlc High Voltage Insulation........................ 2.9-2300
Packing, Transport and Storage
pf Generator Rotors.............................. 2.5-0030
Preventive Measures for Transport and
Storage of Generator Rotors(Summary) 2.5-0031
Checking Desiccant Inpacking of
Components.......................................... 2.5-0032
Insulation Resistance Measurements
on Rotor and Exciter Windings...................... 2.5-0033
Preparation of Machinery Parts.................... 2.5-0200
Checking the Bearing and Seal Insulation...... 2.5-0300
Leakage Tests............................................. 2.5-0310
Flushing the Oil Piping.................................... 2.5-0320
Measures to Prevent Corrosion
During Inspections......................................... 2.5-1003
2.0-0010-7500/3
Turbogenerators Preface
General
This manual contains information on the operation and

maintenance of the turbogenerator. 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
maintenance personnel are fully familiar with the design of the
turbogenerator plant and receive thorough training in operation
and maintaining the unit. Although all the major points have
been brought out in this manual it is however advisable that the
user should contact BHEL wherever necessary. BHEL does not
take any responsibility for any damage brought out by the mal-
operation of the equipment after unit is taken over by customer.

Turbogenerators Note on the Use of the Manual
General
The turbogenerator instruction manual consists of

the following manual sections : Manual section number
2.0 General
Identification number
2.1 Description
2.3 Operation Variant number
2.4 Maintenance
2.5 Inspection Page number
2.9 Appendix
Each section contains a number of separate
instructions, 2.0-0040-0009/1
The manual contains a Table of Contents together O882E
with a List of Effective Pages,Please check your
manual against this list and advise if there any
omissions. Language Symbol
Date
Identification Number
The identification number consists of the above Supplements
mentioned section number, supplemented by a four-
digit code number. It Is indicated in the bottomright- The turbogenerator manual is updated by
hand corner of odd-numbered pages and in the bottom
supplements consisting of new or revised instructions.
left-hand corner of even-numbered pages.
For the user of the manual, the identification All updates received by the user of the manual
number is a sufficient reference for locating a particular should be filled and considered Immediately.
instruction. However, for ordering an instruction, the
Instruction number must be indicated, The supplements are identified by consecutive
numbers, e.g., Supplement No. 4. The collating
Instruction Number instructions received with each supplement should also
The instruction number of the manual section
be filled in the manual to enable a check whether all
number, the identification number, the variant number,
the page number and date. supplements have been delivered.

Turbogenerators Operation Beyond Contract
General Commitment
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 to
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 rises in

accordance with EC standard. Operating the generator in excess of the capability
curves which are part of this O & M Manual will cause increase in Copper
temperature, thermal expansion and higher insulation stresses. Such operation
is not permited 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.

Turbogenerators Safety Instruction
General General Safety Information for Hydrogen-Cooled
Generators
1. General This sign is followed by information and

instructions aimed at preventing injury to
This section contains the relevant information persons.
necessary for safe operation of a generator.
Although the generator is designed to state-of-art
technology and complies with the applicable safety
This sign is followed by information and
standards, hazards which could result in personal injury
to the user or third parties and damage to the generator instructions aimed at preventing damage
or other property cannot be ruled out completely. to property.
Please read this section carefully and make sure
that you comply with the instructions in order to safeguard
against personal injury and damage to the generator. This sign is followed by instructions to
Please note that the safety information in this section ensure efficient and economic operation of
is general and applies to different types of generators. the generator.
Specific safety instructions are included in the operating
instructions provided for the individual components and
The operating instructions also include other signs.
in the various appendices.
All signs are followed by a short explanatory paragraph.
2. Warnings
3. Normal Generator Operation
The operating instructions use a range of key words
and symbols to identify information which is of particular The function of a generator is to convert rotating
importance. Safety-related information and safety mechanical energy to electrical energy. Alternatively
instructions are likewise introduced by key words such generators are used as phase shifters. When coupled
as “Danger”, “Caution”, “Notice” and “Important’ to to gas turbines, generators are used for turbine startup.
help identify the significance of the instructions more To ensure normal and trouble-free operation of the
easily.
generator it is necessary to comply with the operating
z Danger: instructions as well as the inspection and maintenance
intervals specified for the generator.
This category is used to warn against potential lethal BHEL does not accept any liability for any damage
hazards or serious injury to health if the warning is ignored which may occur as a resuit of use of the generator for
or not properly heeded. any other purpose or noncompliance with the afore-
mentioned operating instructions or inspection and
z Caution: maintenance intervals.
This category is used to warn against potential injury

4. General Organization
to health or major damage to property if the warning
is ignored or not properly heeded. The following instructions must be followed to
ensure safe and reliable operation:
z Notice:
z The operating instructions must always be kept on
This category is used when there is no risk to health hand at the place of installation.
but potential damage to property if the notice is z In addition to the operating instructions, the general
ignored or not properly heeded. legal provisions and other regulations for the
prevention of accidents and the protection of the
z Important:
environment must be observed.
This category is used to identify any information
z Prepare shift procedures. The operating instructions
regarding particular procedures or the use of specific may be used as a basis to add regulations which
tools or materials as well as any information relevant take into account specific conditions such as work
to ensure maximum steam turbine efficiency. organization and work sequences.
z Place signs in the buildings, at exits and entrances
In order to highlight the above warnings and notices and near the generator. Compliance with these
in the text, they are used in conjunction with special signs signs must be ensured.
utilizing pictorial symbols (pictographs) such as the
following:

General General Safety Information for Hydrogen-
Cooled Generators
z Any personnel working on the generator and its 8. Shipment, Erection, Startup, Operation,
auxiliary systems must be familiarized with the Service and Shutdown
operating instructions and shift procedures and in
particular with the safety instructions and regulations 8.1 Shipment
before starting work. This particularly applies to The following safety instructions apply during
personnel such as maintenance personnel who do generator shipment
not work on the generator on a regular basis.
z Protective apparel and equipment must be used
where stipulated or required.
z Ensure that the relevant personnel understands all Danger:
safety instructions and warnings.
z Compliance with all safety instructions and warnings Suspended load. Falling loads may
must be ensured. cause injury to persons. Keep away.
z Any irregular events which occur during operation
must be reported directly, and the generator shut
down if necessary. Notice:
5. Personnel Support and lift generator parts only at

specified points.
With regard to personnel working on the generator,
compliance must be ensured with the following:
z Please refer to the shipping documents for
information about the dimensions and weights of
z Personnel must be reliable. generator components.
z Personnel must be appropriately trained and z Do not remove packaging or protective covers during
qualified shipment
z Activities and associated responsibilities are clearly z Only use specified load attachment points. Only use
defined for the personnel. suitable or specified lifting equipment. The lifting
z Work on the generator is performed by authorized equipment must be in good condition and have a
personnel only. sufficient load carrying capacity.
z Personnel requiring or undergoing training must only z Prevent generator rotor from rope-induced damage
be allowed to perform work on the generator or its by using suitable cushions at load attachment points.
auxiliary systems under the constant supervision of z Only use qualified and experienced staff for attaching
an appropriately qualified member of staff. loads or instructing crane operators. The person
z Work on the electrical systems of the generator may issuing instructions must remain within operators
only be performed by electrical engineers or by sight or in voice contact with him.
suitably qualified personnel under the supervision
of an electrical engineer in compliance with the 8.2 Erection
relevant electrical engineering standards. The following safety instructions apply during
generator erection:
6. Modifications of Generator
Do not carry out any modifications to the generator Notice:

or perform any other work on the generator which might
impair safety. Any changes must be approved by BHEL Do not remove any blocks, braces,
prior to their implementation. anchors and/or cushions used during
shipment until just before final erection
or installation of components.
7. Spare Parts
z Before erection, use the building plans to determine
Spare parts must comply with the technical setdown areas and installation locations for heavy
standards set forth by BHEL and other suppliers. lifts.
Compliance with the aforementioned standards is only z Before erection, remove protective coating “and any
ensured if original parts are used. other protective materials from components using a
suitable cleaning agent.

General General Safety Information for Hydrogen-Cooled
Generators
z Carefully check components for any damage. Notify z All mechanical and hydraulic components as well
manufacturer in writing of any damage. as the generator protection system must be checked
z Empty pockets before entering generator. Record with regard to function and settings.
all tools used in a list and check that tools have z Check insulation resistance of winding.
been completely removed from generator when z Check shaft voltages and currents.
finishing work. z Before excitation remove any moisture caused by
z Remove any foreign materials from the generator. temperature drops below the dewpoint using
z Check efficiency of bearing insulation. suitable methods (e.g. drying).
z Check shaft voltages and currents. z Record all operating data after allowing sufficient
time for steady-state conditions to be established.
8.3 Generator Startup z Prepare startup record.
The following safety instructions apply during
generator startup: 8.4 Operation
generator operation:
Danger:
Fire and explosion hazard due to H2 Danger:

leak. The use of fire or open flame
(welding, oxygen cutting ,smoking, etc.) Hot surface. Parts of the generator may
is not allowed in the vicinity of the become hot and cause burns. Do not
generator, the H2 bottle bank, the gas touch.
dryer, the exhaust gas system and the
H2 unit after start of the hydrogen filling
process. Danger:
Persons with pacemakers must not

Danger: enter the turbine building due to
electromagnetic fields in the vicinity of
To prevent damage by accidental the generator.
supply of compressed air into the
generator after this has been filled with
H2 the hose between the compressed z Check the generator regularly for any visible damage
air filter and the control valve connected or defects. Any changes (including changes in
to the compressed air system must operating behavior) must be immediately reported
be removed or at least visibly to the department and/or person(s) responsible. The
disconnect-ed from the compressed generator must be shut down immediately, if
air system by opening one of the two necessary.
bayonet joints. A built-in check valve z Only use lubricants specified by the manufacturer.
prevents backflow from the z Regularly check condition of brushes and sliprings
compressed air filter. z Carry out and record requisite checks during
generator operation.
Danger: 8.5 Maintenance and Inspection

Rotating components. These may generator maintenance and inspection:
cause injury to persons. Before
commencing with generator startup
ensure that personnel are not exposed
to any hazards during the startup
procedure.
“ Involve engineers from BHEL.

General General Safety Information for Hydrogen-
Cooled Generators
Danger: 9. Waste Disposal
Generator startup. This may cause injury Waste products of any kind (e.g. lubricants) must be
to persons. When working on generator disposed of in compliance with the applicable waste
or auxiliary equipment ensure that this is disposal regulations.
electrically isolated and cannot
accidentally be reconnected. In case of 10. Special Hazards
single shaft combined cycle plants
activities at the rotor, the bearings or See below for safety instructions with regard to elec-
opening of the generator stator are only tric current, heat and noise.
accepted after the steam turbine has been
run down. 10.1 Electric Current
Ensure compliance with the following instructions:
Danger:
Danger:
Do not start turbine-generator set if work
is being carried out on or near the Electric current. The generator must be
generator. shut down immediately in the event of loss
of control voltage.
z Work may only be performed by qualified personnel.
z Ensure compliance with the maintenance and z Work on the electrical systems of the generator may
inspection intervals and the scope of work set forth only be performed by electrical engineers or by suit-
in the operating instructions. ably qualified personnel under the supervision of an
z Operating personnel must be notified before starting electrical engineer in compliance with the relevant
and maintenance, inspections or repair work. electrical engineering standards.
Appoint a suitably qualified supervisor. z Components which are undergoing maintenance
z Empty pockets before entering generator. Record or repairs must be isolated. Check that isolated parts
all tools used in a list and check that tools have are de-energized, then ground and short-circuit. Iso-
been completely removed from generator when late adjacent parts which are still energized.
finishing work. z Regularly check the electrical equipment of the gen-
z Remove any foreign materials from the generator. erator and immediately repair any defects.
z Establish cause of any deposits, abrasion, fretting
corrosion or discoloration and prevent reoccurrence. 10.2 Heat
8.6 Shutdown
Danger:
generator shutdown:
Hot surface. May cause serious burns. Do
not touch.
Danger:
10.3 Noise
Rotating components. These may cause
injury to persons. Ensure that rotor has
coasted down. Do not remove any guards Danger:
until generator has come to a full standstill.
Operating noise of generator may dam-
z Perform and record the requisite checks during and age hearing. Wear ear plugs when in the
following generator shutdown. vicinity of the generator.
z Prepare shutdown report.
z For long shutdown periods, electrically isolate the The generator may produce noise levels of approx.
generator. 90 dB(A) depending on model and type. In the long term
z Take appropriate measures to protect and preserve such noise levels may result in damage to hearing.
generator during shutdown.

Turbogenerators Safe Disposal of Turbogenerator Items
General
In line with ISO 14001 requirements HEEP-BHEL, a) Rubber:

Haridwar has adopted an Environmental policy and
has pledged to fulfil its responsibility of protecting Residue of fluoro-elastomer products, obtained
and conserving the environment around itself. by exposure of fluoro-elastomers like O-rings, rubbers
etc. at very high temperature above 400 degree C, in
The materials, which are scrapped during extreme case of fire etc, should be disposed with
inspections and capital overhaul after consumption great care, such as very high incineration.
of their useful life, are disposed in an environment
friendly manner to protect our natural resources and b) Insulation:
control environment pollution.
Insulation material should be disposed by very
Guidelines given in the following paragraphs can high incineration.
go a long way in planning the activity of scrapping the
hazardous material effectively in an echo friendly c) Plastics and glass:
manner.
May be disposed as scrap material for recycling
A proper system of waste disposal should also and reuse.
be evolved and its compliance ensured and
necessary precautions as published from time to time 3. Lubricating Oil and Grease:
adhered to while disposing hazardous material.
These items can be disposed/recycled/ reused
Generator is manufactured mainly from three as follows:
types of items namely,
a) Lubricating Oil :
1. Metals:
To be recycled after cleaning as far as possible.
Structured steel, Cast steel, Forged steel, brass, After it has become unserviceable, it may be
bronze etc. disposed as follows:
2. Non Metals: Send the discarded oil to registered refiners who

have facilities to reclaim the oil by
Rubber, insulation, plastics, glass etc.
- physio-chemical treatment for further use in
3. Lubricating oil and Greases. non-critical applications.
- send the used oil to parties who are licensed to
Disposal of Generator wastes: handle and dispose used lubricating oil.
- burn off the discarded oil in boiler furnace by
1. Metals: mixing with fuel oil.
May be disposed as scrap metal for recycling and b) Grease:

reuse.
It may be disposed for reuse as low-grade
2. Non- Metals: lubrication.

Turbogenerators Rating Plate Data of Generator
Description
Job Name : RAYALSEEMA TP, STAGE - 3
Bharat Heavy Electricals Limited
Turbogenerator
TTTt TYPE: THRI 108/39GTHTTTTTTTTTHJH P.O. NO. : 10251A12701
3 Phase 50 Hz YY PF=0.85 Lag
247 MVA 210 MW
15750 V 9056 A 3000 RPM
Coolant : Hydrogen Spec: IS 5422, IEC-34
Gas Pressure : 3 kg/cm2 (G) Insulation Class-F
Excitation: Voltage=251 V, Current=2260 A
Division : Haridwar YEAR : 2009

Turbogenerators Generator Design Features
Description Design and Cooling System
1. General in a closed circuit by two axial-flow fans arranged on the

rotor shaft joumals. Cold gas is drawn by the fans from
The two-pole generator uses direct hydrogen cooling the cooler compartments. The cooling gas flow is divided
for the rotor winding and indirect hydrogen cooling for into three flow paths after each fan:
the stator winding. The losses in the remaining generator
Flow path 1
components, such as iron losses, friction and windage
losses and stray losses, are also dissipated through is directed into the rotor end winding space and cools the
hydrogen. rotor winding.
The generator frame is pressure-resistant and
gastight and equipped with end shields at each end. Part of the cooling gas flows past the individual coils for
The generator consists of the following components: cooling the rotor end winding and then leaves the end
Stator : winding space via bores in the rotor teeth and grooves in
Stator Frame the rotor body.
Stator core and winding assembly The other portion of the cooling gas flow is directed from
Baffle and labyrinth rings the rotor end winding space into the slot-bottom ducts
Terminal bushings from where it is discharged into the air gap via a large
Hydrogen coolers number of radial ventilating slots in the coils and bores in
Rotor : the rotor wedges. Along these paths the heat of the rotor
Rotor shaft winding is directly transferred to the cooling gas.
Rotor winding The hot gas mixes with the cold gas of flow path 3 in the
Rotor retaining rings air gap.
Field connections
Sliprings and brush gear Flow path 2
Bearings cools the stator end winding. The stator end winding is
Shaft seals part of the cold gas discharge space behind the blower.
The following additional auxiliaries are required for Bores in the first axial rib behind of which the first hot gas
generator operation: compartment is situated assure effective cooling of the
stator end winding. The cooling gas passes the coil sides
Bearing oil supply system
and leaves the stator end winding via the bores.
Seal oil system
A small part of the cooling gas is supplied to the terminal
Gas system bushings on EE. The cold gas flows into each terminal
bushing via gas pipes from the EE discharge space. It
passes the central bores in terminal bushings, is reversed
2. Cooling System at the opposite end of the copper conductor and then
returned to the EE blower suction space between the in-
The heat losses arising in the generator interior are sulator and the copper conductor.
dissipated to the secondary coolant (raw water,
condensate, etc.) through hydrogen. Flow path 3
Direct cooling of the rotor essentially eliminates hot is directed into the air gap between the rotor retaining
spots and differential temperatures between adjacent ring. The gas flows via a multitude of ventilating slots to
components which could result in mechanical stresses, the stator core and the stator winding, where it mixes
particularly to the copper conductors, insulation and rotor with the hot gas of path 1.
body. The cooling gas then flows radially outward, thereby cool-
ing further portions of the stator core and stator winding.
3. Hydrogen Cooling Circuit The hot gas enters the hot gas compartment and is re-
turned to the coolers for recooling and drawn again by
The hydrogen is circulated in the generator interior the fans.

Turbogenerators General Design Features
Description Stator
1. Stator core and winding assembly during operation are

transmitted to the outer casing via welded springs
The stator is manufactured as a two-part structure: through supporting cages or rings.
the outer casing and the stator core and winding
assembly. Following separate manufacturing, the stator 3.1 Stator Core
core and winding assembly is mounted in the outer The stator core is stacked with insulated electrical
casing by means of welded springs. sheetsteel laminations with a low loss index. To remove
the heat, a large number of spacer segments, placed at
2. Outer Casing intervals along the bore length, divide the core into
sections. Axial compression of the stator core is obtained
The outer casing is of gastight and pressure- by insulated guide bars on the outer circumference,
resistant welded construction. On its inner surface, the clamping fingers, pressure plates and nonmagnetic
outer casing is provided with circumferential and axial through-type clamping bolts, which are insulated from
ribs. the core. The stator core is grounded via one guide bar.
The hydrogen coolers are arranged horizontally in The clamping fingers ensure a uniform clamping
the outer casing. pressure, especially within the range of the teeth, and
End shields containing the shaft seal and bearing provide for uniform, intensive cooling of the stator core
components are bolted to the casing end walls. ends.
Laterally arranged feet are welded to the shell to
support the outer casing on the foundation. The stator 3.2 Stator Winding
feet are firmly bolted to the foundation through the The stator winding is a fractional-pitch two-layer
machine sole plates. type consisting of individual bars. The bars are located
in slots of rectangular cross-section which are uniformly
3. Core and Winding Assembly distributed on the circumference of the stator core. On
account of the global-VPI process, the stator winding is
The mechanical forces and torques arising in the stator firmly bonded to the stator core.

Description Stator Winding
1. Conductor Construction are inserted or used in all locations where a large-area

support is necessary or where spaces have to be filled.
The stator winding is a fractional-pitch duplex lap
type consisting of individual bars. The bars are located 3. Global-VPI Process
in slots of rectangular cross-section which are uniformly
distributed on the circumference of the stator core. The stator core and winding is pre-dried in a vacuum
To minimize the stray losses, the bars are composed tank, evacuated and impregnated by being immersed in
of separately insulated strands which are transposed in epoxy resin.
the slot portion. After this extensive impregnation cycle involving
The electrical connections between the top and pressurizing by the VPI method (vacuum pressure
bottom bars are made with brazed connection straps. impregnation), the surplus resin is drained until the
The stator winding is connected in the generator cooling air passages are free from impregnating resin.
interior. The stator winding connections are brought out The complete stator is then placed in an oven for curing
to bushings. Current transformers for metering and the resin at a temperature of about 140°C (284 0F).
relaying purposes can be mounted on the bushings. The Micalastic system in combination with the
global-VPI process ensures
2. Micalastic High-Voltage Insulation and a void-free high-voltage insulation along the entire length
Bar Locking System of the bars,
a mechanically firm bond between all winding
The high-voltage insulation of the stator winding is components and between the winding components and
provided according to the Mlcalastlc system. the core,
With this insulation system, several half-overlapped firm locking in place of the winding when subjected to
continuous layers of mica tape are applied to the bars. thermal stresses during operation.
The dry mica tape is a composite tape built up from a
thin, highstrength glass fabric and selected micapaper.
The number of layers, i.e. the thickness of the insulation, 4. Tests
depends on the machine voltage. The final layer of
Quality assurance is implemented by
semiconducting tapes applied to the surface within the
slot range serves as outer and end corona protection to strand testing during bar manufacture
prevent partial discharges and arcing in the slot and at impregnation check of the winding during impregnation
the transition from the slot to the end winding. The taped dc test during and after winding installation
bars are then inserted into the slots of the stator core dissipation factor measurement after the global-VPI
and connected up. process and hardening
Following this, all securing, blocking and lashing operat- ac test of the individual phase windings
ions required for the winding support system are performed. as stipulated in the applicable national and international
Glass fabric mats, capable of swelling in impregnating resin, specifications.
Fig.1 Prepared Stator in Global-VPI Plant

Description Rotor
1. Rotor Shaft fiber fabric with Nomex filler are used for slot insulation.
The slot wedges are made of high-conductivity material
The rotor shaft is a single-piece solid forging and thus act as damper winding. At their ends the slot
manufactured from a vacuum casting. Slots for insertion wedges are ‘short-circuited through the retaining rings.
of the field winding are milled into the rotor body. The
longitudinal slots are distributed over the circumference
so that two solid poles are obtained. 3. Rotor Retaining Rings
To ensure that only high-quality forgings are used,
strength tests, material analysis, and ultrasonic tests are The centrifugal forces of the rotor end windings are
performed during manufacture of the rotor. contained by single-piece rotor retaining rings. The
After completion, the rotor is balanced in various retaining rings are made of non-magnetic high-strength
planes at different speeds and then subjected to an steel in order to reduce stray losses. Each retaining ring
overspeed test at 120% of rated speed for two minutes. with its shrink-fitted insert ring is shrunk onto the rotor
body in an overhung position. The retaining ring is
secured in the axial position by a snap ring.
2. Rotor Winding 4. Field Connections

The rotor winding consists of several coils which are The field current is supplied to the rotor winding
inserted into the slots and series-connected such that through radial terminal bolts and two insulated low-
two coii groups form one pole. Each coil consists of power semicircular conductors located in hollow bores
several series connected turns, each of which consists of the rotor and sllprlng shafts. The electrical connection
of two longitudinal and two transverse turns which are is established at the coupling between the rotor and slip
connected by brazing in the end section. ring shafts with Multlkontakt plug-in contacts which allow
The rotor winding consists of silver-bearing copper tor unobstructed thermal expansion of the field current
ensuring an increased thermal stability. leads in both shaft bores.
The individual turns of the coils are insulated from each
other by interlayers. L-shaped strips of laminated epoxy glass
Flg.1 Rotor Shaft

Description Hydrogen Cooler
The hydrogen cooler is a shell and tube type heat All parallel-connected water paths must have equal
exchanger which cools the hydrogen gas in the generator. flow resistances to ensure a uniform cooling water supply
The heat removed from the hydrogen Is dissipated to the cooler sections and equal cold gas temperatures
through the cooling water. The cooling water flows downstream of the individual sections. The required
through the tubes, while the hydrogen is passed around cooling water volume flow is adjusted by control valves
the finned tubes. on the hot water side. Controlling the cooling water
The hydrogen cooler is subdivided into sections which volume flow on the outlet side ensures an uninterrupted
are horizontally mounted In the stator frame. water flow through the cooler sections so that proper
At the turbine end, the water connections are brought cooler performance will not be impaired.
out from the stator frame through gland-type seals To maintain the cold gas temperature at an
allowing for free movement. At the exciter end, the cooler approximately constant level under all operating
tubesheet is solidly bolted to the stator frame. conditions, a motor-operated control valve is arranged
The cooler sections are parallel-connected on their in the common cooling waler outlet line. This control valve
water sides. Shutoff valves are Installed in the lines is activated by temperature transmitters located upstream
upstream of the cooler sections. and downstream of the cooler sections.
Flg.1 Cooling Water Connections in a Double Section Cooler
BHEL, Haridwar 2.1-01440-7500/1

Description Bearings
1. Bearings
The sleeve bearings are provided with hydraulic shaft

lift oil during startup and turning gear operation. To
eliminate shaft currents, all bearings are insulated from
the stator and base plate. 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.
Measurement and any required recording of the
temperatures are performed in conjunction with the
turbine supervision. The bearings have provisions tor
fitting vibration pickups to monitor bearing vibrations.
2. Bearing 011 System
Both bearings of the generator and the bearing of

the exciter unit or slip ring shaft are connected to the Fig. 1 Bearing
turbine lube oil supply.
1. Connection for shaft lift oil

2. Thermocouple
3. Bearing sleeve
Fig. 2 Solid Model of Bearing

Description Shaft Seals
The points where the rotor shaft passes through maintained at a higher level than the gas pressure
the stator casing are provided with a radial seal ring. within the generator casing. The oil drained on the
The seal ring is guided in the seal ring carrier which hydrogen and air sides of the seal rings is returned
is bolted to the seal ring carrier flange and insulated to the seal oil system through drains in the stator
to prevent the flow of shaft currents. The seal ring is end shields. In the seal oil system the oil is
lined with babbitt on the shaft journal side. The gap regenerated by a vacuum treatment and then
between the seal ring and the shaft is sealed with returned to the shaft seals.
seal oil. The seal oil is supplied to the sealing gap On the air side, pressure oil is supplied laterally
from the seal ring chamber via radial bores and an to the seal ring via an annular groove. This ensures
annular groove in the seal ring. To ensure effective free axial movement of the seal ring.
sealing, the seal oil pressure in the annular gap is
Fig. 1 Shaft Seal
1. Oil wiper ring (air side) 9. Oil wiper ring H2side

2. Seal ring chamber 10. Seal strip
3. Annular groove for 11. Rotor shaft
pressure oil 12. Inner labyrinth ring
4. Babbitt 13. Insulation
5. Seal ring inlet bore

Description Seal Oil System for Shaft Seals
1 Construction of the Seal Oil System A vacuum pump keeps the seal oil in the seal oil
tank under vacuum and largely extracts the gas absorbed
The shaft seals are supplied with seal oil from the
by the oil while passing through the hydrogen and air
seal oil system which consists of the following principal
atmospheres. A deterioration of the hydrogen purity in
components:
the generator is thus largely avoided.
Seal oil storage tank (in bearing oil drain line)
Seal oil tank incl. vacuum pump
2.3 Seal Oil Pumps
Intermediate oil tank
Two seal oil pumps are directly connected to the
Seal oil pumps (2 x 100%)
seal oil tank on their suction sides.
Standby seal oil pump (1 x 100%)
One of the two seal oil pumps is always in operation
Pressure controller downstream of each pump
while the second one remains activated for starting. If
Seal oil coolers (2 x 100%)
neither of the two pumps can establish the specified seal
Seal oil filters (2 x 100 %)
oil pressure, the standby seal oil pump is automatically
Differential pressure control valves (2 x 100%)
started. It is directly connected to the seal oil storage
Except for the seal oil storage tank, all the above
tank.
major components are combined in one unit.
The seal oil pressure downstream of each full-capacity
seal oil pump is maintained constant by one pressure
2 Seal Oil Circuit controller each while the respective pump is in service.
The seal oil is drawn from the seal oil tank by the
seal oil pump in service and passed to the shaft seals 2.4 Seal Oil Pressure Regulation
via coolers, filters and differential pressure regulating The seal oil pressure required upstream of the shaft
valve. seals is controlled by the differential pressure control
valve according to the preset value, i.e., the specified
difference between the seal oil pressure and the hydrogen
2.1 Seal Oil Storage Tank pressure.
The seal oil storage tank is a larger-diameter pipe For reasons of availability, two differential pressure
section in the bearing oil return line of the generator. After control valves with graded settings are provided.
the bearing oil supply system has been taken into
operation, the seal oil storage tank will always be partly
filled, which ensures continuous operation of the seal oil 3. Seal Oil Drain
system. The seal oil storage tank and the seal oil tank
are interconnected by piping. 3.1 Hydrogen Side Seal Oil Drain
The exhauster of the waste gas system maintains a The seal oil drained from the hydrogen side is passed
slight vacuum in the seal oil storage tank. to the intermediate oil tank via the generator
prechambers. The intermediate oil tank acts as a gas
barrier. A float-operated valve in the drain line keeps the
2.2 Seal Oil Tank oil level in the Intermediate oil tank at a predetermined
The seal oil tank is arranged below the seal oil level, thus preventing gas from entering the oil drain
storage tank. The oil from the seal oil storage tank is system. During normal operation, the float-operated valve
available at oil column pressure upstream of the float- remains continuously activated to return the hydrogen
operated valve in the seal oil tank inlet. side seal oil to the seal oil circuit. The seal oil leaving the
The float-operated valve in the inlet pipe keeps the intermediate oil tank is admitted into the seal oil tank by
oil level in the seal oil tank at a predetermined level and the action of the vacuum maintained in the seal oil tank.
compensates for a low oil level in the tank by admitting
oil from the seal oil storage tank and the intermediate oil
tank. During normal operation, the float-operated valve 3.2 Air Side Seal Oil Drain
remains continuously activated to admit the volume of The seal oil drained from the air side of the shaft
oil drawn by the seal oil pump in service. seals flows directly into the bearing oil return line for being
returned to the seal oil storage tank.

Description Seal Oil System (Simplified Diagram)
Single Flow Seal Oil System
Fig. 1. Simplified Diagram for Single Flow Seal Oil System
1. Seal oil storage tank 8. Seal oil cooler

2. Vacuum pump 9. Seal oil filter
3. Seal oil tank 10. Differential pressure control valve
4. Pressure controller 11. Shaft seal
5. Main seal oil pump 12. Generator prechamber
6. Check valve 13. Intermediate seal oil tank
7. Standby seal oil pump 14. Flow control valve for seal oil ring relief

Description Gas System
1. General is eight times higher than that of air. For more effective
coolIng, the hydrogen in the generator is pressurized.
The gas system contains all equipment necessary
for filling the generator with CO2, hydrogen or air and
removal of these media, and for operation of the generator 3. Carbon Dioxide Supply (CO2)
filled with hydrogen.
The gas system consists of: As a precaution against explosive hydrogen-air
H2 supply mixtures, the generator must be filled with an inert gas
CO2 supply (CO2 prior to H2 filling and H2 removal.
Pressure reducers The generator must be filled with CO2 until it is
Pressure gauges positively ensured that no explosive mixture will form
Miscellaneous shutoff valves during the subsequent filling or emptying procedures.
Purity metering equipment
Gas dryer CO2 flash evaporator
Flowmeters 4. Compressed Air Supply
2. Hydrogen Supply (H2) To remove the CO2 from the generator, compressed
air must be admitted into the generator.
The heat losses arising in the generator are dissipated The compressed air must be clean and dry. For this
through hydrogen. The heat dissipating capacity of hydrogen reason, a compressed air filter is installed the filler line.

Description Gas System
Simplified Diagram

Turbogenerators Rating Plate Data
Description General and Electrical Data
General
Job Name RAYALSEEMA TP, STAGE-3
Generator Type THRI 108/39
Excitation BRUSHLESS
Year of manufacture 2009
Rated Data and Outputs Turbogenerator

Apparent Power 247 MVA
Active Power 210 MW
Current 9056 A
Voltage 15.75 KV +/- 787 V
Speed 50 s-1
Frequency 50Hz
Power Factor 0.85
Inner connection of stator winding YY
H2 pressure 3 kg/cm2 (g)
Continuous permanent
unbalanced load 8%
Rated Field Current for Rated 2260 A
Output
Rated Field Voltage 251 V
The machines are designed in conformity with VDE 0530/ IEC-34/1 and should be operated according to these
specifications. The field current is no criterion of the load carrying capacity of the turbogenerator.
Resistance in Ohms Turbogenerator

(20°C)
Stator Winding U-X 0.0010656 Ohms
(Standard Value) V-Y 0.0010656 Ohms
W-Z 0.0010656 Ohms
Rotor Winding –
(Standard Value) 0.089242 Ohms

Turbogenerators Technical Data
Description Mechanical Data
Torques, Critical Speeds, etc. Torques and speeds units

Maximum short-circuit torque of stator 6457 Knm
at line to line single phase short circuit
Moment of inertla of generator rotor shaft 4980 kgm 2
Critical speed (calculated) nk1 1282 Rpm
nk2 3551 Rpm
Generator Volume and Filling Quantities Volume Units

Generator Volume (gas volume) 77 m3
CO2 filling quantity 154 m3
H2 filling quantity (4kg/cm2) 424 m3
Weights Weight Units

Stator with end shields and coolers 215300 kg
Shipping weight of stator 196000 kg
Rotor 39000 kg
H2 Cooler twin section including water channels 2700 kg
Component Material Component Material

Rotor Shaft 26 NiCrMoV145 Stator Frame Fe410 WB/IS2062
Rotor copper Silver bearing copper End Shield Fe410WB
Rotor Wedges CuNi2Si Electrial Sheet Steel Cold Rolled silicon
steel 1.5 W/Kg at 1 Tesla
Retaining Rings X8CrMnN1818K Stator Copper ETP Copper
* CO2 quantities kept on stock must always be sufficient for removal of existing hydrogen filling.
All values are approximate.

Description Excitation System
Design Data
A-wheel (positive polarity) BHd L1220 type BHEL EDN make

No. / Type of diodes 30 Nos.
No. / Type of fuses 30 Nos.
Resistance/voltage/current per fuse approx. 300 μΩ , 700V , 400 A
No. of RC networks 6 Nos.
B-wheel (negative polarity) BHd L1320 type BHEL EDN make

No. / Type of diodes 30 Nos.
No. / Type of fuses 30 Nos.
Resistance/voltage/current per fuse approx. 300 μΩ , 700V, 400 A
No. of RC networks 6 Nos.
Stroboscope Type ZEN-SS-77

Voltage 240V
Frequency 50/60 Hz
No. of stroboscope 1 No.
Exciter air dryer FFB-170

Type M/s Bryair Make
Rating 4.6 kW
Voltage 230V
Frequency 50 Hz
Adsorption air flow rate 120 m3/h
Regeneration air flow rate 35m 3/h
No. of dryer 1 No.

Description Cooler Data
Design Data for Hydrogen Cooler Units Materials and Pressure

4 Sections, 25% each
Hydrogen Pressure 3 Kg/cm2 (g) Materials :
Gas Flow 33 m 3/min Fins Cu
Heat dissipating capacity 2248 KW Tubes 90/10 Cu Ni
Cold gas temperature 45 0
C Tubesheets C-Steel
Hot gas temperature 60.5 0
C Water Channels C-Steel
Gas pressure drop 600 Pa Pressures :
Cooling water flow 280 m3/hr design pressure 10 Kg/cm3
Maximum inlet water temperature 38 0
C Test pressure 15 Kg/cm2
Water outlet temperature 45.5 0
C
Water pressure drop 11.5 MWC
Design Data for seal oil cooler Units Materials and Pressure
Oil Flow 12 M3/hr Materials :
Heat dissipating capacity 70 KW Tubes Admirality Brass
Tubesheet C-Steel
Oil inlet temperature 57.5 0
C
Water Channels C-Steel
Oil outlet temperature 45 0
C
Cooling Water Side pressure:
Oil Pressure drop (approximate) 0.7 bar Design pressure 12 Kg/cm2
Cooling water flow 130 m3/hr Test pressure 18 Kg/cm2
C Oil Side Pressure:
Water outlet temperature 38.5 0
C Design pressure 12 Kg/cm2
Test Pressure 18 Kg/cm2
Water Pressure drop (approximate) 3.5 MWC
Design Data for Exciter Air Cooler Units Materials and Pressure
Air Flow 11 m 3 /s Materials :
Heat dissipating capacity 210 KW Fins Cu
Tubes 90/10 Cu Ni
Cold air temperature 43.5 0
C
Tubesheets C-Steel
Hot air temperature 60.1 0
C
Water Channels C-Steel
Air pressure drop 500 Pa
Cooling water flow 200 m3/hr Pressure:
C Design pressure 10 Kg/cm2
Water outlet temperature 39 0
C Test pressure 15 Kg/cm2
Water Pressure drop 4.5 MWC

Turbogenerators Technical data
Description Reactive Capability Curve

Turbogenerators Oil Specification
Description
INTRODUCTION 2. Viscosity lndex Min.97 IS 1448 (P:56)

This standard specifies the turbine oil recommended 3.a Inorganic Acidity Nil IS 1448 (P:2)
for use in governing and lubrication systems of the b Organic Acidity Max. 0.14 IS 1448 (P:2)
turboset. mg. of KOH
per gm of
REQUIREMENTS the oil
c Neutralization no. Max. 0.2 mg D-IS 1012-58
Description
(Total Acidity) of KOH per
Oil of viscosity class ISO VG shall be used. The oil
gm of oil.
shall be a petroleum product with or without additives to
4. Color Max.2 IS 1448 (P:12)
meet the requirement of this standard. The finished oil
5. Specific gravity 0.852 IS 1448 (P:32)
shall be clear and free from water, suspended matter,
at 500C
dirt, sediment and other impurities.
6. Flash point, cleve Min. 2000C IS 1448 P:59
land open cup
The turbine oil shall not contain additives having any
7. Copper strip corro- Not worse IS 14489 P:15
negative effects on the materials of the oil system. The
sion test at 1000C that No. 1
turbine oil must be capable of withstanding bearing
for 3 hrs.
temperature of max. 115°C and oil tank temperature of
8. Pour point -60C Max IS 1448 P:10
max. 65°C without physical and chemical degradation.
9. Rust preventing O-A max. DIN 51585
characteristics
The properties of the oil shall not be affected by
10. Emulsion characte- 40-40-0 DIN 51599
centrifuging or by water washing or by filtering.
ristics (20 mint.)
11. Total acidity after Max. 2.0 mg DIN 51587
Compatibility
1000 hrs. oxidation of KOH per
For the topping up of the oil system it is preferable if
gm. of oil
the oil used is of the same brand and quality as that
12. Foaming charact-
already in the system. However, if the same brand of oil
eristic at 250C
is not available and where it is intended to mix in different
(a) Foaming tendency Max 400 cm3 ASTM D892
products that individually conform to this standard, a
(b) Foaming stability Max 450 s
compatibility test should be conducted before actual
13. Deaseration capacity 4 minutes DIN 51381
mixing the oils. Samples of both oils in equal volumes
at 500C Max.
should be mixed and centrifuged for about 40 hrs. and
14. Ash (% by weight) Max. 0.01 IS:1448 P:4
then mixture must comply fully with the requirements of
15. Water content by Max. 0.01/% ISO 3733
this standard.
weight
16. Content of solid 0.01% max. DIN 51592
Properties
particles by weight
The oil should comply with the requirements given
17. Particle distribution 17/14 min. ISO 4406
in table below when tested according to the test methods
18. Water release 300 S Max. DIN 51589
given in the respective standards mentioned against
each.
For obvious reason we don't give any special recom-
The properties of the turbine medium oil shall be as
mendation to particular brand of oil to be used in the oil
follow :-
system of our turbosets.Any brand of the oil complying
S.No Properties Value Test Method with the above standards may be used e.g., Turbine oil-
1.a Kinematic Viscosity 47.5 CS IS 1448 (P:25) 46 & Servoprime-46 of IOC Turbinal-47 of Hindustan pe-
at 37.8°C to 49.5 CS troleum, Turbol 46 of Bharat Petroleum.
b Kinematic Viscosity 28 CS IS 1448 (P:25)
at 500C

Turbogenerators Gas Specification
Description
1. Compressed Air The compressed air shall be available at a gauge

The compressed air shall be free of corrosive pressure between 6 and 9 bar.
contaminants and hazardous gases, flammable or
toxic. Volumetric flow rate: 40 to 60 dm3/s stp1
144 to 216 m3/h.
The maximum total oil or hydrocarbon content,
exclusive of noncondensables, shall be as close tc
zero (O)w/w or v/v as possible, and under no 2. Carbon Dioxide (CO2)
circumstances shall it exceed one (1) ppm w/w or
v/v under normal operating conditions. Carbon dioxide shall be made available with a purity
> 99.9% v/v. The remaining 0.1 % v/v shall be free of
The compressed air shall be practically free of dust. corrosive contaminants: traces of ammonia (NH3)
The maximum particle size in the air stream shall and sulphur dioxide (SO2) shall not be detectable by
be five (5) micrometers. analysis.
The oxygen content of the expanded air shall be 3. Hydrogen (H2)

between 20 and 21% v/v.
The hydrogen gas shall be made available with a
The dew point at line pressure shall be at least 15°C purity > 99.9% v/v. The remaining 0.1 % v/v shall be
below the minimum possible generator free of corrosive contaminants; traces of ammonia
temperature. In no case should the dew pomt at line (NH 3 ) and sulphur dioxide (SO 2 ) shall not be
pressure exceed 100C. detectable by analysis.
1) stp=standard temperature and pressure, 00C and 1.013 bar, to DIN 1343
The gauge pressures and temperatures indicated are those at the inlets of the generator gas supply units.

Turbogenerators Stator
Description Stator Frame
1. General and axial ribs. The arrangement and dimensioning of

To facilitate manufacturing and assembly, the stator the ribs are determined by the cooling gas passages
consists of the following main components: and the required mechanical strength and stiffness.
Dimensioning of the ribs considers vibration specific
Stator frame features as well, resulting in sometimes larger wall
Core and winding assembly thicknesses than required by strength.
Plate springs In addition, the use of the hydrogen for the generator
End shield bearing incl. shaft seal cooling requires the frame to be pressure-resistant up to
Hydrogen cooler an internal pressure of approximately 10bar (130psig).
Manifolds are arranged inside the stator casing at the
2. Stator Frame
top and bottom for filling the generator with H2 and CO2.
The welded stator frame is fabricated from structural The connections of the manifolds are located side by
steel. The stator inner casing with the electrical active side in the lower part of the generator casing.
components is elastically supported in the outer casing At the exciter end of the outer casing openings are
by plate springs. A rigid casing is required due to forces
provided for bringing out the winding ends or to receive
and torques arising in operation. They are transferred to
the foundation via the welded-on stator feet. the terminal bushings.
The welded casing is internally reinforced by radial The front side casing walls are seated by bolted on
end shields.
Fig. 1 Stator Frame

1 Cooler well 4 Manifold
2 Frame rib 5 Flange for end shield
3 Stacking beam 6 Stator foot

Description Core and Winding Assembly
After stacking of the stator core, the insulated guide The supporting rings are welded together to form a
bars are installed in the respective slots. The required cage. They transmit the mechanical forces to the outer
stiffness is obtained by welding supporting rings and the casing via welded springs.
pressure plates to the guide bars.
Flg.1 Core and Winding Assembly

Description Stator Winding; Total Impregnation-Process
The complete core and winding assembly is pre- drains off the exposed areas of the stator core on heating
dried in a vacuum tank, evacuated and impregnated by without blocking any cooling air passages.
being immersed in epoxy resin. Numerous control measures are performed during
evacuation, impregnation and curing for quality
assurance of the various treatment steps.
Prior to installation of the core and winding assembly
in the outer casing, a dissipation factor measurement of
each phase winding is performed, dependent on the
machine voltage and as stipulated in the applicable
national and International specifications.
A final dielectric test provides evidence of proper
impregnation and confirms the electrical quality of the
stator winding Insulation.
Fig. 1 Global-VPI-Plant at BHEL Haridwar
After this extensive impregnation cycle involving

pressurizing according to the VPI method (vacuum
pressure impregnation), the surplus resin is drained until
all cooling air passages are free from impregnating resin.
The complete stator is then placed in an oven for curing
at a temperature of 140°C.
All mica tapes and pads of glass fabric mat to be
impregnated for improving their mechanical strength
contain a catalyst in order to accelerate curing, whereas Fig. 2 Prepared Stator Core In Global-VPI-Plant
the epoxy resin contains no catalyst and thus freely
Fig.3 Winding Bars with green Insulation Fig 4. Bars layed in stator slots Fig.5 Preperation for
Impregnation
Fig.6 Impregnated Stator Fig.7 Impregnated Stator Winding Fig 8. Impregnated Stator Winding,
Winding after curing in the oven ready for insertion in Stator Body

Description Stator End Shields
Pressure-resistant end shields are provided to close

the cooler assembly at the turbine end and the stator
frame at the exciter end. The end shields contain the
generator bearings and shaft seals.
The horizontally split end shields is of hollow box
type construction. Radial and axial ribs together with the
end walls provide for the necessary stiffness to the end
shields.
All bearing and seal oil inlet and outlet pipes are
permanently installed in the end shield.
1. Flange for shaft seal (H2 side)

2. Drain for seal oil (H2 side)
3. Pipe for seal oil supply
4. Lower half bearing bracket
5. Upper half bearing bracket
1. Stator frame
2. Upper half bearing bracket
3. Joint
Fig.2 Stator End Shield (VIew from Generator
4. Lower half bearing bracket Interior)
5. Connection for bearing oil inlet
6. Connection for bearing oil outlet
7. Connection tor seal oil drain
Flg.1 Assembled Stator End Shield

The lower half end shields accommodate the
insulated bearing saddles. The insulation prevents any
short-circuiting of shaft currents across the bearings.
The bearing saddle supports the spherical bearing
sleeve and due to its shape ensures self-alignment of
the bearing with respect to the rotor axis.
The bearing oil is supplied to the lubricating gap via in
the bearing saddle and in the lower bearing sleeve.
The bearing compartment is sealed on the air side
with labyrinth rings. On the hydrogen side the bearing
compartment is closed by the shaft seal and labyrinth
rings. The oil for the shaft seal is admitted via integrally
welded pipes. The seal oil drained towards the air side Is
drained together with the bearing oil. The seal oil drained
towards the hydrogen side is first collected In a gas and
Fig.3 Three dimensional view of End Shield
airtight prechamber below the bearing compartment for
defoaming and then passed to the seal oil supply system.

Description Hydraulic Testing and Anchoring of Stator
Frame
1. Hydraulic Testing of Stator Frame 2. Sealing the Bolted Flange Joints
Following manufacturing, the empty stator frame with The bolted flange joints which must be gastight (e.g.,
attached cooler header, end shields and terminal box is end shields) are sealed with a plastic sealing compound.
subjected to a hydraulic test at 10 bar to ensure that it will On completion of the assembly of each component, the
be capable of withstanding maximum explosion pressures. sealing compound is injected into the respective
The water pressure is increased in steps, with the pres- grooves.
sure being reduced to atmospheric pressure after each step Round flanges (e.g., manhole covers, bushings.
to allow for measurement of any permanent deformations. terminal box) are sealed with O-ring packings.
This test also checks for leakage at the weld seams.
In addition, the welded structure is subjected to an air Gastight sealing of the flanged connection between
pressure test to check its gastightness. the cooler assembly and the rotor frame is achieved by
field welding.
1 2 3
1. Nipple
2. Press
3. End Shield
Fig. 1 Sealing the End Shield

Description Anchoring of Generator to Foundation
Fig. 1 Anchoring of Generator to Foundation
1. Stator frame
2. Stator foot
3. Foundation
4. Anchor bolt
5. Gravel

Description Stator Core
In order to minimize the hysteresis and eddy-current The stepped arrangement of the laminations at the
losses of the rotating magnetic flux, which interacts with core ends provides for an efficient support of the tooth
the core, the entire core is built up of thin laminations. portion and, in addition, contributes to a reduction of eddy-
Each lamination layer is made up from a number of indi- current losses and local heating in this area. The clamp-
vidual segments. ing fingers are made of non-magnetic steel to avoid eddy-
current losses.
The segments are punched in one operation from After compression and clamping of the core, the core
0.65 mm (0.0256in.) thick electrical sheet-steel lamina- key bars are inserted into the slots provided in the back
tions having a high silicon content, carefully deburred of the core and welded to the pressure plates.
and then coated with insulating varnish on both sides.
The core is stacked with lamination segments in in-

dividual layers while being supported on the pressure
plate with its welded clamping fingers. The segments
are staggered from layer to layer so that a core of high
mechanical strength and uniform permeability to mag-
netic flux is obtained. Stacking mandrels and bolts in-
serted into the winding slots and bores during stacking
provide smooth slot walls.
Fig. 2. Preparations for Compression of Stator core

As shown in Fig. 3, all key bars, except for one, are
insulated from the core. To provide for grounding of the
core along its entire length, a copper rope is inserted be-
tween one grooved key bar and core.
Fig. 1 Stator Core During Stacking

To obtain the maximum compression and eliminate
undue setting during operation. the laminations are hy-
draulically compressed during the stacking procedure
when certain heights of stack are reached. The complete
stack is kept under pressure and located in the frame by
means of clamping bolts and pressure plates.
Fig. 3 Insulation and Grounding of Stator Core
The clamping bolts running through the core are
1. Core key bar 3. Lamination segment
made of non-magnetic steel and are insulated from the
2. Insulation 4. Copper rope
core and the pressure plate.
To remove the heat, spacer segments, placed at intervals
The pressure is transmitted from the pressure plates along the bore length, divide the core into sections to provide
to the core by clamping fingers. The clamping fingers radial passages for unobstructed cooling gas flow. In the core
extend up to the ends of the teeth, thus ensuring a firm end portions, the cooling ducts are spaced more closely to
compression in the area of the teeth. account for the higher losses and to ensure more intensive

Description Stator Core
cooling of the narrow core sections.
1 2 3 4
1 6 5
Fig.1 Grounding of Stator Core
1. Core key bar 4. Radial cooling duct

2. Insulation 5. Pressure plate
3. Copper rope for grounding 6. Clamping finger
Note: The figure does not correspond to the condition as installed. The stotted core beam with the cu-rope was turned
by 1800 for the figure.

Description Stator Core Support Rings and Flat Springs
Fig.2 Solid Model of Stator Core showing the arrangement of Support Rings and Flat springs

Description Cooling of Stator End Portion
Fig.1 Cooling of Stator End Portion (General Arrangement Drawing)

Description Conductor Construction and High-Voltage
Insulation
1. General, Connection strands due to the slot crossfield and end winding flux
The three-phase stator winding is a fractional-pitch leakage and ensures that minimum circulating currents
two layer type consisting of individual bars. Each stator exist. The current flowing through the conductor is thus
slot accommodates two bars. uniformly distributed over the entire bar cross-section so
that the current-dependent losses are reduced.
At the Roebel crossover points, the insulation is rein-
forced with insulating strip inserts.
Fig.1 Lap Type Winding
Tp = pole pitch 1 2
Fig. 1 Lap Type Winding Fig.2 Stator Bar
1. Strand
The slot bottom bars and top bars are displaced 2. Crossover insulation
from each other by one winding pitch and connected at
their ends to form coil groups. To ensure that the strands are firmly bonded
The coil groups are connected together with phase together and to give dimensional stability in the slot
connectors inside the stator frame as shown in the portion, the bars are cured in an electrically heated press.
connection diagram. Prior to applying the bar insulation, the bar ends are
This arrangement and the shape of the bars at the bent with a special device which shapes the involutes
ends result in a cone-shaped winding having particularly over a cone shell. This ensures a uniform spacing of the
favorable characteristics both in respect of its electrical bars over the entire length of the end turns after
properties and resistance to magnetically induced forces. installation.
The bars afford maximum operating reliability, since each In the course of manufacture, the bars are subjected to
coil consists of only one turn. This makes the turn numerous electrical tests for quality control.
insulation and the main insulation identical.
2. High-Voltage Insulation
2. Conductor Construction
The high-voltage insulation is provided according
The bar consists of a large number of separately
to the proven Micalastlc system. With this insulation
insulated strands which are transposed to reduce the
system, several half-overlapped continuous layers of dry
skin effect losses.
mica/glass fabric tape are applied from end to end on
The strands of small rectangular cross-section are
the stator bars. The tape is a composite tape built up
provided with a braided glass fiber insulation and arranged
from a thin, high-strength backing material to which the
side by side over the slot width. The individual layers are
mica is bonded by a small amount of epoxy as an
insulated from each other by a vertical separator. In the
adhesive for further processing.
straightslot portion the strands are transposed by 3600.
The bent bar ends are then provided with a final
The transposition provides for a mutual
protective wrapping of highly flexible glass fabric tapes
neutralization of the voltages induced in the individual
in order to obtain a smooth surface.

Turbogenerators Connetion Diagram of Stator Winding
Description
BHEL, Haridwar 2.1- 2301-7500/1

Description Stator Slot
Fig.1 Stator Slot
1. Stator core 6. Top bar

2. Slot Wedge 7. Center filler
3. Slide strip 8. Bottom bar
4. Top strip 9. Solid strand
5. Vertical separating strip 10. High voltage insulation

Description Micalastic High Voltage Insulation
Totally Impregnated Stator Windings
High-quality mica, selected epoxy resins and a This high-quality insulation system is the result of
matching vacuum impregnation process are the systematic development. Its reliability is assured by
characteristic features of the Micalastic insulation for large continuous quality control throughout the manufacturing
turbogenerators. process.
Fig. 1 Indirect Cooled Post-lmpregnated Stator Winding

Totally Impregnated Stator Windings
Fig. 2 Post Impregnated Stator
Bar Manufacture system which ensures uniform control of the electric field
The bars consisting of insulated strands are without corona discharges.
consolidated to the required size and shape by applying The end turns are provided with an outer cover of
heat and pressure to resin-saturated filler layers in the highly flexible armoring tape in order to obtain a smooth
straight slot section and in the end winding areas. . surface.
The high voltage insulation consists of the
specified number of half-overlapped, continuous Winding Assembly
layers of dry mica tape applied from end to end on The pre-insulated and pre-shaped bars are
the stator bars. A semiconducting tape applied as a carefully placed into the slots of the stator core. In the
final wrapping in the slot section provides for a good end windings, dry glass fabric pads are inserted between
electrical contact with the grounded parts via the stator the coils as spacers, and the end turns are then lashed
core. Specially treated tapes are applied to the bar to each other and to the end winding support structure
portions just outside the slot to provide a corona grading with glass fabric

Post-Impregnated Stator Windings
tapes. The insulated bars in the slot section are covered
with prefabricated glass fabric pads and locked in plan
by inserting slot wedges.
The phase connectors are likewise insulated with

mica tapes. They are secured to the support brackets,
using spacer blocks and lashings similar to those in the
end windings, and then connected to the respective stator
bars.
The stator bars and all phase connectors are then

taped with dry mica tape and with an outer cover of
armoring tape as used on the end turns. .
Impregnation and Curing
The stator core with the coils installed in place

is predried in a vacuum tank, evacuated and impregnated
by being flooded with epoxy resin. After this extensive
impregnation cycle involving the application of
pressure, the surplus impregnating resin is drained.
The complete stator is then placed in an oven for curing.
Fig. 4 Curing Oven
The application of appropriate monitoring meth-

ods ensures adherence to the specified conditions and
limits during evacuation, heating, impregnation and cur-
ing of the fully wound stator.
Fig.3 Vacuum tank for Impregnation
After this extensive impregnation cycle involving

the application of pressure, the surplus impregnating
resin is drained. The complete stator is then placed in an
oven for curing.All mica tapes and parts to be impregnated
for achieving an improved mechanical strength include
an accelerator to speed up the curing process. The
impregnating resin itself contains no accelerator and can
thus drain off from the non-insulated surfaces of the core Fig. 5 End Winding
as heat is applied so that all cooling passages remain Tests
free from resin. During bar manufacture, the standard strand tests
according to VDE/IEC specifications are performed.Only
bars without short-circuits between strands are released
for further

Post-Impregnated Stator Windings
processing. The insulation is applied continuously from end to end on

After installation of the taped bars in the core slots, the stator bars providing effective protection against ov-
dc tests are carried out In order to promptly identify and ervoltages arising during normal operation and against
eliminate any defects and weak points produced in the the high stresses that may occur at the slot ends when
winding during installation without causing damage to high test voltages are applied.
other parts of the Insulation.
After impregnation and curing of the winding, a
dissipation factor vs. voltage measurement as stipulated
in the applicable national and international standard
specifications is performed for each bar between all
individual phase windings and the total winding.
Dissipation factor limit to

KEMA specifications
X= mean value
l l = 1 sigma scatterband
Fig. 7 Electrical Life of Full-Size Bars With
Mlcalastlc Insulation
Fig. 6 Dielectric Dissipation Factor of a Phase
Winding of a Post-Impregnated Fully Wound-Stator Mlcalastic has a long electrical life as determined on
for UN = 10.5 kV as a Function of the Voltage, hundreds of experimental bars and verified on numerous
Measured at RT fullsize bars.
Mlcalastic is a good conductor of heat by reason of
Guiding values for the dissipation factor and its rise its high mica content and the voidfree synthetic resin.
with the voltage are merely given in the KEMA Efficient heat transfer is particularly Important for dissi-
specifications. According to these specifications, the pation of the upper losses in machines that require thick
maximum value shall not exceed 0.04 at 20 % of rated insulation because of the high voltages and are not de-
voltage, and the rise shall not be greater than 0.006 per signed with direct cooled windings.
20 % of rated voltage up to 60 % of rated voltage and
0.008 per 20 % of rated voltage upto rated voltage.
Windings manufactured by the Mlcalastlc post-
impregnation process comply with these limits.
The higher rise of the dissipation factor as compared
to the limit values established for individual conductor
insulations using a guard electrode arrangement
results from the loss attributable to the voltage grading
material applied at the slot ends, A final dielectric
strength test performed at 105 % of the winding test
voltage (Up = 2 UN + 1 kV) serves to verify proper
impregnation and the electrical quality of the insulation
before the stator is installed in the outer frame.
Properties of Mlcalastic
The Micalastic post-impregnation process ensures a
mechanically firm bond between all winding components
and between the winding and the stator which is capable
of withstanding the various temperature rises occurring Fig. 8 Dielectric Dissipation Factor of a Phase Wind-
during operation. The Mlcalastlc system thus provides for ing of a Post-Impregnated Fully Wound Stator for UN
reliable insulation of the windings at all machine voltages. = 10.5 KV as a Function of Voltage and Temperature

Description Construction of High-Voltage Insulation
Fig.1 Construction of High-Voltage Insulation
Item Component Insulant, semiconductive material

No.
1. Strand Insulation Braided glass fiber insulation
2. Strand bonding Epoxy resin
3. Crossover Insulation Micanite
4. Crossover filter Micanite
5. ®
Micalastic insulation Mica tape, vacuum impregnated with epoxy resin
6. Outer corona protection Conductive polyester mat tape
Note: The number of conductors shown does not necessary correspond to the number of conductors of the
generator described.
®
Registered trade-mark.
BHEL, Haridwar 2.1.-2321-0006/1

Description Stator Winding
Corona Protection
To prevent potential differences and possible corona good electrical contact with the grounded stator frame
discharges between the insulation and the slot wall, the via the core.
bars are provided with an outer corona protection in the The semi-conductive end corona protection applied at the
slot section and with an end corona protection at the transitions from the slots to the end winding portions ensures
transitions from the slots to the end winding portions. uniform control of the electric field without corona discharges.
After application of the high-voltage insulation, a semi- The bent bar ends are then provided with a final wrapping
conductive polyester mat tape is applied to ensure a of highly flexible tapes in order to obtain a smooth surface.
1 2 3 1 2 3
Fig.1 Application of Outer Corona Protection Fig.2 Application of Final Wrapping

1. High-voltage insulation 1. Outer corona protection
2. Outer corona protection 2. Final wrapping
3. Bent bar end 3. End corona protection

Description Coil and End Winding Support System
The insulated bars are placed in the slots of the obtained. A small taper angle is used to keep the stray
stator core. All gaps and spaces, due to the design and losses to a minimum.
manufacturing, are filled with pads of glass fabric mat In the end winding areas, the involute-shaped indi-
capable of being impregnated. vidual bars are arranged in parallel and with uniform spac-
After installation of the bars, dc tests are performed to ing. To obtain a short-circuit-proof structure, the bars are
promptly identify and correct any weak points in the insulation. lashed to winding supports and one support ring over
In the slot section of the stator core, the bars are pads of glass fabric mat with glass fabric tapes capable
secured in position with slot wedges. Outside the slot of being impregnated.
section, the bars are shaped so that, with the winding Both the bottom bars and top bars thus form a cone-
placed in the slots, cone-shaped end windings are shaped layer each which ensures mutual support of the bars.
1 2 3 4 5 6 7
Fig.1 End Winding Support System
1. Stator end winding 5. Support bracket

2. Support ring 6. Clamping bolt
3. Ties 7. Pressure plate
4. Winding Support

Turbogenerators Stator End Winding
Description
1 2 3
1. Core
2. Clamping Finger
3. Pressure Plate for core
4. Phase Connector
5. Terminal Bushing

Description Electrical Connection of Bars and Phase
Connectors
1. Electrical Connection of Bars 2. Phase Connectors
The electrical connection between the top and bot- The phase connectors consist of flat copper sections,
tom bars is made by brazing. Before brazing, the bar the cross-section of which results in a low specific current
ends are attached to copper straps or sleeves. After braz- loading. The connections to the stator winding are of
ing, the bar ends and copper straps or sleeves form solid riveted and soldered type and are likewise wrapped with
conductive connections. dry micapaper/glass fabric tapes.
The coil connections are then wrapped with dry The phase connectors are firmly mounted on the
micapaper/glass fabric tapes applied half-overlapped. The winding support, using clamping pieces and glass fabric
thickness of the wrapper depends on the machine volt- tapes.
age. The gaps between the individual coil connections
being sufficiently large, no additional insulation is required.
1 2 3 4
Flg.1 Stator End Winding
1. End winding 3. Phase connector

2. Coil connection 4. Stator core

Description Terminal Bushings
1. Arrangement of Terminal Bushings

The beginnings and ends of the three phase Bushing-type current transformers for metering and
windings are brought out from the stator frame through relaying may be mounted on the bushings outside the
terminal bushings which provide for seal against hydrogen stator frame. The main lead extension is connected to
leakage. the air side connection flange of the terminal bushing.

Description Construction and Cooling of Terminal Bushings
2. Construction of Terminal Bushings 3. Cooling of Terminal Bushings

The tubular bushing is designed for direct gas The loss heat generated in the copper conductor
cooling and consists of a tubular copper conductor with of the bushing is directly dissipated to the cooling gas
connection flange on the hydrogen side and a cylindrical flowing through the conductor.
connection flange on the air side. Cold gas is passed from the TE or EE discharge
The air side and hydrogen side connection flanges being below the hp-cover via the gas duct to the terminal
are silver-plated to minimize the contact resistances of
bushings. The gas flows from the lower connection flange
the bolted connections.
through the copper conductor, leaves the bushing via the
The bushing is insulated with an epoxy resin
bores at the end and is reversed between conductor and
cylinder. The insulator and the tubular copper conductor insulator to the blower suction space.
are sealed against each other by means of an O-ring.
The mounting flange of the bushing is fitted over the
insulator and cemented in position. The mounting flange
is additionally sealed against the insulator by means of
a round-cord packing.
1
5
1 2 3 4 5 6
Fig. 1 Terminal Bushing Fig. 2 Cooling of Terminal Bushings
1. Hydrogen side connection flange 1. Air side terminal bolt

2. Cooling gas inlet 2. Rubber gasket
3. Cooling gas outlet 3. Mounting flange
4. Insulator 4. Insulating cylinder
5. Mounting flange 5. Tubular copper conductor
6. Air side connection flange 6. Hydrogen side connection flange

Turbogenerators Rotor
Description Rotor Shaft
The rotor shaft is forged from a vacuum cast steel Due to the non-uniform slot distribution on the cir-
ingot. Comprehensive tests ensure adherence to the cumference, different moments of inertia are obtained in
specified mechanical and magnetic properties as well as the main axes of the rotor. This in turn causes oscillating
a homogeneous forging. shaft deflections at twice the system frequency. To re-
The rotor consists of an electrically active portion and duce these vibrations, the deflections in the direction of
the two shaft ends. An integrally forged flange coupling the pole axis and the neutral axis are compensated by
to connect the rotor to the turbine is located outboard of transverse slotting of the poles.
the bearing. The rotor teeth at the ends of the rotor body are pro-
Approximately 60% of the rotor body circumference is vided with axial and radial ducts, enabling the cooling
provided with longitudinal slots which hold the field wind- gas to be discharged into the air gap for intensive cool-
ing. Slot pitch is selected so that the two solid poles are ing of the end windings.
displaced by 1800.
Fig. 1 Rotor Shaft
Fig. 2 Solid Model of Rotor Shaft

Description Cooling of Rotor Winding
1. General 3. End Winding Cooling Zone

The rotor winding is symmetrical relative to the The cooling gas for the end winding is drawn from
machine center and the pole axis. The coils in each quarter below the rotor retaining ring by the self-pumping rotor.
obtained by the symmetrical configuration are subdivided The cooling gas enters the spaces between the coils at
into two cooling zones, i.a. the slot cooling zone and the the axial-to-transverse conductor transitions where it
end winding cooling zone, which in turn is subdivided divides into the axial conductor stream and the
into two separate cooling sections. transverse conductor stream. The cooling gas flow is
directed by an appropriate system of cooling gas baffles
2. Slot Cooling Zone of insulating material which ensure intensive cooling of
the rotor coils in the end windings. The gas used for
The cooling gas for the slot portion is admitted into
cooling the axial conductors is discharged to the air gap
the slot bottom ducts below the rotor winding at the end
via ducts in the ends of the rotor teeth, while the gas for
of the rotor body. As the rotor turns, the cooling gas is
cooling the transverse conductors is discharged to the
passed through the radial ducts in the winding, insulating
air gap at the pole center via a cooling gas duct beneath
layers, slot-top fillers and rotor wedges by auto-circulation
end winding and slots in the pole area.
due to the centrifugal pumping head developed by the
rotor and then discharged into the air gap.
Flg.1 Cooling Gas Ducts In Rotor Slot
Flg.1 End Winding Cooling in Rotor

Description R-Cooling System for Rotor

Description Rotor Winding
1. Rotor Winding 2.1 Rotor Slot Wedges
1.1 Construction To protect the winding against the effects of the

The rotor winding consists of several coils which are centrifugal force, the winding is secured in the slots with
inserted into the slots and series-connected such that two wedges. The slot, wedges are made from an alloy
coil groups form one pole. Each coil consists of several featuring high strength and good electrical conductivity,
series connected turns, each of which consists of two and are used as damper winding bars. The slot wedges
lateral and two transverse conductors which are extend below the shrink seats of the retaining rings. The
connected by brazing in the end section. rings act as short-circuit rings to induced currents in the
damper winding.
1.2 Conductor Material
2.2 End Winding Bracing
The conductors are made of copper with a silver
content of approximately 0.1 %. As compared to The spaces between the individual coils in the end
electrolytic copper, silver-alloyed copper features high winding are filled with insulating members. The insulating
strength properties at higher temperatures so that coil members prevent coil movement and are used for
deformations due to thermal stresses are eliminated. intensive cooling of the rotor end winding.
1.3 Insulation
The insulation between the individual turns is made

of layers of glass fiber laminate. The coils are insulated
from the rotor body with L-shaped strips of glass fiber
laminate with Nomex filler.
To obtain the required leakage paths between the coil
and the frame, thick top strips of glass fiber laminate are
inserted below the slot wedges. The top strips are provided
with axial slots of the same cross-section and spacing as
used on the rotor winding.
2. Location of Parts In Rotor Winding Flg.1 Rotor End Winding With Fillers

Description Rotor Slot
Fig.1 Rotor Slot

1. Rotor slot wedge 6. Slot liner
2. Cooling gas duct at ends of rotor body (cooling gas for end winding). 7. Conductor
3. Cooling gas outlet duct in rotor slot wedge 8. Winding insulation
4. Rotor Shaft 9. Slot bottom duct
5. Top strip 10. Ventilating slot through conductors
Note:- The number of conductors shown does not necessary correspond to the number of conductors of the generator described.

Description Rotor End Winding
Fig.1 Rotor End Winding

1. Rotor body 6. Retaining ring
2. Snap ring 7. End ring
3. Terminal lug 8. Nut for balancing weights
4. Rotor winding 9. Radial bolt
5. Filler
Note:The number of conductor of conductors shown does not necessarily correspond to the number of conductors of the generator
described.

Turbogenerators Arrangement of Damper Bars
Description in Rotor Body
1 Rotor body
2 Damper bar
3 Silver-plated rotor end wedge
4 Rotor winding
5 Retaining ring
6 Silver-plated shrink seat
7 Transverse slot in the pole area
8 Rotor wedge

Description Rotor Retaining Ring
The rotor retaining rings contain the centrifugal forces

due to the end windings. One end of each ring is shrunk
on the rotor body, while the other end of the ring overhangs
the end windings without contacting the shaft. This
ensures an unobstructed shaft deflection at the end
windings.
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.
A snap ring is provided for additional protection against
axial displacement of the retaining ring.
To reduce the stray losses and retain strength, the rings
are made of non-magnetic, cold-worked material.
Comprehensive tests, such as ultrasonic examination
and liquid penetrant examination, ensure adherence to
the specified mechanical properties.
The retaining ring shrink-fit areas act as short-circuit
rings to induced currents in the damper system. To ensure
low contact resistance, the shrink seats of the retaining
rings are coated with nickel, aluminium and silver by a
three-step flame spraying process.
Fig. 1 Ultrasonic Examination of Retaining

Ring before Shrink Fitting

Description Field Current Lead
1. General 3. Radial Bolt

The field current lead provides the electrical The current lead located in the axial shaft bore is
connection between the rotor winding and the slipring connected to the rotor winding by a radial bolt and terminal
shaft. lug. Contact pressures are mainained with expanding
The field curret lead consists of: cones. The radial bolt is screwed in the field current lead.
z Current lead in the shaft bore The contact pressures increase due to centrifugal
z Radial bolt force during operation. All contact surfaces are silver-
z Terminal lug plated to obtain a low contact resistance.
2. Field Current Lead in Shaft Bore 4. Terminal Lug

The leads are run in the axial direction from the radial The terminal lug consists of a copper conductor of
bolt to the slipring coupling. They consist of two semi- rectangular cross-section. One end of the terminal lug is
circular conductors insulated from each other and from brazed to the rotor winding, while the other end is screwed
the shaft by a tube. The field current leads are connected to the radial bolt.
to the sliprings at the coupling with MULTI-CONTACT
plug-in contacts which allow for unobstructed thermal
expansion of the field current leads.

Turbogenerators Mechanical and Electrical
Description Connection of EE Coupling
Fig.1 Rotor End Winding

1. Generator rotor 6. Insulation
2. H2-seal between half coupling 7. MULTI-CONTACT plug-in socket strip
3. Coupling bolt 8. MULTI-CONTACT plug-in bolt
4. Slipring rotor 9. Field current lead in exciter rotor shaft
5. Insulation 10. Insulation
Note:- The sketch must not in agreement with all design details of the actual generator.

Description Rotor Fan
The generator cooling gas is circulated by two axial- The moving blades of the fan have threaded roots for
flow fans located on the two shaft journals. To augment being screwed into the rotor shaft. The blades are drop
the cooling of the rotor winding, the pressure established forged from an aluminum alloy. Threaded root fastening
by the fan works in conjunction with the gas expelled from permits the blade angle to be changed. Each blade is
the discharge ports along the rotor. secured at its root with a threaded pin.
Fig.1 Rotor Fan
1. Rotor retaining ring 4. Moving blade

2. Balancing slot 5. Shaft journal
3. Cooling gas inlet

Description Rotor Fan and Fan Baffle Ring
Fig.1 Rotor Fan and Fan Baffle Ring

1. Baffle ring 4. Balancing slot
2. Fan blade 5. Rotor shaft
3. Threaded pin
Fig.2 Rotor Fan

Turbogenerators Cooler
Description Hydrogen Cooler
The hydrogen cooler is a shell-and-tube type heat The return water channel is bolted to the exciter-end
exchanger which cools the hydrogen gas in the generator. tubesheet over a flat gasket. This arrangement permits
The heat removed from the hydrogen is dissipated through the return water channel to be detached for cleaning, even
the cooling water. The cooling water flows through the when the generator is in operation and filled with
tubes, while the hydrogen is passed around the finned hydrogen.
tubes. The turbine-end tubesheet is sealed in the stator
The cooler is subdivided into sections which are housing but is freely movable and capable of following
horizontally mounted in the stator housing. the differential movements between stator and cooler due
The cooling water flows through the tubes to the different thermal expansions resulting from the
according to the cross flow counter-current principle as different materials and temperatures.
referred to the hydrogen flow. The water flows through Attached to the turbine-end tubesheet is the inlet/
the cooler in a horizontal direction. The cold cooling water outlet water channel with its cooling water inlet and outlet
flows to the return water channel on the cold gas side, pipes.
and the heated water is returned on the hot gas side. A seal cap is bolted to the stator housing over the
This cooling water flow passage is obtained through a inlet/outlet water channel. The seal cap has openings for
partition in the inlet/outlet water channel. bringing out the cooling water pipes. Gastight sealing is
Each cooler section consists of the tube bundle, done by gland type seals which are simultaneously
the two tubesheets, the return water channel, and the pressed against the outer circumference of the cooling
inlet/outlet water channel. To obtain a larger heat transfer water inlet/outlet pipes and against the sealing face of
surface, the tubes have copper fins which are metallically these seal gap by a compression ring. This sealing
joined to the tubes by tinning. The ends of the tubes are arrangement allows for free thermal expansion of the
expanded into the tube-sheets. cooler.
The two side walls of structural steel brace the The cooler sections are parallel-connected on their
cooler and direct the hydrogen flow. They are attached to water sides. Shutoff valves are installed in the lines
the tube sheets in a manner which permits them to move upstream and downstream of the cooler sections. The
freely to allow for expansion of the tube bundle. required cooling water volume flow depends on the
Flexible seal strips bolted to the side walls seal the generator output and is adjusted by a control valve on
gaps between the cooler section and the cooler wall, thus the heated water side. Controlling the cooling water
preventing uncooled hydrogen from flowing past the cooler volume flow on the outlet side ensures an uninterrupted
section. water flow through the cooler sections so that proper
The exciter-end tubesheet is larger than the cooler performance will not be impaired.
wall opening and is bolted to the stator housing. Gastight
sealing of this tubesheet is done by a packing.

Turbogenerators Cooler
Description Hydrogen Cooler (Drawing)
1 2
II
3
1. Inlet/Outlet Water Channel

2. Return Water Channel
3. Stator Frame
4. Cooler Tubes
5. Sealing Strip
6. Hydrogen Sealing Gasket

Turbogenerators Bearing
Description Generator Bearings
Fig. 1 Exciter-End Generator Bearing
1. Flange for wiper mounting 3. Stop 5. Bearing insulation

2. Upper bearing sleeve 4. Bearing saddle 6. Lower half of stator end shield
The rotor shaft is supported in sleeve bearings having upper half of the stator end shield. The locator should be
forced-oil lubrication. The bearings are located in the adjusted to maintain a clearance of 0.2 mm between the
stator end shields. The oil required for bearing lubrication bearing sleeve and the insulation of the radial locator.
and cooling is obtained from the turbine oil supply system A stop is provided at the bearing sleeve joint to
and supplied to the lubricating gap via pipes permanently prevent the bearing from turning in the saddle.
installed inside the lower half of the stator end shield and The inner surface of the cast bearing sleeve body is
via grooves in the bearing saddle and lower bearing provided with spiral dovetail grooves which firmly hold
sleeve. the babbitt liner to the bearing sleeve body. The lower
The lower bearing sleeve with its self-aligning outer bearing sleeve has a groove to admit the bearing oil to
portion rests on the bearing saddle. The bearing saddle the bearing surface. The upper sleeve consists of an
is insulated from the stator end shield to prevent the flow overflow groove through which the oil flows over the shaft
of shaft currents and provide for insulation of the generator journals and is fed to the lubricating gap. The oil is drained
bearing from ground. The radial locator serves to locate laterally from the lubricating gap, caught by wipers,
the bearing in the vertical direction and is bolted to the collected in the bearing compartment and returned to the

Description Generator Bearings
turbine oil tank via pipes.

All generator bearings are provided with a hydraulic
shaft lift oil system to reduce bearing friction during startup
of the turbine-generator. High pressure oil is forced
between the bearing surface and the shaft journal, lifting
the rotor shaft to allow the formation of a lubricating oil
film.
The bearing temperature is monitored with
thermocouples located approximately in the plane of
maximum oil film pressure. The thermocouples are
screwed in position on both sides of the lower bearing
sleeve from outside with the detectors extending to the
babbitt liner.
FIg.2 Upper Bearing Sleeve
1. Overflow groove
2. Babbitt
3. Stop

Description Generator Bearings (Typical Arrangement)
1. Connection for bearing vapor exhauster 11. Connection for shaft lift oil
2. End shield, upper half 12. Bearing oil inlet
3. Radial bearing locator 13. Hex plug
4. Upper bearing sleeve 14. Bearing oil drain
5. Tangential bearing locator 15. Connection for level detector
6. Rotor shaft 16. Connection for seal oil inlet
7. Shaft lift oil system 17. Connection for ring relief
8. Bearing saddle 18. Drain for air side seal oil
9. Bearing insulation 19. Drain for H2 side seal oil
10. End shield, lower half * Joint

Description Measuring of Bearing Temperature
1. End shield 5. Bearing Shell

2. Thermocouple lead 6. Thermoelement
3. Insulation 7. Bearing Babbit
4. Bearing seal support

Description Generator Bearing Insulation
1. End Shield 3. Bearing oil inlet

2. Bearing saddle 6. Bearing Insulation
1. End Shield 4. Insulation

2. Bearing Saddle 5. Mounting screw
3. Bearing oil inlet 6. Bearing insulation

Turbogenerators Shaft Seal
Description Description of Shaft Seal
The rotor shaft ends are brought out of the gastight annular groove of the seal ring via passages in the seal
enclosure through shaft seals as shown on the attached ring carrier and seal ring. A continuous film of oil is
drawing. (See also 2.1.4-10610, Shaft Seal- Drawing.) maintained between the shaft and the seal ring. The
With this type of shaft seal, the escape of hydrogen clearance between shaft and seal ring is such that friction
between the rotating shaft and the housing is prevented losses are minimized and an oil film of sufficient
by maintaining a continuous film of oil between the shaft thickness is maintained without an unnecessarily large
and a non-rotating floating seal ring. To accomplish this, oil flow. Temperature rise of the seal oil is therefore small
seal oil is fed to the seal ring in a closed circuit at a which contributes to reliable sealing. The babbitt lining
pressure which is slightly higher than the hydrogen of the seal ring ensures high reliability even in the event
pressure. In addition, the air side seal ring is supplied of mixed friction.
with jacking oil to assure free axial movement. The seal oil pump delivers the oil at a pressure
The shaft seal is characterized by its short axial maintained 0.7 to 1.0 bar above the generator hydrogen
length, its independence from the-respective axial and gas pressure at the shaft seal by means of a differential
radial position of the shaft and an oil supply circuit with pressure valve.
facilities for continuous vacuum treatment of the oil. More Higher pressure oil for ring relief is fed to the annular
details are given in a separate description. (See also groove in the air side seal ring carrier and forced between
2.1.4-44000, Description of Seal Oil System.) the seal ring and the seal ring carrier. In this way the oil
The two halves of the babbitted seal ring float on the and gas pressures acting on the seal ring are balanced,
shaft journal with a small clearance and are guided in and the friction between seal ring and seal ring carrier is
axial direction by a divided seal ring carrier resistant to reduced. The seal ring is thus free to adjust its radial
distortion and bending. The seal ring is relatively free to position, which is important during the starting period.
move in the radial direction, but is restrained from rotating The seal ring will adjust its position according to the
by use of a pin. The seal ring carrier, bolted to the end shaft position as dictated by the oil film thickness and
shield, is insulated to prevent the flow of shaft currents. the vibratory condition.
The oil is supplied to the shaft seal at two different The seal ring need not follow the axial movement of
pressures (seal oil pressure and higher pressure oil for the generator shaft, which is primarily caused by the
ring relief) through the mounting flange of the seal ring turbine expansion. The design permits the shaft to slide
carrier at the end shield. The seal oil is admitted into the through the seal ring without impairing the sealing effect.
Fig. 1 Solid model of Shaft seal assembly

Description Insulation and Sealing of Seal Ring Carrier
1. End shield bearing (top section) 6. Thrust bolt for seal

2. Shaft seal insultion 7. Seal ring carrier (bottom section)
3. Seal ring 8. Rotor shaft
4. Antirotation device 9. Bearing shell support
5. Joint

Turbogenerators Seal Oil System
Description
1. General to the seal oil tank, so that an approximately constant

seal oil pressure is established downstream of the seal
The rotor shaft ends are brought out of the gastight oil pumps.
and pressure-resistant enclosure through shaft seals. The
shaft seals are supplied with pressurized seal oil to 3.2 Seal Oil Pressure Regulation Upstream
prevent hydrogen losses at the shaft and air entry into of the Shaft Seals
the hydrogen-cooled generator. The required seal oil pressure (0.8 to 1.5 bar above
Details of the shaft seal are given in a separate hydrogen casing pressure) is controlled by a pressure
description. regulating valve. In order to ensure greater availability,
As long as the seal oil pressure in the annular gap two pressure regulating valves with graded settings are
exceeds the gas pressure in the generator, no hydrogen provided.
escapes from the generator housing. The shaft seal is Depending on the differential pressure setting, a
supplied with seal oil from a separate system. The oil in larger or smaller quantity of oil flows to the shaft seals,
the seal oil system is the same as that used in the turbine- so that the required seal oil pressure is established at
generator journal bearings. the shaft seals.
The seal oil system consists of the seal oil unit and The function of the pressure regulating valves can
the connecting pipework to and from the generator. The be seen in the attached drawing. Since the gas and signal
arrangement chosen provides for easy and simple oil pressures act in opposite directions, the valve stem is
supervision of the seal oil system. moved upwards or downwards when the pressures
become unbalanced. The valve cone is arranged so that
2. Seal Oil Circuit the valve opens further for a downward movement of the
During normal operation, the main seal oil pump 1 valve stem (occurs at rising gas pressure or falling seal
draws the seal oil from the seal oil tank and feeds it to oil pressure). The increased oil flow results in a rise of
the shaft seals via coolers and filters. The seal oil supplied the seal oil pressure at the shaft seals. Setting of the
to the shaft seals is drained towards the hydrogen side desired differential pressure (set value) to be maintained
and the air side through the annular gaps between the by the valve is done by a corresponding preloading of
shaft and the seal rings. The seal oil which drains towards the working diaphragm. The preloading is adjusted with
the air is returned directly to the seal oil tank via a float a compression spring, the upper end of which is rigidly
valve. The seal oil which drains towards the hydrogen connected to the valve yoke, while its lower end is linked
side is first collected in the generator prechambers and to the valve stem by means of an adjusting nut.
then passed to the intermediate oil tank.
Three seal oil pumps are provided for oil circulation. 4. Seal Oil Drains
In the event of a failure of the main seal oil pump due to
a mechnical or electrical fault, the main seal oil pump 2 The oil drained from the hydrogen side of the shaft
automatically takes over. seals is discharged into the generator prechambers. The
If both pumps fail, the seal oil supply is taken over by prechambers reduce the oil flow and permit the escape
the standby seal oil pump without any interruption. The of entrained gas bubbles and defoaming of the oil.
seal oil supply is thus designed as a self-contained system. Downstream of the prechambers. the oil flows are
combined and returned into the intermediate seal oil tank.
A float valve keeps the oil level in this tank at a
3. Seal Oil Pressure Regulation predetermined level and prevents the ingress of hydrogen
Oil pressures which exceed the generator gas into the vacuum. The oil from the intermediate oil tank is
pressure are required to ensure proper functioning of the returned into the vaccum tank together with the seal oil
shaft seals. The seal oil pressure is controlled in two drained from the air side of the shaft seals via a fIot
stages. valve. It excessive amount of oil is supplied to the vaccum
tank an over-flow upstream of the regulating valve allows
3.1 Seal Oil Pressure Regulation Downstream of the
some oil to return to the seal oil storage tank.
Seal Oil Pumps
The small amount of hydrogen escaping from the
The seal Oil pressure downstream of each pump is
generator together with the oil does not present a danger
separately maintained constant by a self-operated
to the generator surroundings since the seal oil storage
pressure regulating valve working on the relief-valve
tank is connected to the bearing vapour exhausters to
principle.
ensure continuous venting.
Depending on the valve setting and the pressure
signal prevailing (seal oil pressure downstream of the
pump), a large or smaller quantity of seal oil is returned 5. Seal Ring Relief .
To ensure free movement of the seal ring even at
higher casing pressures the shaft seals are provided with

pressure oil for seal ring relief. This system must be in 6. Vacuum Treatment System
operation when the generator is operated at gas pressures
of more than 1 bar. The seal oil in the Vacuum tank is subjected to a
vacuum treatment. A vacuum pump establishes a
The oil supply for ring relief is obtained upstream of vacuum in the vaccum-tank which removes entrained
the differential pressure regulating valve. The required air bubbles from the seal oil. The seal oil supplied to the
pressure setting for each shaft seal is done separately shaft seals by the seal oil pumps is thus largely free of
by means of a flow control valve. gas which prevents a deterloration of the hydrogen purity
in the generator.

Description Constant Pressure Controller
Fig. 1 Constant Pressure Controller
1. Valve disc 6. Compression springs

2. Valve seat 7. Actuating rod
3. Valve steam 8. Working diaphragm
4. Spring retainer for set-point adjustment 9. Vent
5. Relief bellows 10. Signal line

Description Seal Oil Unit
Single-Flow Shaft Seal
1. DIFFERENTIAL CONTROLLER 4. STANDBY SEAL OIL PUMP

2. SEAL OIL PUMP 5. DC MOTOR
3. SEAL OIL TANK

Description Seal Oil Unit
Single-Flow Shaft Seal
1. SEAL OIL PUMP 5. SEAL OIL FILTER

2. SEAL OIL TANK 6. LOWER VALVE FOR SEAL OIL CHANGEOVER
3. INTERMEDIATE OIL TANK ( OIL SIDE)
4. SEAL OIL COOLER 7. CABINET

Description Differential Pressure Control Valve
Fig. 1 Differential Pressure Control Valve

1. Valve housing 7. Impulse connection (-), housing pressure
2. Valve cone 8. Working diaphragm
3. Relief bellows 9. Impulse connection (+), seal oil pressure
4. Interseal 10. Adjusting spring
5. Union nut 11. Adjusting nut for limit reference value
6. Diaphragm housing

Turbogenerators Seal Oil Diagram
Description
TAG NO. DESCRIPTION

_________________________________________________________________
MKA06 PRE CHAMBER TE
MKA06 CL001 Level switch at Pre-Chamber TE
MKA07 PRE CHAMBER EE
MKA07 CL001 Level switch at Pre-Chamber EE
MKW01 SEAL OIL STORAGE TANK
MKW01 AA151 Gate valve between SEAL Oil Storage Tank and Vacuum Tank
MKW01 AA201 Seal Oil Storage Tank drain
MKW01 AA211 U-loop drain after Seal Oil Storage tank
MKW01 BB001 Seal Oil Storage Tank (SOST)
MKW01 CL001 Level switch at SOST
MKW06 H2 SIDE S.O. DRAIN & INTERMEDIATE OIL TANK
MKW06 AA001 Float valve at Intermediate Oil Tank (IOT)

MKW06 AA008 By-pass valve at IOT float valve
MKW06 AA151 Gate valve after float valve of IOT
MKW06 AA201 Drain valve in U-loop of hydrogen side drain
MKW06 AA301 Isolating valve of level gauge of IOT
MKW06 AA331 Isolating valve of level gauge of IOT
MKW06 BB001 Intermediate oil tank (IOT)
MKW06 CL001 Level switch at IOT

MKW06 CL501 Level gauge at IOT
MKW06 CT001 H2 Side Seal Oil Outlet Temp./TE

MKW07 CT001 H2 Side Seal Oil Outlet Temp./EE
MKW08 CT001 Air Side Seal Oil Drain Temp.
MKW10 VACUUM TANK
MKW10 AA001 Float valve at Vacuum Tank

MKW10 AA011 By-pass valve at vacuum Pump
MKW10 AA101 Gate valve at inlet to VT before float valve
MKW10 AA301 Isolating valve of level gauge at Vacuum Tank.
MKW10 AA331 Isolating valve of level gauge at Vacuum Tank.
MKW11 AA121 Isolating valve at inlet to Vacuum Pump-1
MKW12 AA121 Isolating valve at inlet to Vacuum Pump-2
MKW11 AN001 Vacuum Pump-1
MKW12 AN001 Vacuum Pump-2

Description
TAG NO. DESCRIPTION

_________________________________________________________________
MKW11 AA011 Isolating valve at the outlet to vacuum pump-1

MKW12 AA011 Isolating valve at the outlet to vacuum pump-2
MKW10 BB001 Vacuum Tank (VT)
MKW10 CL001 Level switch at Vacuum Tank for level high

MKW10 CL002 Level switch at Vacuum Tank for level low
MKW10 CL501 Level in Vacuum Tank (Level Gauge)
MKW10 CP001 Vacuum Transmitter

MKW10 CP501 Vacuum gauge
MKW11 SEAL OIL LINE PUMP-1
MKW11 AA001 Constant Pressure Regulator after AC Seal Oil Pump (SOP) 1
MKW11 AA031 Safety valve at AC Seal Oil Pump 1
MKW11 AA051 Non return shut off valve after AC Seal Oil Pump 1
MKW11 AA101 Gate valve at inlet of AC Seal Oil Pump 1
MKW11 AA181 Gate valve after constant pr. regulator (CPR) 1
MKW11 AA185 Bypass valve to seal oil system
MKW11 AP001 AC Seal Oil Pump SOP) 1

MKW11 BP301 Orifice Plate before actuator of CPR 1
MKW11 CP001 Pressure Transmitter after AC Seal Oil Pump 1
MKW11 CP501 Pressure gauge after AC Seal Oil Pump 1
MKW11 CT001 Seal oil temp. before seal oil coolers.

MKW11 CT501 Dial thermometer before seal oil coolers
MKW12 SEAL OIL LINE PUMP-2
MKW12 AA001 Constant Pressure Regulator after AC SOP2

MKW12 AA031 Safety valve at AC Seal Oil Pump 2
MKW12 AA051 Non return shut off valve after AC SOP2
MKW12 AA101 Gate valve at inlet of AC Seal Oil Pump 2
MKW12 AA181 Gate valve after constant pr. regulator (CPR) 2
MKW12 AP001 AC Seal oil pump 2
MKW12 CP001 Pressure Transmitter after AC Seal Oil Pump 2
MKW12 CP501 Pressure gauge after AC Seal Oil Pump 2

Description
TAG NO. DESCRIPTION

_________________________________________________________________
MKW13 SEAL OIL LINE DC SEAL OIL PUMP
MKW13 AA001 Constant Pressure Regulator after DC SOP

MKW13 AA031 Safety valve at DC Seal Oil Pump
MKW13 AA051 Non return shut off valve after DC SOP
MKW13 AA101 Gate valve at inlet of DC Seal Oil Pump
MKW13 AA181 Gate valve after constant pr. regulator 3
MKW13 AP001 DC Seal oil pump
MKW13 CP001 Pressure Transmitter after DC Seal Oil Pump
MKW13 CP501 Pressure gauge after DC Seal Oil Pump
MKW21 SEAL OIL SUPPLY LINE COOLER 1 & FILTER 1
MKW21 AA121 Seal Oil Cooler filling valve

MKW21 AA151 3-way valve (bottom) of double change over valve across coolers
MKW21 AA152 3-way valve (top) of double change over valve across coolers
MKW21 AA157 3-way valve (bottom) of double change over valve across
Duplex Filter (DF)
MKW21 AA158 3-way valve (top) of double change over valve across Duplex
Filter
MKW21 AA201 Seal Oil Cooler 1 oil side drain valve
MKW21 AA211 Seal Oil Filter 1 drain valve
MKW21 AA251 Seal Oil Cooler 1 oil side vent valve
MKW21 AA261 Seal Oil Filter 1 vent valve
MKW21 AA341 Isolating valve for DPS across DF
MKW21 AA371 Isolating valve for DPS across DF
MKW21 AC001 Seal Oil Cooler 1
MKW21 AT001 Seal Oil Filter 1 of Duplex Filter
MKW21 CP021 Differential pressure switch with in-built indicator across DF
MKW21 CP501 Pressure gauge after DF
MKW21 CT001 Duplex RTD after DF
MKW21 CT501 Dial thermometer after DF

Description
TAG NO. DESCRIPTION

_________________________________________________________________
MKW22 SEAL OIL SUPPLY LINE COOLER 2 & FILTER 2
MKW22 AA201 Seal Oil Cooler 2 oil side drain valve

MKW22 AA211 Seal Oil Filter 2 drain valve
MKW22 AA251 Seal Oil Cooler 2 oil side vent valve
MKW22 AA261 Seal Oil Filter 2 vent valve
MKW22 AC001 Seal Oil Cooler 2
MKW22 AT001 Seal Oil Filter 2 of Duplex Filter
MKW31 SEAL OIL SUPPLY TE
MKW31 AA001 Differential Pressure Regulator 1

MKW31 AA101 Globe valve at inlet of DPR 1
MKW31 AA111 Globe valve at outlet of DPR1
MKW31 AA112 Globe valve before flow meter
MKW31 AA113 Globe valve after flow meter
MKW31 AA114 Globe (Needle) valve for flow meter bypass
MKW31 AA311 Seal Oil impulse valve to DPR (Needle valve)
MKW31 AA321 Root valve to seal oil/ Hydrogen DPT.
MKW31 AA322 Root valve to Seal oil PT.
MKW31 CF551 Seal oil flow meter TE

MKW31 CP002 Pressure of seal oil before shaft seal/ TE
MKW31 CP051 Pressure switch for seal oil pressure
MKW31 CP551 Seal oil pressure gauge for seal oil to seals.
MKW32 SEAL OIL SUPPLY EE
MKW32 AA001 Differential Pressure Regulator 2

MKW32 AA101 Globe valve at inlet of DPR 2
MKW32 AA111 Globe valve at outlet of DPR 2
MKW32 AA112 Globe valve before flow meter.
MKW32 AA114 Globe(Needle) valve for flow meter bypass
MKW32 AA311 Seal oil impulse valve to DPR 2 (Needle valve).
MKW32 CF551 Seal oil flow meter EE

MKW32 CP002 Pressure transmitter before seals EE

Description
TAG NO. DESCRIPTION

_________________________________________________________________
MKW35 RING RELIEF OIL SUPPLY TE
MKW35 AA001 Flow regulator (FR) TE

MKW35 AA011 Regulating by pass valve across FR TE
MKW35 AA101 Globe valve at inlet of flow regulator TE
MKW35 AA111 Globe valve at outlet of flow regulator TE
MKW35 AA114 Globe valve for flow meter bypass.
MKW35 AA301 Root valve of hydrogen equivalent oil line to DPRs
MKW35 CF551 Ring relief oil flow meter TE
MKW36 RING RELIEF OIL SUPPLY EE
MKW36 AA001 Flow regulator (FR) EE

MKW36 AA011 Regulating by pass valve across FR EE
MKW36 AA101 Globe valve at inlet of flow regulator EE
MKW36 AA111 Globe valve at outlet of flow regulator EE
MKW36 AA114 Globe valve for flow meter bypass
MKW36 CF551 Ring relief oil flow meter EE
MKW39 GAS IMPULSE TO DPRVs
MKW39 AA311 Hydrogen equivalent oil impulse valve to DPR 2

MKW39 AA321 Hydrogen equivalent oil impulse valve to DPR 1
MKW39 AA301 Hydrogen equivalent oil impulse to Seal oil/ H2 DPT
PGB61 COOLING WATER SUPPLY TO SEAL OIL COOLERS
PGB61 AA551 Seal Oil Cooler 1 CW vent

PGB61 AA552 Seal Oil Cooler 2 CW vent
PGB61 AA571 Seal Oil Cooler 1 CW drain
PGB61 AA572 Seal Oil Cooler 2 CW drain

Description Regulator for Seal Ring Relief Oil
Mode of Operation
The oil flows through the regulator in the direction of the actuating diaphragm via a bore in the cone. The
the arrow. The flow rate depends on the cross-sectional actuating diaghragm converts the differential pressure
areas adjusted by the orifice and the cone. For flow produced by the orifice into an actuating force which in
regulation, the pressure before the orifice is transmitted turn adjusts the cone. The pressure drop across the
to the high-pressure side of the actuating diaphragm and regulator is constant and nearly independent of the
the pressure after the orifice to the low-pressure side of pressure before the orifice. This ensures a constant
volumetric flow rate for seal ring relief under all conditions
of operation.
1. Setpolnt adjuster 5. Cone

Fig. 2 Regulator for Constant Flow Rate
2. Protective cover 6. Impulse line
3. Orifice (shown displaced)
4. Seat 7. Actuating diaphragm
Fig. 2 Regulator, Sectional View

Description Bearing Vapor Exhauster
The bearing vapor exhauster In the waste gas system

establishes a slight vacuum condition. The generator
bearing compartments, the seal oil tank, the gas dryer
and in case of single-flow seal oil units, the vacuum
pump, join the vapor exhauster.
The vapor exhauster establishes a vacuum in the
generator bearing compartments which prevents the
escape of oil vapor from the bearing compartments along
the shaft. In addition, the vapor exhauster draws off any
hydrogen gas which may be admitted into the bearing
compartments in the event of a shaft seal failure.
The vapor 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.
For safety reasons, two exhausters have been
arranged. If, due to an electric or mechanical failure, the
exhauster in operation fails, the second ready-for-
operation exhauster takes over.
Fig. 2 Vapor Exhauster -Drawing
1. Packing washer 5. Regreasing device

2. Seal collar 6. Exhauster housing
3. Motor shaft 7. Fan impeller
4. Motor flange
Note: The photograph shows a typical equipment which
may not correspond in all details to the specific equipment
described.
Fig. 1 Vapor Exhauster
1. Drive motor 3. Suction branch

2. Regreasing device 4. Delivery branch

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

Description Vacuum Pump
1. General 3. Technical Data

A vacuum pump establishes a vacuum in the Displacement - 70 Litrs/Min
Vacuum tank and draws off the air released from the oil. Ultimate vacuum - 0.2 mm/Hg
When the alarm High Oil level is given, a level transmitter Oil temp. - 850C (max.)
in vacuum tank switches off the vacuum pump. Motor rating - 0.37 KW
Power supply - 415 volt,3∅,50 HZ
2. Construction and Mode of Operation
The vacuum pump is of oil-sealed rotary sliding vane
type. 4. Oil Seperator
The pump consists of an eccentrically mounted rotor The oil seperator is combined with a float-operated
(4) in a stator (3). The rotor is fitted with two sliding vanes valve, resulting in considerably longer maintenance
(5) which follow the casing bore, thereby dividing the intervals for the vacuum pump. The oil consumption is
pump chamber into several spaces. The volume in each negligibly small, and a daily check of the oil level is not
space varies periodically as the rotor revolves. required. The oil separated from the exhaust air is
The gas drawn in via the intake port into the pump collected automatically and returned to the pump
chamber. After the sliding vane has closed the inlet port, chamber whenever a predetermined oil level is reached.
the air in the pump chamber is pushed forward and Benefits of oil Seperator with oil return :
compressed. Oil injected into the pump chamber serves
for lubrication and sealing between the pump chamber Remove of entrained tube oil particles by filtration.
wall and the vane tips as well as for lubricating and sealing Return of lube oil into the intake channel
the vanes (5) In the rotor (4). downstream of the intake port valve by means of a
The gas compressed in the pump chamber is float-operated valve.
discharged into the waste gas pipe via the discharge port. No operating costs due to loss of lube oil.
The oil entrained in the compressed gas is separated Standard filter element
from the gas in the oil separator which provides for both Built-in relief valve
fiitlation of the oil and removal of mechanical impurities.
To avoid the condensation of vapours in the pump The filter is installed at the exhaust port of the
chamber, a pre-determined quantity of air (gas ballast) Vacuum pump, and lube oil return pipe is connected to
is admitted at the beginning of the compression cycle. the intermediate flange beneath the intake. An effective
The gas ballast valve is opened and screwed by means filter element separates the entrained oil from the exhaust
of sowed handle. air.
A very small quantity of secondary air which is The oil collects in the housing of the vapours filter.
additionally admitted into the pump chamber has a Whenever a predetermined oil level is reached the rising
silencing effect and prevents the knocking noise (oil float opens an outlet port. The lube oil is drawn through
hammer) normally occurring when the ultimate pressure the pipe connecting the outlet port to the intake and
is reached. returned to the tube connecting the outlet port to the intake
When the vacuum pump is stopped, the main return and returned to the lube oil circuit of the vacuum pump.
valve provided in the exhaust side gets closed and seals
the vacuum in the tank.
The built-in oil sight glass allows easy checking
of the oil level in the pump.

Description Seal Oil Coolers and Seal Oil Filters
1. Seal Oil Coolers sealed with viton ‘O’ Ring. The Iower tube plate is held
The seal oil coolers are multiple-pass heat ex- between the lower water box. Drain and vent plugs are
changers with bare tubes. The seal oil circulates through provided on upper & lower water box to facilitate draining
the coolers outside of the tubes with shell baffles of water/oil.
directing the fluid in crossflow. The cooling water flows
through the tubes. 2. Seal Oil Filters
The cooler consists of the cooler shell the upper and
lower water boxes and the tube bundle with integral inner The seal oil filters are of magnetic strainer type, the
casing with the upper and lower tube sheets. The inner magnetic strainer consists of the filter housing with a
casing ensure perfect sealing with baffles and prevents filtering cage and the filter cover.
oil by-passing. The filtering cage consists of fine-mesh wire cloth
The cooling water inlet and outlet flanges and an with support strainers on both sides and the magnet bars.
opening for cooler cleaning are located at the lower water The seal oil entering the filter must first passes through
box. The seal oil inlet and outlet flanges are located on the magnetic field set up by the magnet bars so that aII
the cooler shell. The lower tube sheet is stationary and iron particles contained in the seal oil are attracted by
fixed in position between the lower water box and the the magnet bars. The seal oil then flows through the fine-
cooler shell. mesh wire cloth which retains all dirt particles containing
The upper tube sheet is a floating type and no iron.

Description Seal Oil Cooler
1. Deflection Chamber 4. Tube bundle

2. Seal 5. Shell
3. Screw union 6. Cooler Foot

Description Seal Oil Filter
1. Changeover Lever 4. Drain

2. Vent 5. Pressure Equalising Valve
3. Filter housing with strainer wit magnetic 6. Differential Pressure Indicator
bars

Description Vacuum Regulating Valve
General
time constant and so precisely that the preselected
The MR 16 diaphragm pressure regulator is an
control pressure is kept constant with an inaccuracy of
absolute pressure controller by means of which the
only approximately 2%.
pumping speed of vacuum pumps can be matched
automatically and without input of energy to the gas
The instrument is equipped with all valves and
accumulation in the vacuum system.
Connections required to enable easy adjustment and
control of reference pressure and system pressure under
This regulation is achieved with an extremely low
varying operating conditions.
time constant and so precisely that the preselected control

Turbogenerators Gas System
Description
1. General
The gas system consists of the following and low pressure side protects the pipe system against
components: inadmissible high pressure.
CO2 Distributor
H2 Distributor 4. Compressed Air Supply
Gas dryer To remove the CO 2 from the generator, a com-
Gas Unit pressed air supply with compressed air filter is connected
The design of the gas system complies with the to the compressed air system of the power plant.
safety regulations according to DIN VDE 0530, Para 3 Under all operating conditions, except for CO2 purging,
and with the German pressure vessel code. the compressed air hose between the filter and the
generator pipe system should be disconnected. This
2. Hydrogen Supply visible break Is to ensure that no air can be admitted into
The hydrogen for the generator is supplied from a hydrogen filled generator.
the Hydrogen Distributor. The hydrogen should have a
minimum purity of > 99.9% v/v. 5. H2 Supply System
2.1 H2 Distributor 5.1 H2 Supply Unit

The H2 bottles are connected to the manifold on the To aid in operation of the gas system, the Gas unit is
distributor. Valves on the bottles and valves on the furnished with a mimic diagram on the face of the panel.
manifold allow replacement of individual bottles during The shutoff valves used in the gas system are of a
operation. The hydrogen is stored In the steel bottles at special type ensuring gas tightness.
a very high pressure. The hydrogen gas available in the
manifold at bottle pressure Is passed to two parallel 5.2 Casing Pressure Measurement
connected pressure reducers for expansion to the For measuring and checking the gas pressure in the
required Intermediate pressure and Is then passed to generator, the Gas Unit is provided with a pressure
pressure reducers in the Gas unit for expansion to the transmitter and pressure gauges for local measurement.
pressure required for generator operation. Relief valves For safety, the pressure transmitter is of an explosion proof
on the low pressure sides of all pressure reducers are design.
connected to an outlet pipe system through which any
excess hydrogen Is passed to the atmosphere. Single- 5.3 Electrical Purity Mater System
stage construction of the pressure reducers ensures a The transmitter for the CO2/H2 purity meter system in
constant pressure, even under low or no flow conditions, the H2 supply unit is also of an explosion proof design.
and allows large volume flow, of hydrogen to be reduced The meter system operates on the thermal conductivity
In pressure during the hydrogen filling procedure. melhod. The meter system measures the H2 content of
the gas in the generator as well as the composition of
3. Carbon Dioxide Supply gas mixtures (CO 2/air and H2/CO 2) during filling and
As a precaution against explosive mixtures, air must emptying of the generator. This system is housed In a
never be directly replaced with hydrogen during generator separate Gas panel ( Gas analyser cabinet ).
filling nor the hydrogen replaced directly with air during
the emptying procedure. In both cases, the generator 5.5 Gas Analysis
must be scavenged or purged with an inert gas, carbon In addition, facilities are provided for gas sampling
dioxide (CO2) being used for this purpose. for chemical analysis of the gas in the generator.
3.1 CO2 Distributor 8.0 Refrigeration Gas Dryer

The carbon dioxide Is supplied in steel bottles in A small amount of the hydrogen circulating In the
the liquid state. The bottles should be provided with generator for cooling is passed through a gas dryer. The
risers to ensure complete emptying. The arrangement gas inlet and gas outlet pipes of the gas dryer are
of the CO2 distributor corresponds to that of the H 2 connected at points of the generator with dlfferant static
distributors. The liquid CO 2, which is stored under heads (differential fan preesure), so that the gas Is forced
pressure, is fed to the CO2 vapouriser. through the dryer by the differential pressure only.
3.2 CO2 Vapourlsor The gas to be dried is passed through the drier
The liquid CO2 Is evaporated and expanded in a and is cooled sufficiently to condense the moisture from
CO2 vapourisor. The heat for vaporization is supplied to gaseous to liquid state with the help of Refrigeration
the vapourisor electrically. A temperature control is system. The moisture is separated from the gas in the
provided so that freezing of the vapourlsor is prevented, form of water droplets and is collected in drain collector.
and the CO2 is admitted into the generator at the proper The dried gas is returned to the generator. The drier also
temperature. One relief valve each on the high pressure condenses any oil vapours present in the hydrogen gas.

Turbogenerators Gas System Diagram
Description
TAG NO. DESCRIPTION

___________________________________________________________
MKG10 H2 SUPPLY FROM CYLINDER
MKG10 AA111 Gas valve between hydrogen cylinders and gas manifold
MKG10 CP001 Pressure transmitter on hydrogen gas manifold
MKG10 CP501 Pressure gauge on hydrogen gas manifold
MKG11 H2 SUPPLY PR-1
MKG11 AA121 Gas valve at inlet of first stage pressure regulator 1

MKG11 AA151 Gas valve at outlet of first stage pressure regulator 1
MKG11 AA160 Hydrogen gas inlet from hydrogen distributor to gas unit
MKG11 BY001 First stage hydrogen pressure regulator 1
MKG12 AA121 Gas valve at inlet of first stage hydrogen pressure regulator 2
MKG12 AA151 Gas valve at outlet of first stage hydrogen pressure regulator 2
MKG12 BY001 First stage hydrogen pressure regulator 2
MKG15 AA121 Gas valve at inlet of second stage hydrogen pressure regulator 1
MKG15 AA151 3-way valve at outlet of second stage pressure regulator
MKG15 BY001 Second stage hydrogen pressure regulator 1
MKG16 AA121 Gas valve at inlet of second stage hydrogen pressure regulator 2
MKG16 BY001 Second stage hydrogen pressure regulator 2

Description
TAG NO. DESCRIPTION

_____________________________________________________________
MKG18 MAIN H2 SUPPLY & DISCHARGE LINE
MKG18 AA101 3-way valve for hydrogen supply to generator

MKG18 CP001 Hydrogen pressure transmitter for Gen. casing pressure
MKG18 CP501 Hydrogen pressure gauge for Gen. casing pressure
MKG19 GAS EXHAUST LINE
MKG19 AA155 Gas valve for purging gas to atmosphere

MKG19 BP155 Orifice plate in gas discharge line
MKG21 HYDROGEN GENERATOR PLANT LINE
MKG21 AA160 Connecting valve to hydrogen generator plant
MKG25 GAS ANALYSER
MKG25 AA021 Gas valve between generator and gas analyser cabinet
MKG25 AA022 Gas valve between generator and gas analyser cabinet
MKG30 GAS SAMPLING
MKG30 AA401 Gas sampling valve on gas unit

MKG30 AA410 3-way valve for measuring gas supply to gas analyser
MKG31/ 35 GAS PURITY METER LINE
MKG31 AA101 Isolating valve for cylinder hydrogen/ carbon dioxide gas to
gas analyzer
MKG31 CQ001 Gas Analyser
MKG35 AA381 Isolating valve at generator for gas from Gas Analyser.
MKG69 GAS DRIER
MKG69 AA101 Gas valve at the inlet of oil trap

MKG69 AA112 Drain valve for oil trap
MKG69 AA501 Outlet from Refrigeration Gas Drier-1
MKG69 AA504 Inlet to Refrigeration Gas Drier-1
MKG69 AA506 Inlet to Dew Point Meter
MKG69 AA507 Outlet from Dew Point Meter
MKG69 AA508 Inlet to Refrigeration Gas Drier - 2
MKG69 AA509 Output from Refrigeration Gas Drier - 2
MKG69 BT001 Refrigeration gas drier-1
MKG69 BT011 Refrigeration gas drier-2
MKG69 BT002 Oil Trap
MKG69 CL001 Level switch at oil trap
MKG69 CM001 Dew Point Meter .

Description
TAG NO. DESCRIPTION

_____________________________________________________________
MKG70 CO2 SUPPLY FROM CYLINDER
MKG70 AA111 Gas valve between carbon dioxide cylinders and manifold
MKG70 CP501 Carbon dioxide manifold pressure gauge
MKG71 LINE UP TO CO 2 VAPOURISER
MKG71 AA031 Safety valve at inlet of CO2 Vapouriser

MKG71 AA131 Isolating valve at inlet of CO2 Vapouriser
MKG71 AH001 CO2 Vapouriser
MKG71 CT001 Thermostat at CO2 Vapouriser

MKG71 CT501 Dial thermometer at CO2 Vapouriser
MKG75 LINE AFTER CO2 VAPOURISER
MKG75 AA035 Safety valve at outlet of CO2 Vapouriser

MKG75 AA036 Gas valve between gas unit & CO2 distributor
MKG75 BP151 Orifice plate at outlet of CO2 Vapouriser
MKG78 CO 2 SUPPLY TO GENERATOR
MKG78 AA111 3-way valve for CO2 supply/ discharge
MKG91 AIR SUPPLY LINE
MKG91 AA101 Air inlet valve before water and oil trap
MKG91 AA105 Air inlet valve after water and oil trap
MKG91 AT001 Water and oil trap

Description CO2 Vapourisor
1 General heat transfer to the copper pipe coil and thus to the
CO2 is used to displace air from the generator CO2 flowing through the pipe coil.
before hydrogen filling and to displace hydrogen from The heat transmitting liquid is filled into the CO2
the generator before filling the generator with air. vapourisor through the expansion vessel mounted on
Since the CO2 is available in the liquid state, it top of the housing. For protection against excessive
must be expanded into a gas before use. The CO2 is heating, a thermostat maintaining a constant
expanded in a CO2 vapourisor. temperature is arranged in the housing holding the
heat transmitting liquid. For protection against
2 Design features and mode of operation
excessive pressures in the CO2 line, one relief valve is
The CO 2 vapourisor consists of a tubular
housing closed by flanges at both ends. One arranged before and after the CO2 vapourisor.
flange carries electrical heating elements, which are The orifice at the CO2 outlet of the expansion
connected to terminals in the terminal box mounted vessel provides for an expansion of the CO2 obtained
external to the flange. The opposite flange contains from the bottles from a pressure of 25 to 7 psig.
the inlet and outlet to the cooled copper pipe Heating of the CO2 in the copper pipe coil is sufficient
of the evaporator. The horizontally arranged housing is to prevent icing of the expansion device at the prevailing
filled with a heat transmitting liquid to ensure a better flow velocities.
1 Thermometer 8 Shutoff valve before CO2 flash evaporator

2 Vent for heat transmitting liquid 9 CO2inlet
3 Copper pipe coil 10 CO2 outlet
4 Insulation 11 Housing
5 Expansion vessel 12 Heating element
6 Relief valve before CO2 flash evaporator 13 Drain for heat transmitting liquid
7 Thermostat 14 Terminal box
Fig. 1 CO2 flash evaporator

Description CO2 Flash Evaporator Control Logic
1. Activation 2. Deactivation
The heater of the CO2 flash evaporator is switched The heater of the CO2 flash evaporator is switched
on by setting the switch to the On position. off by setting the switch to the Off position.
The temperature of the heat transfer liquid in the
CO2 flash evaporator is controlled by the thermostat. 2.1 Conditions for Switching Off
which is designed as an on-off controller to maintain Switch in position Off
proper temperature. and
temperature of CO2 flash evaporator heater MKG71
1.1 Conditions for Switching On CTOO1 > set value.
Switch in position On
and
temperature of CO2 flash evaporator heater MKG71
CTOO1 < set value.
MKG71 CT001 < set value
MKG71 CT001 >set value

Switch in position off
Switch in position on
CO2 flash evaporator heater Off CO2 flash evaporator heater On

Turbogenerators Refrigeration Dryer
Description
1.0 Introduction a gas to gas heat exchanger. The hot moist gas on the primary
The gas to be dried is passed through the drier side is cooled in advance through the dried and cold gas on the
and is cooled sufficiently to condense the moisture from secondary side. This heat exchanger is shell and tube type with
gaseous to liquid state with the help of Refrigeration cold gas passing through tubes.
system. The moisture is separated from the gas in the After the pre-cooling, the H2 gas passes through
form of water droplets and is collected in drain collec- the evaporator which is Freon to gas heat exchanger. In
tor. The dried gas is returned to the generator. The drier this way cooling takes place at constant pressure dew
also condenses any oil vapours present in the hydro- point up to 2-3° C. The evaporator is again a shell and
gen gas. tube type heat exchanger in which refrigerant from con-
denser passes through copper tubes and precooled
2.0 Technical Data : H2 gas surrounding the tubes. This way heat from H2
a)Capacity : 40 m3 / hr gas is taken way by liquid circulating through tubes.
b)Inlet temperature : 60 ° C max . The H2 gas sheds excess moisture, which is col-
c)Inlet pressure (Design) : 4 kg/ cm2 (g) max lected in the condensate chamber. The cold dry H2 gas
d)Outlet gas dew point : + 3 ° C to + 5 ° C is passed through pre-cooler where it is heated to about
e)Refrigerant : Freon 22 8-10° C below the inlet gas temperature and is finally
f)Compressor capacity : 3225 Kcal / hr led to the generator.
g)Power supply : 230 V AC. 1 phase The condensate chamber is provided with a sight
h)Inlet / Outlet flange : Nb 50 NP 10 glass. The water from the condensate chamber shall
Connections be manually drained. The gaseous Freon leaving evapo-
i)Unit size ( Lx BxH ) : ~ 1100 x 900 x 1620 rator is compressed by a hermetically sealed compres-
j)Unit weight : 400 kg (approx.) sor and cooled in the condenser. The compressor,
therefore, provides the required cooling power.
3.0 Main Components:
The dryer comprises of the following main 6.0 Instrumentation
components: For monitoring the performance of the dryer, following
• Hermetically scaled compressor instruments are provided on the front panel of the dryer:·
• Condenser
• Shell / tube type evaporator (Freon to H2 heat • Temperature gauge at H2 gas inlet to dryer
exchanger) • Temperature gauge at H2 gas outlet from dryer
• Fan for condenser • Evaporator gas temperature indicator
• Pre- cooler (Gas to gas heat exchanger )
• Condensate chamber The setting of the Digital temperature controller
shall decide the pressure dew Point of dried H2 gas.
4.0 Special Constructional Features The compressor shall be cut off automatically when
Designed to ensure very low pressure drop in the primary the gas is cooled to 2-3°C in the evaporator and shall
Gas Circuit of the order of 8mm water column. restart at about 6-7°C which is the reset temperature.
Electrical equipment and Hydrogen containing equipment All the gauges, controls and lamp indications are
are isolated through a physical barrier for ensuring safety. The provided on the front panel of the dryer for ease of
electrical equipment is housed in the bottom portion and equip- operation.The electrical items of the dryer are housed
ment containing hydrogen gas including piping are housed in the in the bottom part of the dryer and Hydrogen circuit is
top portion. Any H2 gas leakage gets vented out from the top housed in the upper part with a separator in between.
ventilating holes. The drier can be programmed to The top portion is provided with vent outlet. The dryer
shall be mounted on a fixed foundation and connected
run automatically for a chosen cycle of - On Time - Off Time.
across turbine end generator fan.
Modular Construction: Major components of the refrig-
eration circuit ( electrical circuit ) can be taken out and replaced
7.0 General Arrangement and Installation
in situ.
All butt welds are 100% radiographed. The electrical items of the dryer are housed in
Incorporation of a precooler to increase efficiency as well the bottom part of the dryer and Hydrogen circuit is
as to increase the temperature of outgoing gas from chiller to housed in the upper part with a separator in between.
generator to avoid thermal jerks. The top portion is provided with vent outlet. The dryer
shall be mounted on a fixed foundation and connected
5.0 Description across turbine end generator fan.
Moist Hydrogen from the generator is first passed through

Turbogenerators Automatic Controls
Description Cooling Gas Temperature Control
Due to load variations during operation and the The resulting deviation is fed back to the controller which
resulting thermal expansions and contractions. the actuates the cooling water control valve with its output
generator is subjected to stresses. signals.
In order to reduce these stresses. the hydrogen To improve the quality of control, the hot gas
cooling circuit is provided with a temperature control temperature is additionally fed to the controller as
system to control the hydrogen cooling gas temperature vanishing pulse. Fast-rate load changes are thus detected
so that the active generator components are maintained and evaluated at an early stage
at the proper temperature level. The cooling water supply to the hydrogen coolers is
The requirements for the temperature control system opened already during startup of the unit when the
are described below: temperature of the hydrogen cooling gas has risen due
to the windage losses at the gas.
In order to maintain a low temperature level In the
ϑ cold = Cold gas temperature generator, the reference of the cold gas temperature (26-
ϑ hot = Hot gas temperature 50°C) should be set at the lowest possible value
dependent on the cooling water temperature, ensuring
Δϑ = ϑhot - ϑcold with generator carrying full load that the cold gas temperature will not drop below the
minimum level of 10°C during startup. .
The temperature rise Δϑ at full load is the temperature Parallel shifting of the curves shown in Fig. 1 is
difference between the hot and cold hydrogen cooling possible by adjustment of the cold gas reference.
gas as given in the hydrogen cooler design data. The control valve must be absolutely tight when in
The hydrogen cooling gas temperature control the closed position to ensure that the cooling gas
system controls the cold gas temperature by throttling temperature will not drop while the generator is being
the cooling water flow on the hydrogen cooler outlet side shut down.
so that a constant cold gas temperature is maintained For details on the operation and technical features
over the entira load range. of this equipment, see equipment supplier’s operating
The cold gas temperature is measured directly after instructions.
the hydrogen cooler and fed to the PI controller as The required temperatures for setting the cooling
controlled variable. In the controller. the controlled variable gas temperature control system are stated In Cooler Date
is compared with a constant reference set value. and Oparating Values.
Fig.1 Cooling Gas Temperature as a Function of Generator Load

PI Controller (GAMP)
+ -
SUM
2
S
6
40 O C
+ -
SUM
2
Adjustable 5-50O C
3
5
PI
1 4
Feedback 4-20 ma
H2 cooling gas
Actuator
M Motor
7
Cooling Water
Cold Gas Temperature Control valve
GENERATOR
1. Temperature RTD (PT100) 5. Position indicator with deviation indication

2. Summing junction 6. Reference Setter
3. PI Controller (soft) 7. Motor operated control valve
4. Control tile
Fig.2 Control Diagram
2.1-8010-0007/2
Turbogenerators Control, Protection and Monitoring Devices
Description Safety Equipment for Hydrogen Operation
The use of hydrogen as coolant in the generator The loop is designed to withstand momentary pressure
calls for special safety equipment to ensure that surges.
hazardous operating conditions which, might endanger
personnel or the plant, will not occur. The bearing oil circuit and the seal oil circuit are
separated from each other. Via the ring relief a small
The safety and protective measures provided for the amount of oil is continuously admitted into the seal oil
generator are described in detail in this section. The circuit. The oil admitted is returned to the bearing oil
required measuring and alarm equipment is discussed circuit from the oil drained towards the air side. The return
elsewhere in this manual. oil is admitted to the seal oil storage tank.
During normal operation. leaks may develop which The measures outlined above have the following effects:
result in a continuous escape of hydrogen. Long-time z The bearing compartments and the oil drain pipe
experience has shown that no operational restrictions
are ventilated continuously so that no explosive
are required as long as the hydrogen losses do not
hazard will arise during normal operation.
exceed 18 m3 (s.t.p.)* during any 24-hour period. The z During normal operation, practically no hydrogen will
surroundings of the generator and the hydrogen supply enter the turbine lube oil tank via the loop seal
system should not be endangered if sound engineering together with the seal oil drained from the shaft
principles were followed in plant design and provision is seals, since the hydrogen is already extracted in the
made for ample ventilation of these areas so that the seal oil storage tank.
formation of localized hydrogen pockets or explosive z The isolating action of the loop seal prevents the
hydrogen-air mixtures is precluded. hydrogen escaping due to small leakages from
flowing into the turbine through the only partly filled
Particular precautions are taken with respect to a H2 oil drain pipe.
leak in the bearing compartment. A special vapor
exhauster creates a slight vacuum in the generator The seal oil storage tank is continuously vented via
bearing compartments to prevent the escape of oil vapor the vapor exhauster provided for the bearing
from the bearing compartments along the shaft. Any compartments. The exhauster creates a slight vacuum
hydrogen collecting in the bearing compartment will be in the seal oil storage tank so that the oil saturated with
drawn off by the exhauster and vented. hydrogen is degassed. After remaining in this tank for a
predetermined time, the degassed oil is returned to the
Operation of the exhauster is monitored by a turbine oil tank together with the bearing oil via a loop
pressure transmitter with limit switch. If the exhauster seal.
fails, the second exhauster on standby is automatically
started. This continuous ventilation of the seal oil storage tank
prevents the formation of any explosive hydrogen-air
To prevent the hydrogen which enters the bearing mixture.
compartment from escaping via the oil drain pipes, the
To avoid any danger to the unit due to the hydrogen supply,
drain oil is returned to the turbine oil tank via the seal oil
only two hydrogen bottles should be opened if the bottle
storage tank and a loop seal. This loop seal is
supply is used.
permanently filled with oil to prevent the escape of gas.

Description Waste Gas System
1. General during normal generator operation from escaping to the

turbine building via the oil wipers.
Large generators are cooled with hydrogen gas The exhausters also remove any hydrogen gas
since this offers better heat transfer properties than air which may have penetrated into the bearing
and also reduces windage losses due to its lower density. compartments in the event of shaft seal failures.
Because of its low density, hydrogen is an extremely
volatile gas, and since it is not possible to rule out the 2.4 Seal Oil Storage Tank
possibility of hydrogen escaping into the generator The bearing oil which flows through the seal oil
bearing compartments or accumulating in the seal oil storage tank mixes with the seal oil and contains small
storage tank, it is necessary that these be vented amounts of hydrogen gas. The oil settles in the seal oil
continuously. The objective of this measure is to prevent storage tank and degases due to the subatmospheric
hydrogen from escaping into the turbine building or the pressure conditions.
lube-oil system of the turbine.
The waste gas is removed by a vapor exhauster and 2.5 Vacuum Pump
discharged to the environs via a separate vent pipe routed The vacuum pump is used to remove the air and
directly through the roof of the turbine building. hydrogen gas from the seal oil in the seal oil storage
tank. This gas mixture is then routed to the waste gas
2. Waste Gas System Vapor Exhauster system.
2.1 Subatmospheric Pressure 3. Other Vent Pipes

The subatmospheric pressure required to remove
The waste gas system comprises other vent pipes
the gas from the system is generated by two vapor
which are also routed through the roof of the turbine
exhausters which are arranged in a redundant
building. These pipes are designed to vent large
configuration and are rated for continuous operation. The
quantities of waste gas to the environs.
piping for the exhausters is laid out such that they operate
The following equipment is connected to the vent pipes:
in parallel.
Gas purity meter .
Commissioning of the exhausters is performed prior
Generator gas removal system (normal reduction
to filling the seal oil system, and both exhausters can be
rate)
shut down manually. Following completion of the
commissioning activities, one exhauster is activated
3.1 Gas Purity Meter
while the other remains in standby.
The gas flowing through the two gas purity meters
(< 2 x 60 dm3/h) is combined downstream of the meters
2.2 Waste Gas Removal
and then discharged to the environs via a separate vent
The following equipment is connected to the vapor pipe.
exhausters:
Generator bearing compartments (TE and EE) 3.2 Generator Gas Removal System
Seal oil storage tank The vent pipe for the generator gas removal system
Is used to discharge gases such as air, CO2 and H2
Vacuum pump which are displaced when filling the generator with
Gas dryer hydrogen or when removing the hydrogen from the
generator. In order to ensure that the large volume of
2.3 TE and EE Generator Bearing Compartments vented hydrogen gas is distributed evenly over the roof of
The subatmospheric pressure in the bearing the turbine building, the exhaust end of this vent pipe is
compartments prevents any bearing oil vapor produced star-shaped.

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

Description Generator Mechanical Equipment Protection
1. Tripping CrIteria components through which secondary cooling water or

seal oil flows inside the generator.
Turbogenerators require comprehensive safety and
Secondary cooling water flows through the hydrogen
supervisory devices to prevent damage and long forced
coolers located in the stator. Generator operation will
outages.
only be endangered by these coolants in the event of
The protective equipment detects dangerous
large leakages. As a result of high hydrogen pressure,
operating conditions at an early stage and prevents them
little water will emerge from a small leak. Hydrogen will,
from developing into damaging conditions. The protection
however, enter into the water circuit. The hdrogen loss
relieves the operating personnel from making the
can be derived from the hydrogen consumption of the
necessary fast decisions.
generator.
The following criteria are sensed by the generator
Operation of the generator will be seriously
mechanical equipment protection and processed by the
endangered in the event of major ingress of water which
generator protection circuits:
will collect in the generator terminal box. Due to the
restricted volume of the compartment the liquid can rise
1.1 High cold gas temperature In generator
quickly, resulting in a terminal short-circuit or ground fault.
In order to prevent such a failure, two level detectors are
1.2 Liquid in Generator Terminal Box
connected to the generator terminal box to activate the
generator mechanical equipment protection before a
1.3 High Hot Air Temperature in Exciter Unit
critical level is reached.
Each of these criteria activates a turbine trip. The
generator is disconnected from the system and de- 2.3 Exciter Unit Protection Against Overheating
excited through the two-channel reverse power relay. The protection circuit covering criterion 1.3 prevents
overheating of exciter in case of insufficient cooling (failure
2. Protection Circuits
of exciter coolers).
2.1 Generator Protection Against Overheating by The hot air temperature after the main exciter is
High Cooling Gas Temperature sensed with resistance temperature detectors in a
The protection circuit covering criterion 1.1 prevents two channel configuration and transmitted directly to
insufficient cooling and thus overheating of the hydrogen- the two channel protection circuit.
cooled components in case of high cooling gas
temperature. 3 Protection Circuit Design
The cold gas temperature is sensed with resistance
temperature detectors in a two channel configuration and All protection circuits of the generator mechanical
transmitted directly to the two channel protection circuit. equipmentt protection embody a 2- out- of- 2 logic which
facilitates for functional testing, analog signal
2.2 Generator Protection Against Internal Ground Fault comparison and backup energising. Both channels must
or Terminal Short-Circuit respond to activate a trip.
This redundant system prevents erroneous tripping
The generator may be damaged by leaks in due to an active fault.

Description Tripping Scheme for Generator Mechanical
Equipment Protection
TT GCB FB A
Liquid in generator terminal DOX
High cold gas temperature
High hot air temperature in main exciter
Tripout via reverse power protection (Short time initiation)
TT = Turbine trip
GCB = Generator circuit breaker
FB = Field breaker
A = Alarm

Turbogenerators Control,Protection and Monitoring Devices
Description Electrical Generator Protection
Generators are high-quality machines for securing z A one-line-to-ground fault may develop to a double
the best possible continuity of power supply. In addition ground fault, resulting in dangerous magnetic
to a suitable technical design and responsible mode of unbalances, especially on four-pole generators.
operation, provision must therefore be made for automatic
To minimize the consequential damage, it is
protection facilities. This protection must ensure a fast
recommended to provide two-pole and four-pole
and selective detection of any faults in order to minimize
generators with a protection circuit featuring a delayed
their dangerous effects.
response. In the core of four-pole generators, the rotor
The protective equipment must be designed so that
ground fault protection must always operate to avoid the
any serious fault will result in an immediate disconnection
hazard of sudden, extremely high vibrations due to
and de-excitation of the generator. Faults which do not
magnetic unbalances.
cause any direct damage must be brought to the attention
of the operating staff, enabling them to operate the unit Relay time: approximately 1 s
outside the critical range or to take precautionary
measures for shutdown. 4. Underexcitation Protection
Generators may be endangered by short-circuits, Failure of the voltage regulator, maloperation of the
ground faults, overvoltages, underexcitation and generator or transformer control systems, and generator
excessive thermal stresses. operation in a system with capacitive load may result in
The following protective equipment is recommended: a reduction of the excitation required to ensure system
stability below a predetermined minimum value. Short-
1. Differential Protection circuits or interruptions in the field circuit result in a
Breakdown of insulation between different stator complete loss of field and thus in instability of the
phase windings results in an internal short-circuit The generator. This causes higher temperature rises in the
fault is ‘detected by a differential relay which initiates rotor and core end portions, rotor overvoltage, system
immediate isolation and de-excitation of the generator. swings and torsional vibrations of the shaft.
In order to obtain a hIgh sensitivity, the protected area A momentary excursion beyond the steady-state
should include the generator only. stability limit must not necessarily result in a loss of
stability. Therefore it is advisable to design the
Operating value: 0,2 ... 0,4 /N
underexcitation protection so that a warning will be given
Relay time: < 60 ms when the steady-state stability limit is reached. The
In certain cases, the generator may also be included generator will be shut down after a few seconds only.
In the differential protection for the main transformer and The protection must operate instantaneously if a loss
station service feeder. Generator faults are then detected of field occurs when the steady-state stability limit is
by two differential protection devices. reached.
If the loss of field cannot be detected directly (e.g.
exciters with rotating diodes), it is recommended to
2. Stator Ground Fault Protection introduce a second stator criterion covering the range of
the permeance values 1/xd and 1/X’d and to provide for
Breakdown of insulation between the stator winding
instantaneous tripping when this criterion is exceeded.
and frame results in a stator ground fault. If possible, the
stator ground fault protection should cover the complete
winding, including the neutral point of the generator. The 5. Overcurrent Protection
protection is to initiate immediate isolation and de- System faults may result in (inadmissible) thermal
excitation of the generator. . stressing of the generator. For this reason, an overcurrent
Relay time: < 1s protection should be provided which operates on failure
of the system protection.
The load resistance of a grounding transformer and
A definite-time delay overcurrent relay may be used
any required boost to raise the neutral point potential
for this purpose, however, its relay time should be longer
should be selected so that the ground current due to a
than that of the system protection.
fault will amount to less than 15 A.
Operating value: 1.3 IN
3. Rotor Ground Fault Protection Relay time: 6... 8 s maximum
To avoid long relay times, it is recommended to equip
Rapid fault detection is required for the following reasons:
large generators with an inverse-time-delay (impedance)
z An interruption of the field circuit with arcing releases relay. This relay is energized by overcurrent and operates
high amounts of energy in the form of heat which with long or short-time setting, dependent on the location
may cause severe burning. of the short circuit.

Description Electrical Generator Protection
If connected to the generator neutral point, the At rated voltage, the generator can be continuously
overcurrent protection serves as back-up protection for operated at rated kVA up to 95 % of rated frequency.
the differential protection. To avoid excessive magnetic and thermal stressing,
it is recommended to provide an under-frequency
protection.
6. Load Unbalance Protection Since the frequency deviation due to a system
Generators operating in an interconnected system disturbance is normally accompanied by a voltage
are normally subjected to small load unbalances only. deviation. the protection should be designed on the basis
However, all one and two-line-to-ground faults occurring of the permissible load characteristic of the generator on
in the system, phase breakages or circuit breaker failures frequency and voltage deviations.
are in fact load unbalances which may result in unduly
high thermal stressing of the rotor. 9. Reverse Power Protection
It is recommended to provide a two-stage-Ioad
The reserve power protection system acts as standby
unbalance protection. When the continuously permissible
for the operational shutdown programme of the turbine I
load unbalance is reached, an alarm is given, whereas a
& C system which disconnects the generator from the
time dependent isolation from the system occurs when
grid. In addition, this system gets into action, if the tuboset
this value is exceeded.
runs at reserve power due to operation reasons, e.g. due
In case of Iarge units, it is recommended to provide
to increasing system frequencies.
a protection with unbalanced load time characteristic.
Continuous reserve power operation is allowed; it
Operating value and relay time should be matched to the
endangers neither the gas turbine nor the generator. The
load unbalance time characteristic applicable to the
generator should be disconnected from the grid, however,
particular generator.
after about 4 seconds to avoid taking the relatively large
motoring power of about 20 % generator rating from the
7. Rise-in-Voltage Protection system for an undue period of time.
Rejection of partial or complete system loads causes

10. Overvoltage Protection
a voltage rise, followed by an increase in the prime mover
speed. This may result in the generator and the apparatus The use of surge diverters on the high-voltage side
connected to it being endangered by unduly high voltages. of the unit transformer is considered sufficient for
Maloperation during manual voltage regulation of the protecting the generator against atmospheric overvoltages
generator may also result in inadmissible voltage and switching surges in the system.
stressing of these devices. Due to the sudden voltage With a view to a possible flashover from the high-
variations resulting from switching operations, it is voltage winding to the low-voltage winding in the unit
advisable, at least in the case of large units, to provide a transformer, it is, however, advisable to provide surge
two-stage rise-in-voltage protection, i.e.: diverters for the generator too, which should be
with high (1,45 x UN operating value and instantaneous connected between the phases and ground.
tripping; with low (1.2 x UN) operating value and delayed Normally, the surge diverters are installed in the direct
tripping. vicinity of the unit transformer. It is assumed that switching
surges due to a load isolator or circuit breaker connected
between the generator and transformer will not endanger
8. Under-Frequency Protection
the generator.
Major disturbances in an interconnected system may Care should be taken to provide explosion-proof surge
result in operation of the generator at under-frequency. diverters or suitable constructional measures in order to
avoid danger to persons or nearby plant components.
Design Principle Over Voltage

Reseal Voltage Approximately 1.2-1.4 x UN (allowing for power-frequency over
voltage on load rejection)
Power-frequency sparkover voltage approximately 2 x UN ( < test voltage for stator winding, e.g. VDE
0530, Up =2UN+1Kv)
Impulse sparkover voltage <4 x UN

Description Tripping Scheme for Electrical Generator
Protection
Alarm is initiated when the electrical generator protection system is tripped. Individual alarms for each criterion are provided.

Description Rotor Grounding System
Grounding brushes are fitted to the turbine-end stator

end shield to remove the static charges of the shafts.
The brush holders are arranged with 900 displace-

ment, which ensures that at least one brush will make
contact with the rotating shaft journal.
Fig.1 Arrangement of Brush Holders
1. Stator end shield 3. Rotor shaft

2. Brush holder 4. Turbine bearing

Description Arrangement of Brush Holders for
Rotor Grounding System
1. Brush holder
2. Grounding brush (Design A)
3. Grounding brush (Design B)
4. Brush Spindle
5. Insulation
6. Rotor shaft
7. Labyrinth ring
8. End shield

Turbogenerators Measuring Devices and Supervisory
Description Equipment
Introduction
The supervisory equipment consists of alarms and devices are combinedto form one supervisory unit.
measuring devices. The measuring devices give visual
indication of the syatem parameters, the alarm devices Closely associated with the supervisory equipment
initiate visual or audible signals in the event of a controlled are regulating alarms, automatic controls and protective
quantity falling below or exceeding the predetermined devices which provide for a reduction of the manual
limit values. In many cases, the measuring and alarm supervisory work.
devices are

Turbogenerators Temperature Transducers
Description Resistance Temperature Detectors and
Thermocouples
1.1.2 Four-Wire Connection

1. Resistance Temperature Detectors (RTD’s) If the two element leads are not alike or if the
RTD’s are used for temperature measurements three-wire method of compensation would be too costly
on the generator, e.g. to measure the slot a four-wire circuit should be used. Fig. 2 shows the
temperatures,cold gas and hot gas temperatures. circuit diagram of the four-wire method.
Both RTD’s with four-wire connection and double-
element RTD’s with eight-wire connection are used.
When making measurements with RTD’s the
resistance element is exposed to the temperature to
be measured. The RTD works on the change in
electrical resistance of a conductor due to temperature.
The approximate value may be calculated by the
following formula:
R = R0 • (1 + alpha • 7)
where
R0 = reference resistance at 0°C
alpha = temperature coefficient and
T = temperature in °C.
The standard reference resistance of the

platinum resistance element is 100 ohms. The Fig. 2 Wire-Wire Connection
temperature coefficient amounts to alpha = 3.85 x 10-
3
°C-1, this being the mean value for the range 0- 100°C. Leads RL1 and RL2 form the pair of lead wires to the
RTD Pt 100, while the other set of lead wires RL3 and
RL4 from the RTD are connected to amplifier V. Being a
normal differential amplifier, it amplifies only the voltage
drop across the RTD to the required output voltage
level.
Due to the mostly very high input resistance of
amplifier V, the resistance of lead wires RL3 and RL4 from
the RTD to the amplifier is negligible, even if it would
be substantially increased by the provision of a safety
barrier (explosion protection).
2. Thermocouples
Thermocouples are used for temperature
Fig. 1 Resistance Characteristic for measurements on the generator, e.g. to measure the
Platinum RTD’s 100 ohm at °C generator and exciter bearing temperatures.
Thermocouples are mainly employed where small time
1.1 Circuit Connections constants require fast temperature indication,
The two-wire connection, far commonly used,
involves errors in case of long leads. Long leads are 2.1 Principle
exposed to different temperatures, and the lead Temperature measurement with thermocouples is
resistances then reach values in the order of the carried out as follows:
resistance of the RTD element. Two conductors of dissimilar materials, i.e. the
positive and the negative conductor (thermoelectric
1.1.1 Three-Wire Connection elements), are joined at one end (hot junction) so as to
If a third lead is connected to the element in produce an electromotive force (emf), i.e., a
addition to the two element leads, automatic thermoelectric emf (in mV). The magnitude of the emf is
compensation for lead wire resistance including its dependent upon the temperature difference between
changes can be achieved by relatively simple means, the temperature to be measured and that of the other
the only prerequisite being that the resistance of the two ends of the conductors.
two leads forming the pair to the element are always
the same.

Thermocouple Temperature limits Max. cont. Parameter Color Codes Indicator
temp.in air Pos. pole
Neg. pole
°C
Cu -NiCu - 200 - + 600 400 » 4.3mV/I00 degC red brown
Fe-CuNi -200 - + 900 700 » 5.3 mV/100 degC red blue
NiCr-Ni ±0 - + 1200 1000 » 4.1 mV/100 degC red green Moving coil
Pt Rh-Pt ±0 - + 1600 1300 » 0.6 mV/100 degC red white
NiCr-Constantan ±0 - + 1000 400 » 6 3 mV/100 degC red purple
Cu-CuNi brown
Fe-CuNi blue
NlCr-Ni green
PtRh-Pt white
NiCr-Constantan red
The insulating sleeve of the positive lead is
provided with a red mark in addition to the color code
1. Hot junction 5 Connecting cables
2. Thermocouple 6 Millivoltmeter 2.3 Cold Junction
3. Compensation lead 7 Compensating resistotor For measuring a temperature by means of a
4 Cold junction correction thermocouple the cold junction temperature must be
known. A cold junction at a temperature of 0°C can
Fig. 3 Thermocouple be very earily produced oy melting ice. The use of
thermostats with reference junction tempera
To use the thermoelectric emf for temperature tures of 20°C and 50°C is also possible. Note that in
measurement, the free ends of the conductors are these cases certain corrections must be added to the
exposed to a constant temperature (cold junction calibration figures of the particular thermocouple
temperature) and connected to a millivoltmeter which are referred to 0°C. To do this, add the
calibrated in °C thermoelectric emf due to the cold junction temperature
to the measured thermoelectric emf and
add measuring point temperature to obtain the total
thermoelectric emf.
Temperature in °C
‘•’3. 4Voltages as a Function of Temperature

for Siandarzied Thermocouples
2.2 Compensating Leads ;

The compensating leads serve to extend the
thermocouple up to the cold junction. When exposed
to a temperature up to 2000C they produce the same
thermoelectric emf as the associated thermocouple. 1 Compensator
See DIN 43710 for calibration data and limits of error 2 Generator
of compensating leads. 3 Double-pole double-throw switch
The compensating leads used for the different
Fig. 5 Circuit Arrangement for Connection of
thermocouples are identified by colors:
Several Thermocouples
2.1-8410-0004/2
The cold junction can, however, also be To obtain a simpler circuit, the large number of
implemented by using a PT100 RTD for thermocouples used on the generator can be
determination of the actual temperature. The connected to a double-pole measuring point selector
temperature is refered to the calibration figure for 0 switch enabling the respective thermocouple to be
°C by electronic means. The electronic cold junction connected to a compensator for measurement.
also avoids the temperature error due to the junction
between the compensating leads and the copper
leads.
2.1-8410-0004/3
Turbogenerators Temperature Transducers
Description Rod-Type Thermostats
Rod-type thermostats are used for detecting

temperature limits. These instruments utilize the
different coefficients of thermal expansion of two
dissimilar metals.
When exposed to a temperature rise a rod

arranged inside a tube and fitted to one end of it
features a linear expansion different from that of the
surrounding tube. As a result of this, a movement is
initiated in a switching head at the other end of the
detector tube, which in turn, actuates a changeover
contact. This changeover contact operates on rising
and falling temperature when the set value is reached.
The contacts are connected to the detector tube
through a mechanism providing for sudden
changeover. Since the rod-type thermostats are
employed for temperature detection in pressurized
surroundings, they must always be used in
connection, with protective tubes.
1. Switching head 4. Template

2. Spring catch 5. Ground Terminal
3. Protective tubes 6. Setting dial with temp. scale
Fig.1 Rod type Thermostat

Turbogenerators Pressure Transmitters for Seal Oil
Pressure Switches
Description
1. Pressure Switches in Seal Oil Circuit

Pressure switches are used for supervision of
pressures and for control of pressure-dependent
actions, e.g. starting and stopping of pumps, fault
indication and initiation of alarms.
A pressure variation in the pressure sensor
causes a stainless steel bellows to actuate a micro
switch (changeover switch with silver snap action
contact) in the switch assembly via a linkage system.
The silver snap-action contact ensures reliable
contact which is not affected by pressure fluctuations
and shocks.
1 . Pressure gauge
With snap-action contacts the circuits are closed
2 . Pressure switch
and opened suddenly and independent of the rate of
3 . Shutoff valve
pressure variation.
Fig. 1 Pressure Gauge and Shutoff Valves

Turbogenerators Differential Pressure Transmitters for
Description Vacuum Measurement
1 Differential Pressure Indicator AAH

300 With Barton Cell TDHZ 224
The instrument is of a purely mechanical
type. The measuring system consists of a Barton cell
[1] with direct connected indicator for measurement of
the vacuum in the seal oil tank.
The front section and its mechanical system
are firmly screwed together with the measuring
mechanism. The rotation of the torque tube shaft is
transmitted to the pointer axle via the drive arm and a
toothed segment. The mechanical system includes
facilities for zero adjustment, correction and linearity
correction. In addition, the torque tube shaft carries
the switching segment for actuating the limit switch
which is separately adjustable from outside to any
desired operating point without opening the indicator
housing.
1 Barton cell
2 Vacuum indicator
Fig.1 Differential Pressure Indicator With Barton Cell
[Also refer to the following information

[1] 2.1-8413 Barton Cell for Vacuum Measurement —
Type THDZ 224

Turbogenerators Bearing Vibration Pickup
Description
The vibration pickup to measure absolute bearing

vibrations works on the piezoelectric principle. Pickups
of this design do not contain any movable parts. They
are, therefore, very rugged and reliable in operation, re-
quiring no maintenance work.
The pickup is connected to a separate charge am-
plifier via a low-noise cable.
The amplified signal is passed to a monitoring sys-
tem which initiates alarm or switching function, if the limit
values set are exceeded. Furthermore, the monitoring
system produces an output signal of 4-20 MA being
passed to an indicator and a recorder.
Fig. 1 Piezoelectric Vibration Pickup

Turbogenerators Shaft Vibration Pickup
Description Relative Vibration Measurement
Two pickups. displaced by 90°, are used to measure Each radial displacement of the shaft relative to the
the vibration of the rotating shaft relative to the stationary casing and thus relative to the transducer unbalances
casing. the balanced bridge circuit and produces an ac voltage.
The system for measurement of the relative shaft The amplitude of this ac voltage is a measure of the air
vibration detects each radial periodic movement of the gap and thus of the radial shaft position.
shaft relative to the casing. The mechanical shaft vibration also changes the
The system is of a noncontact type and measure the amplitude of the bridge ac voltage with the frequency of
distance between the transducer and the shaft by a the mechanical shaft vibration (relative vibration).
inductive method.
The transducer is attached to the bearing or casing
so that an air gap is obtained between the transducer tip
and the shaft, with the shaft providing the magnetic flux
return path for the coil. A change in the air gap results in
a change in the resistance of the magnetic circuit and
thus in the inductance of the coil.
Fig. 1 Installation Location for Pickup

Turbogenerators Supervision of Generator
Description
The arrangement of the measuring points and su- 2. Cold and Hot Gas Temperatures
pervisory equipment at the generator is illustrated in the
attached diagram. The temperatures of the hot and cold gases are
measured by RTD’s upstream and downstream of the
1. Stator Slot Temperature hydrogen coolers Separate RTD’s are provided to be
used with the hydrogen temperature control system and
The slot temperatures are measured with resistance the generator electronical equipment protection.
temperature detectors (RTD’s). The platinum measur- Temperature detectors located in the generator
ing wire is embedded in a molded plastic body which interior are mounted in gastight protective tubes welded
provides for insulation and pressure relief. to the stator frame.
3. Stator Liquid Detection
Liquid (cooling water from hydrogen cooler or seal

oil) entering the generator housing is sensed by level
detectors assembled in gastight housings and
connecting to pipes from the low-level points of the
generator. See Fig. 3.
Fig. 1 Stator Slot Resistance Temperature Detector

1. Resistance temperature detector 4. Bottom bar
2. Top bar 5. Stator core
3. Separator
The RTD’s are embedded directly in the stator slots
between the bottom and top bars at points where the
highest temperatures are expected.
The RTD’s are characterized by a constant
temperature vs. resistance characteristic, high
mechanical strength and insensitivity to electrical and
magnetic fields.
Fig. 2 Level Detector Fig. 3 Level Detector Rack
1. Thread ing
2. Aluminium housing 4. Detectors
3. Remove seal cup by turn- 5. Cable connection

Turbogenerators Generator Measuring Points
Description
TAG NO. DESCRIPTION

___________________________________________________________
MKA11 STATOR FRAME TE
MKA11 AA126 Gas Valve before level detector stator frame - TE

MKA11 AA128 Gas Valve after level detector stator frame - TE
MKA11 CL021 Level Switch - stator frame - TE
MKA11 BZ128 Sight Glass after level detector stator frame - TE
MKA16 TERMINAL BUSHING AND STATOR FRAME – EE
MKA16 AA116 Gas Valve before level detector stator frame - EE

MKA16 AA117 Gas Valve before level detector stator frame - EE
MKA16 AA118 Gas Valve after level detector stator frame - EE
MKA16 AA136 Gas Valve before level detector terminal bushings
MKA16 AA138 Gas Valve after level detector terminal bushings
MKA16 CL011 Level Switch - Terminal Bushing Top
MKA16 CL012 Level Switch - Terminal Bushing Top
MKA16 CL031 Level Switch - Terminal Bushing Bottom
MKA16 BZ118 Sight Glass after level detector stator frame - EE
MKA16 BZ138 Sight Glass after level detector terminal bushings
MKA20 RESISTANCE TEMP DETECTOR
MKA20 CT001... 24 Simplex RTD in Stator Winding
MKA31 THERMOCOUPLE IN STATOR CORE – TURBINE END
MKA31 CT001 ... 12 Simplex Thermocouple in Stator core - TE
MKA32 THERMOCOUPLE IN STATOR CORE – EXCITER END
MKA32 CT001 ... 12 Simplex Thermocouple in Stator core - EE
MKA70 HYDROGEN COOLERS
MKA70 AC011 H2 Cooler ‘A’

MKA70 AC021 H2 Cooler ‘B’
MKA70 AC031 H2 Cooler ‘C’
MKA70 AC041 H2 Cooler ‘D’

Description
TAG NO . DESCRIPTION
MKA75 COLD GAS TEMPERATURE MEASUREMENT AFTER H2 COOLERS
MKA75 CT011 Duplex RTD for Cold Gas Temperature after H2 coolers A & B
MKA75 CT031 Duplex RTD for Cold Gas Temperature after H2 coolers C & D
MKA76 HOT GAS TEMPERATURE MEASUREMENT BEFORE H2 COOLERS
MKA76 CT011 Duplex RTD for Hot Gas Temperature before H2 cooler A & B
MKA76 CT012 Duplex RTD for Hot Gas Temperature before H2 cooler A & B
MKA76 CT021 Duplex RTD for Hot Gas Temperature before H2 cooler C& D
MKA76 CT022 Duplex RTD for Hot Gas Temperature before H2 cooler C& D
MKD11 TEMPERATURE / VIBRATION MEASUREMENT – TURBINE END
MKD11 CT014 Triplex Thermocouple for Bearing Temperature - TE

MKD11 CT018 Triplex Thermocouple for Bearing Temperature - TE
MKD11 CY021 Absolute Bearing vibration measurement - TE

MKD11 CY022 Absolute Bearing vibration measurement - TE
MKD11 CY041 Relative Shaft vibration measurement - TE
MKD11 CY042 Relative Shaft vibration measurement - TE
MKD12 TEMPERATURE / VIBRATION MEASUREMENT – EXCITER END
MKD12 CT014 Triplex Thermocouple for Bearing Temperature - EE

MKD12 CT018 Triplex Thermocouple for Bearing Temperature - EE

Description
TAG NO. DESCRIPTION
MKD12 CY021 Absolute Bearing vibration measurement - EE

MKD12 CY022 Absolute Bearing vibration measurement - EE
MKD12 CY041 Relative Shaft vibration measurement - EE
MKD12 CY042 Relative Shaft vibration measurement - EE
PGB31 INLET LINE TO H2 COOLER
PGB31 AA501 Isolating Valve before H 2 cooler ‘A’

PGB31 AA502 Isolating Valve before H2 cooler ‘B’
PGB31 AA503 Isolating Valve before H2 cooler ‘C’
PGB31 AA504 Isolating Valve before H2 cooler ‘D’
PGB31 AA571 Drain Valve before H2 cooler ‘A’
PGB31 AA572 Drain Valve before H2 cooler ‘B’
PGB31 AA573 Drain Valve before H2 cooler ‘C’
PGB31 AA574 Drain Valve before H2 cooler ‘D’
PGB30 CT501 Temp Gauge in the cooling water inlet line.

PGB30 CT001 Duplex RTD in the cooling water inlet line.
PGB32 OUTLET LINE FROM H2 COOLER
PGB32 AA501 Regulating Glove Valve after H2 cooler ‘A’

PGB32 AA502 Regulating Glove Valve after H2 cooler ‘B’
PGB32 AA503 Regulating Glove Valve after H2 cooler ‘C’
PGB32 AA504 Regulating Glove Valve after H2 cooler ‘D’
PGB32 AA571 Drain Valve after H2 cooler ‘A’
PGB32 AA572 Drain Valve after H2 cooler ‘B’
PGB32 AA573 Drain Valve after H2 cooler ‘C’
PGB32 AA574 Drain Valve after H2 cooler ‘D’
PGB32 CT001 Duplex RTD for outlet Cooling Water Temp of H2 Cooler ‘A’
PGB32 CT002 Duplex RTD for outlet Cooling Water Temp of H2 Cooler ‘B’
PGB32 CT003 Duplex RTD for outlet Cooling Water Temp of H2 Cooler ‘C’
PGB32 CT004 Duplex RTD for outlet Cooling Water Temp of H2 Cooler ‘D’
PGB33 OUTLET COOLING WATER FROM H2 COOLER HEADER
PGB33 AA001 Motorized Temp Control Valve for Cold Gas Temp. Control
PGB33 CT501 Temp Gauge on outlet Cooling water Header of H2 coolers

Turbogenerators Supervision of Bearing Temperatures
Description
1. Generator Bearing Temperatures
The temperatures of all bearings are measured with

thermocouples or RTD's located in the bearing lower
halves. The actual measuring point is located at the
babbit/sleeve interface.
Measurement and recording of the temperatures are
performed in conjuction with the turbine supervision. The
overall turbine protection is tripped when the maximum
permissible temperature is exceeded.
Fig.1 Arrangement of Bearing Temperature

Measuring Point
1. Rotor Shaft 2. Thermocouple (RTD)

3. Babbit 4. Lower bearing sleeve

Turbogenerators Supervision of Seal Oil System
Description
The location of the transmitters of the measuring and Local indication is provided for setting the pressure
supervisory equipment in the seal oil system is shown in the regulator and for observation.
Seal Oil Diagram.(Refer to 2.1-7111, Seal Oil Diagram)
The most essential measuring and supervisory 2.4 Seal Oil Pressure Downstream of Filter
devices in the seal oil system are: At this pressure gauge the seal oil pressure
Level detectors downstream of the filter can be observed.
Pressure measuring devices The pressure switch activates the standby seal oil
Temperature measuring devices pump, if the set seal oil pressure is not reached.
Volumetric flow rate measuring devices
2.5 Seal Oil Pressures Upstream of TE and
1. Level Detectors EE Shaft Seals
The readings are required for manual adjustment
Within the seal oil system of the seal oil pressures. Pressure transmitters trigger
The oil levels in the TE and EE prechambers alarm signals if the seal oil pressure drops below a
The oil level in the seal oil tank specified low limit.
The oil level in the seal oil storage tank
The oil level in the intermediate oil tank are super- 2.6 Vacuum in Seal Oil Tank
vised. This pressure transmitter signals a loss of vacuum.
A high oil level in the generator prechambers, due to
2.7 Differential Pressure Across Seal Oil Filter
an Increase In the amount of seal oil on the hydrogen
This local indicator displays the degree of filter
side of the shaft seal, results in an alarm. The alarm is
contamination on a dial (red/white) and activates an
initiated when the probe is immersed in oil.
alarm at a preset pressure differential.
A low oil level in the intermediate oil tank and in the
seal oil storage tank is monitored such that an alarm is
activated when the probe is no longer immersed in oil. 3. Temperature Measuring Devices
At high oil level in the seal oil tank, the vacuum pump
is stopped to prevent it from drawing seal oil. The alarm The following temperatures are measured locally:
is activated when the probe is immersed in oil. Seal oil temperature upstream and downstream of
To prevent dry running of seal oil pumps 1 and 2 with seal oil coolers.
low oil level in the seal oil tank, a second probe is provided
to stop seal oil pumps 1 and 2 when the probe is no In addition, the following temperatures are
longer immersed in oil. measured by means of resistance temperature detectors
for remote indication:
2. Pressure Measuring Devices Seal oil temperature downstream of filter
The following pressure measuring points are Seal oil temperature in hydrogen side seal
provided: oil drain, TE and EE.
2.1 Pressure Downstream of Seal Oil Pump 1 4. Volumetric Flow Rate Measuring Devices
On failure of seal oil pump 1, a pressure transmitter
activates seal oil pump 2. If the latter is not ready for The following volumetric flow rate measuring points
operation, the standby seal oil pump is automatically started. are provided:
Local indication is provided for setting the pressure
regulator and for observation. 4.1 Volumetric Flow Rates for TE and EE Shaft Seals
The volumetric flow rate of the seal oil supplied to
2.2 Pressure Downstream of Seal Oil Pump 2 each shaft seal is indicated by a volumetric flow rate
On failure of seal oil pump 2, a pressure transmitter indicator upstream of the shaft seal.
activates seal oil pump 1. If the latter is not ready for
operation, the standby seal oil pump is automatically started. 4.2 Volumetric Flow Rates for TE and EE
Local indication is provided for setting the pressure
Seal Ring Relief
regulator and for observation.
The volumetric flow rate of the seal ring relief oil
supplied to each shaft seal is indicated by a volumetric
2.3 Pressure Downstream of Standby Seal 011 Pump
flow rate indicator upstream of the shaft sea.
A pressure transmitter signals the takeover of the
seal oil supply by the standby seal oil pump.

Turbogenerators Supervision of Gas System
Description
The location of the transmitters of the measuring gauge. The electrical signal of the pressure transmitter
and supervisory equipment in the gas system is shown is used for activating an alarm.
in the Gas Diagram. (Refer to 2.1-7211, Gas Diagram)
The essential measuring and supervisory devices 2.3 H2 pressure at pressure reducers
in the gas system are :
Purity meter system For observation of the pressure setting.
Pressure measuring points 2.4 H2 casing pressure
Temperature measuring points The H2 casing pressure is monitored with a local
pressure gauge, the electrical signal of the pressure
1. Gas Purity Meter System transmitter being used for remote control and supervision.
The gas purity meter system measures the purity of 2.5 H2 High Pressure before Central Supply
the hydrogen gas in the generator as well as the The high pressure is monitored with a pressure
composition of the gas mixtures (CO2/air and H2/CO2) transmitter initiating a signal. In addition, a local indicator
during filling of the generator. The gas purity meter system is used to monitor the H2 high pressure.
is also used when removing the hydrogen from the
generator, where the hydrogen is replaced with carbon 2.6 Pressure before purity meter
dioxide and the carbon dioxide in turn with air. The gas The measuring gas pressure can be observed
required for the measurement is taken from the generator before the purity meters at a local pressure gauge.
or from the filling lines, respectively, and, on completion (Also refer to 2.1.4-49220, Pressure Transmitters.)
of the measurement, is discharged to the atmosphere
through a vent line. 3. Temperature Measuring Points
The indicator of the gas purity meter system is
equipped with a limit switch which provides a signal to Within the gas system, temperature detectors are
initiate an alarm when the purity drops below a preset used for supervision of the gas dryer and CO2 flash
value. evaporator.
2. Pressure Measuring Points The temperatures of the gas dryer heater and of the
heat transfer liquid in the CO 2 flash evaporator are
The following measuring points are provided: detected by means of thermostats and used for control
functions. In addition, the temperature of the heat transfer
2.1 CO2 Bottle Pressure liquid in the CO2 flash evaporator is indicated locally by a
The bottle pressure during CO 2 filling can be thermometer.
observed at a local pressure gauge.
A temperature detector installed in the vent line stops
2.2 H2 bottle pressure the precess if a preset temperature value is reached.
The bottle pressure can be read at the pressure (Also refer to 2.1-8440, Temperature Detectors.)

Turbogenerators Exciter Measuring Points
Description
MKC11 Exciter, general MKC66 Hot Air after rectifier wheels

MKC11 GP001 Lighting, exciter enclosure MKC66 CT001 Temperature of hot air after rectifier wheel
MKC11 GP002 Lighting, exciter enclosure MKC66 CT004 Temperature of hot air after rectifier wheel
MKC30 Main exciter, general MKC71 Space Heaters

MKC30 GP001 Lighting, main exciter
MKC71 AH001 Space Heaters, pilot exciter
MKC35 Main Exciter MKC71 AH002 Space Heaters, main exciter
MKC35 CE001 Quadrature-axis measuring coil 1 for MKC71 AH003 Space Heaters, rectifier wheels
rotor
MKC35 CE002 Quadrature-axis measuring coil 2 for
rotor MKC75 Dry Air Blower
MKC75AT001 Dry Air Blower
MKC36 Rotor winding
MKC36 CE001 Rotor Earth Fault detection Slip MKD21 Exciter Bearing
Rings MKD21 CT014 Temperature of Exciter bearing
MKD21 CT018 Temperature of Exciter bearing
MKC40 Rectifier System MKD21 CY021 Exciter Bearing vibration
MKC40 CU001 Stroboscope, monitoring of rectifier MKD21 Cy022 Exciter Bearing Vibration
set MKD21 CY041 Shaft relative vibration, exciter
bearing
MKC60 AIR COOLER MKD21 CY042 Shaft relative vibration, exciter
MKC60 AC011 Air Cooler bearing
MKC60 AC021 Air Cooler
PGB01 Cooling to Air Cooler
MKC61 Cold Air to main exciter PGB01 CT002 Cooling water inlet temperature to air
MKC61 CT001 Temperature of cold air to main cooler
exciter PGB01 CT015 Cooling water outlet temperature of
air cooler
MKC61 CT004 Temperature of cold air to main PGB01 CT016 Cooling water outlet temperature of
exciter air cooler
MKC65 Hot Air after main exciter

MKC65 CT001 Temperature of hot air after main
exciter
exciter
exciter

Turbogenerators Exciter
Description
Design Features The exciter shown, in Fig. 2 corresponds to the

The exciter consists of : basic arrangement described above.
Rectifier wheels A common shaft carries the rectifier wheels, the

Three-phase main exciter rotor of the main exciter and the permanent-magnet
Three-phase pilot exciter rotor of the pilot exciter. The shaft is rigidly coupled to
Cooler the generator rotor and supported on bearings
Metering and supervisory equipment between the main and pilot exciters. The generator
and exciter rotors are thus supported on a total of three
bearings.
Mechanical coupling of the two shaft assemblies

results in simultaneous coupling of the dc leads in the
central shaft bore through the Multikontakt electrical
contact system consisting of plug-in bolts and contact
strips. This contact system is also designed to
compensate for length variations of the leads due to
thermal expansion.
1. Automatic voltage regulator

2. Permanent-magnet pilot exciter
3. Measuring sliprings with brushes for field
ground fault detection
4. Quadrature-axis measuring coil
5. Three-phase main exciter
6. Diode rectifier set
7. Three-phase lead
8. Multikontakt connector 1. Permanent-magnet rotor
9. Rotor winding of turbogenerator 2. Fan
10. Stator windig of turbogenerator 3. Rotor of main exciter
4. Rectifier wheel
5. Coupling
Fig. 1 Basic Arrangement of Brushless Excitation
System With Rotating Diodes Fig. 2 Exciter Rotor
2. Rectifier Wheels
Fig. 1 shows the basic arrangement of the exciter. The main components of the rectifier wheels are
The three-phase pilot exciter has a revolving field with the silicon diodes, which are arranged in the rectifier
permanent-magnet poles. The three-phase ac is fed wheels in a three-phase bridge circuit. The internal
to the field of the revolving-armature main exciter via a arrangement of a diode is illustrated in Fig. 3. The
stationary-regulator and rectifier unit. The three-phase contact pressure for the silicon wafer is produced by a
ac induced in the rotor of the main exciter is rectified plate spring assembly. The arrangement of the diode
by the rotating rectifier bridge and fed to the field is such that this contact pressure in increased by the
winding of the generator rotor through the dc lead in centrifugal force during rotation.
the rotor shaft.

The two wheels are identical in their mechanical design
and differ only in the forward directions of the diodes.
The direct current from the rectifier wheel is fed to
the dc leads arranged in the central bore of the shaft
via radial bolts.
1 Connector 7 Spring housing

2 Ceramic housing 8 Plate spring
3 Diaphragm cover 9 Clamping pin
4 Protective 10 Silicon wafer 1 DC lead 5 Diode
atmosphere 11 Silicon layer 2 Rectifier wheel 6 Heat sink
5 Flexible lead (negative polarity) 7 Fuse
6 Connection 3 Terminal bolt 8 Three-phase lead
4 Rectifier wheel
Fig. 3 Silicon Diode (positive polarity)
Fig. 5 Rectifier Wheels

Fig. 4 shows additional components contained
in the rectifier wheels. One diode each is mounted in The three-phase alternating current is obtained
each light-alloy heat sink and thus connected in via copper conductors arranged on the shaft
parallel. Associated with each diode is a fuse which circumference between the rectifier wheels and the
serves to switch off the diode if it fails (loss of reverse three-phase main exciter. The conductors are attached
blocking capability). by means of banding clips and equipped with screw-
on lugs for the internal diode connections. The
conductors originate at a bus ring system of the main
exciter rotor.
1 2 3 4
1. RC network
2 Fuse
3 Diode
4 Heat sink 1 2 3 4
1. Diode 3. Fuse
Fig. 4 Components for Rectifier Wheels 2. Three-phase lead 4. Diode Rectifier Wheel
For suppression of the momentary voltage peaks
Fig. 6 Rectifier Wheel
arising from commutation, RC networks, consisting of
one capacitor and one damping resistor each are
provided, and combined in a single resin- 3. Three-Phase Pilot Exciter
encapsulated unit. The three-phase pilot exciter is a six-pole revolving-
field unit. The frame accommodates the laminated core
The arrangement of the components in the with the three-phase winding. The rotor consists of a
rectifier wheels is illustrated in Fig. 5. The insulated and shaft with mounted poles. Each pole consists of
shrunken wheels serve as dc buses for the negative separate permanent magnets which are housed in a
and positive side of the rectifier bridge. This non-magnetic metallic enclosure. The magnets are
arrangement ensures good accessibility of all braced between the shaft and the external pole shoe
components and a minimum of circuit connections. with bolts.
2.1-9100-0029/2
1. Stator 1. Rotor 4. Sliprings for ground
2. Permanent magnet rotor 2. Stator fault detection
3. Stator winding 3. Magnetic pole 5. Bearing housing
Fig. 7 Permanent Magnet Pilot Exciter Fig. 7 Main Exciter
4. Three-Phase Main Exciter 5. Cooling of Exciter
The exciter is air cooled. The cooling air is

The three-phase main exciter is a six-pole circulated in a closed circuit and recooled in cooler
revolving armature unit. Arranged in the frame are the sections arranged in roof fashion at the end of the
poles with the field and damper winding. The field exciter.
winding is arranged on the laminated magnetic poles. The complete exciter is housed in an enclosure
At the pole shoe, bars are provided which are which provides flow paths for circulating of the cooling
connected to form a damper winding. Between the air and serves as cold air compartment. The fan and
two poles a quadrature-axis coil is fitted for inductive the rectifier wheels draw the cool air from the main
measurement of field current. enclosure and expel the warmed air to the
compartment beneath the base plate. The warm air
The rotor consists of stacked laminations which is then returned to the main enclosure via the coolers.
are compressed by through bolts over compression The rectifier wheels are housed in their own
rings. The three phase winding is inserted in the slots enclosure with suitably shaped flow paths providing
of the laminated rotor. The winding conductors are for self-ventilation of the rectifier wheels.
transposed within the core length, and the end turns The main exciter receives cold air from a shaft-
of the rotor winding are secured with steel bands. mounted fan. The fan is located between the pilot
The connections are made on the side facing the exciter and the main exciter and supplies cold air to
rectifier wheels. The winding ends are run to a bus the main exciter via the flow paths in the main
ring system to which the three phase leads leading to enclosure.
the rectifier wheels are also connected. After full The air enters the main exciter from one end and
impregnation with synthetic resin and curing, the is passed into the ducts below the rotor body and
complete rotor is shrunk onto the shaft. A journal discharged through radial slots in the rotor core.
bearing is arranged between the main and pilot The pilot exciter receives cold air from the fan
exciters and has forced-oil lubrication from the turbine before it is supplied to the main exciter. The pilot exciter
oil supply. has no separate discharge connection to the hot air
compartment.
2.1-9100-0029/3
Turbogenerators Basic Arrangement of Excitation System
Description with Rotating Rectifiers
ELR Series (up to 60 Diodes)
1. Automatic voltage regulator 6. Silicon rectifier set

2. Permanent-magnet pilot exciter 7. Three-phase lead
3. Sliprings and measuring brushes 8. Multikontakt connector
for field ground fault detection 9. Rotor winding of turbogenerators
4. Quadrature axis measuring coil 10. Stator winding of turbogenerators
5. Three-phase main exciter
BHEL, Haridwar 2.1- 9101- 0001/1

Turbogenerators Rectifier Wheels
Description ELR Series (up to 48 Diodes)
1 Fuse
2 Heat sink
3 Diode
4 Rectifier wheel (negative polarity)
5 Terminal bolt
6 Hot air outlet Current path
7 Rectifier wheel (positive polarity)
8 AC lead
9 DC lead
10 RC-Network

Turbogenerators Rectifier Wheels and Coupling
Description ELR Series (up to 48 Diodes)
1 Multikontakt connector
2 Coupling
3 Diode
4 Rectifier wheel
5 Fuse
6 AC lead
7 NC network
8 Balancing weights

Turbogenerators Permanent-Magnet,
Description Pilot Exciter Rotor and Fan
4 5
1 2 3
1. Permanent magnet pole

2. Fan
3. Balancing Weights
4. Sliprings for field ground fault detection
5 Rotor of Main Exciter
BHEL, Haridwar 2.1-9104-0002 / 1

Turbogenerators Exciter Cross Section
s Description

Turbogenerators Exciter Cooling Air Circut
Description

Turbogenerators Stroboscope for Fuse Monitoring
Description
The fuses on the rectifier wheels may be checked continuous sequence Of flashes can be interrupted at
during operation with the Stroboscope. A separate any time by actuating the Feed or Return pushbutton.
flash tube is provided for each wheel (A and B). The Following this, a stationary image is obtained which
tubes, which are supplied through a common control ensures accurate checking of a single fuse. After
unit, are permanently installed in the rectifier wheel approximately two minutes, the stroboscope is
enclosure. This permits easy monitoring without any automatically switched off. If this period should not
adjustment outside the exciter enclosure being be sufficient for fuse checking, switching on the
required. stroboscope for another two minutes without delay can
Fig. 1 shows the basic arrangement of a fully be repeated for any desired number of times by
transistorized Stroboscope. The electronics required depressing the On pushbutton.
for control of the light signals are contained in the The stroboscope contains four plug-in printed
control unit and in the tubular lamps. The tubular lamps curcuit boards which can be readily replaced in order
are connected to the control unit by cables. to remedy any faults.
The Stroboscope is located in the rectifier wheel The capacitor and high-voltage transformer
and exciter enclosure so that the fuses may be required to produce the firing pulses for the flash tubes
observed from outside the exciter enclosure while are located on a printed circuit board which is
controlling the stroboscope. accommodated in the handle of the flash lamp.
To synchronize the sequence of flashes with the The operating elements are located on the front
generator rotation, the system frequency is utilized to panel of the control unit for ease of operation. A
activate the flashes. A double synchronous motor, depressed pushbutton is indicated by an illuminated
controlled through two pushbuttons and connected to dot in the pushbutton head.
two potentiometers and IC’s, causes the flash to be The line connector, the two connectors for the
timed so that a slow-motion observation of the fuse flash lamps and the fuse are located on the back of
becomes possible. the control unit.
The observation period for one full revolution of All connectors have a mechanical lock and are
the rectifier wheel (360°) is approximately 25 seconds. protected against dust and splashwater. The cables
At approximately 450°, the flash is reset to its initial are run in flexible metal hoses for protection against
rate, and the observation can be repeated. The mechanical damage.
1. Flash tube 1 (A wheel) 4. Pushbutton for flash tube 2 8. On pushbutton

2. Control unit 5. Feed pushbutton 9. Off pushbutton
3. Pushbutton for flash tube-1 6. Pilot lamp for control voltage 10. Flash tube 2 (B wheel
7. Return pushbutton
Fig.1 Components and Operating Elements of Stroboscope
BHEL, Haridwar 2.1-9140-00027

Turbogenerators Exciter Drying System
Description
1. General
A dryer (dehumidifier) and an anticondensation 2.1.1 Adsorption Section

heating system are provided to avoid the formation of The air to be dehumidified passes through the
moisture condensate inside the exciter with the turbine- adsorption section of the dryer wheel, with part of the
generator at rest or on turning gear. moisture contained in the air being removed by the
adsorbent material, i.e. lithium chloride. The moisture
is removed as a result of the partial pressure drop
2. Mode of Operation existing between the air and the adsorbent material.
The dryer dehumidifies the air within the exciter

enclosure. The dryer wheel is made of a nonflammable
material. On its inlet side, the wheel is provided with a
system of tubular ducts, the surfaces of which are
impregnated with a highly hygroscopic material.
The tubular ducts are dimensioned so that a laminar

flow with low pressure loss is obtained even at high air
velocity.
The moisture absorbed by the dryer wheel is

1. Regeneration air outlet
removed in a regeneration section by a stream ot hot air
2. Dryer wheel
directed through the wheel in the opposite direction of 3. Heater
the inlet air and then discharged to the atmosphere. 4. Ventilator
5. Filter
After regeneration. the dryer wheel material is again 6. Shutoff valve
capable of absorbing moisture. 7. Dry air outlet
Fig. 2 Schematic Diagram

The adsorption of moisture and regeneration of the
dryer wheel material take place simultaneously, using
separate air streams, which ensures a continuous drying 2.1.2 Regeneration Section
of the air. In the regeneration section of the dryer wheel, the accu-
A shutoff valve in the dry air outlet line prevents that mutated moisture is removed from the dryer wheel by
contaminated air from the power house will be drawn the heated regeneration air.
during load operation of the exciter. Continuous rotation of the dryer wheel ensures continu-
ous dehumidification of the air within the exciter..
2.1 Operating Principle of Adsorption Dryer
3. Anticondensation Heating System
The dehumidification takes place in a slowly rotating
dryer wheel (approximately 7 revolutions per hour). The An anticondensation heating system to support the
honeycomb dryer wheel consists oi a magnesium silica dryer is installed in the exciter baseframe. The heaters
alloy containing crystalline lithium chloride. The inlet are rated and arranged so that the temprature in the
side of the dryer wheel is subdivided so that 1/4 is exciter interior is maintained above the dew point level.
available for regeneration and 3/4 for the adsorption The heaters are controlled through rod-type thermostats
section. located in the exciter interior.

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

Turbogenerators Arrangement of Brush Holder for
Description Ground Fault Detection

Turbogenerators Brush Holders for
Description Ground-Fault Detection System

Turbogenerators Precautions Against Contamination
Description of Exciter Unit
1. Collection and Discharge System for The labyrinth seal prevents unfiltered power house
Carbon Brush Dust air from entering the exciter unit.
Carbon brush dust contaminates the exciter unit. Air at a slight gauge pressure is admitted into a
The resulting creepage paths can lead to damage due to compartment between the labyrinth seal teeth. The air
flashover. inlet is located at the enclosure of the rectifier wheels.
The labyrinth seal is bolted to and insulated from the
Contamination of the exciter unit is avoided by front- end generator enclosure.
providing for a controlled discharge of the carbon dust to
the atmosphere. For this purpose, the neutral grounding
sliprings are equipped with a protective cover. The fan 3. Makeup Air Filter
pressure chamber is located outside the protective cover.
A larger makeup air filter is required to handle the
larger air flow required for the carbon dust collecting
The air Circulatlng between the cover seal and the
and discharge system.
neutral grounding sliprings is thus discharged to the
atmosphere via a pipe, taking with it any carbon brush
dust. This makeup air filter is located above the exciter
enclosure and ensures that only filtered air is admitted
2. Labyrinth Seal at Exciter End Generator
into the exciter unit.
Enclosure

Turbogenerators Ground Fault Detection System
Description Brush Dust Extractor
1. Brush dust extractor

2. Brush holder cartridge
3. Brush holder
4. Terminal board
5. Support bracket
6. Exhaust air pipe

Turbogenerators Operating and Setting Values
Operation General
Strict observance of the operating and setting static head in case of pressure measuring points or
values is a prerequisite for reliable operation of the thermal characteristics in case of temperature
turbogenerator. measuring points. These calculated values are
Separate tables are provided for the various intended as guiding values for making the preliminary
design groups of the generator and its auxiliaries. They settings during initial commissioning of the unit.
show the transmitters activating the controls and These settings require certain corrections to
alarms as well as the transmitters acting on the account for the actual conditions. The final settings
generator protection circuits. obtained after startup and initial load operation are to
The Remark column contains additional be entered in the Operating Value column, and the
information on controls, temperatures and pressures. corrected tables should be promptly submitted to
All operating and setting values refer to rated BHEL for revision.
output of generator and maximum cooling water Revised pages will then be sent to the holder of
temperatures under steady-state conditions. the instruction manual as updates the request to
The operating and setting values initially specified discard all pages that have been replaced by those of
in this manual are based on experience under due a later date.
consideration of the specific site conditions, such as

Turbogenerators Operating and Setting Values
Operation Gas Quantities
Recommended
Gas Startup Shutdown Operation
Stock
Replacement of air in Generator Replacement of air in Not permitted Startup :
C02
housing*: Generator housing*: 3. V1
V, = 2.V V1 = 2.V During operation :
2. V1
Replacement of CO2 in genera- Not required Compensation for H2

H2 2.( V1 + V2)
tor housing*: losses :
V1 = 2.5 V 0.5 m3/hr (s.t.p.)
+ consumption**
Filling to operating pressure :
V2 = pe.V
Replacement of CO2 in Not permitted Supply of 40-60 dm3 /

Not required generator housing* : s (s.t.p.) compressed
Air V1 = 3.V air from air system
must be ensured
* It is assumed that generator is at rest during gas filling and removal. Filling during turning gear operation will
result in a higher gas consumption. Due to the whirling motion between the medium to be displaced and medium
admitted, the purity deteriorates so that more gas is required for scavenging.
s.t.p. = standard temperature and pressure, 0 °C and 1.013 bar

In the following, an example is given to illustrate the Amount of H2 required to fill generator to operating
calculation of the amounts of CO2, H2 and air required for pressure (operating pressure in bar x generator volume)
filling. In the example given generator volume and given
operating pressure are assumed. The values for other V1 = P0 . V = 3 . 77 m3 = 231 m3 (s.t.p.)
generator sizes, operating pressures and gas bottle
sizes will vary accordingly. V2 231 m3 (s.t.p.)
Z = ---- = ----------------- = 33 H2 bottles
V3 7 m3 (s.t.p.)
1 Example
1.2 Purging
P0 = Operating pressure, e.g. 3 bar Amount of CO2 required for removing H2 (2 generator
V = Generator volume, e.g. 77 m3 volumes)
V1 = Amount of gas to fill or purge generator
V2 = Amount of gas to fill generator to operating V1 = 2 . V = 2 . 77 m3 = 154 m3 (s.t.p.)
pressure
V3 = H2 bottle volume, e.g. 7 M3 (s.t.p.) V1 154 m3 (s.t.p.)
V4 = CO2 bottle volume, e.g. 12 M3 (s.t.p.) Z = ---- = ---------------- = 13 CO2 bottles
V2 12 m3 (s.t.p.)
Z = Number of bottles required
Amount of compressed air required for removing
1.1 Filling CO2 (3 generator volumes)
Amount of CO2 required for removing air from V1 = 3 . V = 3 . 77 m3 = 231 m3 (s.t.p.)

generator (2 generator volumes)
1.3 Bottle Volume
V1 = 2.77 m3 = 154 m3 (s.t.p.)
H2 bottle 46.7 Liters at 150 bar = 7 m3 (s.t.p.)
V1 154 m3 (s.t.p.)
Z = ---- = ------------------ = 13 CO 2 CO2 bottle : 46.7 Liters = 12 m3 (s.t.p.)
bottles
V2 12 m3 (s.t.p.)
It should be taken into consideration that the bottle
Amount of H 2 required for removing CO 2 from contents cannot be completely used up. For H2 bottles it
generator (2.5 generator volumes) is assumed that the contents can be expanded to a
pressure of approximately 1 bar above the operation
V1 = 2.5 . 77 = 193 m3 (s.t.p.) pressure. This means approximately 3% of the bottle
contents at a final pressure of 4 bar will remain following
V1 193 m3 (s.t.p.) a fill to 3 bar.
Z = ---- = ----------------- = 28 H2 bottles
V2 7 m3 (s.t.p.)
* For reasons of safety, a sufficient number of full CO2 bottles

must be available prior to starting with any generator filling
operations.

Turbogenerators Operating And Setting Values
Operation Stator Supervision
Parameter Tag Number Minimum Setting Value Maximum Setting Value Unit Remark
Control Generator Alarm Operating Control Generator Alarm
Protection Value Protection
Stator slot
temperature
95 -100 > 105 °C
24 RTDS
MKA 20 CT001
to MKACT 024
Stator Core
Temperature
TE-MKA3I CT001 < 90 > 100 > 100 °C

to MKA31CT012
EE-MKA32 CT001
to MKA32CT012
MKA75CT011
MKA75CT012
AB
Cold gas 25 - 45 > 55 >50 °C
MKA75CT013
temp
after H2
MKA75CT031
coolers
CD
MKA76CT011
MKA76CT011
AB
Hot gas l
MKA76CT012 45 - 70 > 75 °C
temp
before H2
MKA76CT021
coolers CD
MKA76CT022
Cooling water
temp before H2 PGB30CT001
coolers < 38 > 38 °C
PGB30CT501
A PGB32CT001
Cooling
water temp B PGB32CT002
after H2 < 50 > 50 °C
coolers C PGB32CT003
D PGB32CT004
Generator X MKD11CT014
Brg. Temp. < 90 > 90 °C
TE Y MKD11CT018
Generator X MKD11CY021 mic

< 84 > 84 ron
Brg. Vibn.
TE Y MKD11CY022 Pk-Pk
Generator X MKD12CT014 > 90

< 90
Brg. Temp.
EE Y MKD12CT018
mic
Generator X MKD12CY021
ron
Brg. Vibn. < 84 > 84
Pk-Pk
EE Y MKD12CY022
The operating and setting values refers to rated output of generator and maximum cooling water temperatures.
BHEL, HarIdwar 2.3-4020-7500/1

Turbogenerators Operating and Setting Valves
Operation Seal Oil System
Parameter Tag Number Minimum Setting Value Operating Minimum Setting Value Unit Remark
Generator value Alarm Generator Control
Control Alarm
Protection Protection
Temperature T E seal MKW06CT001

oil drain 50-60 °C
Temperature E E seal MKW07CT001
oil tank
Vacuum in seal oil tank MKW10CP001 > -0.4 -0.5 Bar
Pressure after pump MKW11CP001 8 10 Bar Change over to
MKW11 AP001 MKW11CP501 MKW12AP001
Pressure relief valve 1 MKW11AA031 14 Bar
Temperature before MKW11CT501 50-60 °C Change over to

cooler MKW1 1 AP001
Pressure after pump MKW12CP001 8 10 Bar

MKWA2 AP001 MKW12CP501
Pressure relief pump 2 MKW12AA031 14 Bar
Pressure after standby MKW13CP001 8 10 Bar Danger alarm

standby pump
pumpMKW13AP001 MKW13CP501
starts
Pressure relief valve 3 MKW13AA031 14 Bar

Differential pressure
seal oil filler MKW21CP021 <1.2 >1.2 Bar
Fixed alarm setting
Temperature after MKW21CT001 > 55 > 60 °C

cooler MKW21CT501 40-45
Seal oil flow rate, TE MKW31CF551 < 50 Ipm
Seal oil pressure MKW31CP051 5.5 Bar

before shaft seal MKW31CPC61 5.5
Oil volumetric flow rate, MKW32CP551 <50 Ipm

EE
Volumetric flow rate, MKW35CF551 <12 Ipm

seal ring relie, TE
Volumetric flow rate, MKW36CF551
seal ring relief, EE <12 Ipm
Seal oil / H2 < 0.9 1.5 >1 .7 Bar

differential Pr
The operating and setting values refers to rated output of generator and maximum cooling water temperatures. All pressure indicated in bar are
guage pressure.
When setting the transmitters, observe static head of oil column. When a seal oil temperature of 55 deg.C is reached, the unit must be shut dowhn
in order to avoid damage
BHEL, Hardwar 2.3-4050-7500/1

Turbogenerators Operating and Setting Valves
Operation Gas System
Minimum Setting Value Operating Minimum Setting Value

Parameter Generator value Generator Control Unit Remark
Tag Number Alarm
Control Alarm
Protection Protection
H2 bottle pressure MKG 10 CP001 < 15 15 - 150 bar

MKG 10 CP501
H2 pressure reduce 1, 8 bar

intermediate pressure MKG 11 BY001
H2 pressure reduce 2, 8 bar

MKG 12 BY001
intermediate pressure
H2 pressure reduce 1, MKG 15 BY001 3 bar

H2 operation
H2 pressure reduce 2, MKG 16 BY001 3 bar

H2 operation
MKG 18 CP001 < 2.8 3 > 3.2 bar
H2 casing pressure MKG 18 CP001
H2 purity MKG 31 CP001 < 90 < 97 > 97 % H2
Co2 bottle pressure MKG 70 CP501 100-150 bar
Relief Value for high MKG 71 AA031 bar

180
pressure Co2
Co 2 flash evaporator MKG 71 CT001 >150 0

C Heater MKG 71AH001
120-130 switches off
heater MKG 71 CT501
Relief Value for low MKG 75 AA035 bar
8
pressure Co2
0
Temp. Controller gas MKG 55 CT001 > 150 C
< 150
dryer heater
The operation and setting values refer to rated output of generator and maximum cooling water temperature.
All pressures indicated in bar are gauge pressures.
BHEL, Hardwar 2.3-4060-7500/1

Minimum Setting Value Minimum Setting Value
Generator Generator
Operating
Parameter Tag Number Control Protection Alarm Value Alarm Protection Con- Unit REMARK
trol
MKC61
35 - 42 > 45
Cold air exciter CT001
BHEL, Hardwar
0
MKC61 C
CT004
Operation
MKC65
55 - 70 > 75
CT002 > 80
0
Hot air, main exciter MKC65 C
Turbogenerators
CT002
MKC66
45- 60 > 65
Hot air, rectifier wheels Heater switches on
CT001
0
C
MKC65 Heater switches on
CT004
MKC 71 > 90
Exciter anti-condensation 45-90
CT001
0
heater C
MKC 71
CT002
< 84 > 84 m
Exciter Brg. Vibration
Pk
m
Exciter Shaft Vibration
< 200 > 200 Pk
< 90 > 90 130 0C High – High
Exciter Brg. Temp 0
C Annunciation
The operation and setting values refer to refer to output of generator and maximum cooling water temperature.
Exciter Supervision
Operating and Setting Values
2.3-4090-7500/1
Turbogenerators Operation Log
Operation General
1. Operating Log may be useful in determining the cause of any

subsequent trouble and speeding up corrections.
During initial startup and during normal
operation, the hydrogen-cooled turbogenerator, 2. Normal and Special Operating
auxiliaries and all instruments and controls should Conditions
be monitored to assure continuous reliable The generator should be continuously
operation. The observations and readings should monitored from startup to shutdown. During initial
be recorded. A typical operating log is contained startup, all checks should be made at frequent
in these operating instructions. This table will, of intervals. Hourly readings may be taken after
course, have to be adapted to the particular completion of the initial trial period.
conditions of the plant. The important requirement A generator is considered to have been taken
is that all checks and readings be made at certain partly into service after hydrogen filling. The seal
predetermined intervals and preferably at the oil system must also remain in service and be
same load point. Any special conditions regarding continuously monitored along with the gas system
the operation of the hydrogen-cooled turbo- as long as hydrogen is maintained in the
generator should be noted separately. Such notes generator.
BHEL, Haridwar 2.3-4100-0001 / 1

Turbogenerators Operating Log
Operation Generator Supervision
Job name:………………… SI. No.:……………………… Remark : …………………..
Operating values1) Unit Date

Tag Number
Active power MW
Reactive power Mvar
Stator current kA
Stator Voltage kV
Field current A
Speed S-1
Generator gas pressure bar
MKA20CTOO1
Stator winding slot temperature °C TO
MKA20CT024
MKA31CTOO1
TE °C TO
MKA31CT012
Stator core temperatures MKA32CTOO1
TO
EE °C MKA32CT012
MKA75CT011
A/B °C MKA75CT012
MKA75CT013
Cold gas after coolers MKA75CT031
C/D °C MKA75CT032
MKA75CT033
MKA76CT011
A&B °C MKA76CT012
Hot gas before coolers MKA76CT021
C&D °C MKA76CT022
PGB30CT001
Cooling water temp, before coolers °C PGB30CT501
A PGB32CT001
Cooling water temp after coolers °C PGB32CT002
B
C PGB32CT003
°C PGB32CT004
D
Cooling water outlet temperatures from °C PGB33CT501
H2 coolers
Front MKD11CT014
Bearing Temperature TE
Rear °C MKD11CT018
Bearing Temperature EE Front MKD12CT014
Rear °C MKD12CT018
Bearing Vibration TE X micron MKD11CY021
Y MKD11CY022
X micron MKD11CY041
Bearing Vibration EE
Y MKD11CY042
X micron MKD12CY021
Shaft Vibration EE
Y MKD12CY022
Shaft Vibration EE X micron MKD11CT014
Y MKD11CT018
* Data should be recorded during steady-state conditions after constant operation for several hours


Tag Number
H2 side seal oil drain temperature TE °C MKW06CT001

EE “C MKW07CT001
Air side seal oil drain temperature “C MKW08CT001
Vacuum in the seal oil tank bar MKW10CP501
Seal oil pressure after ACSOP- 1 bar MKW11CP001
bar MKW11CP501
Seal oil pressure after ACSOP-2 bar MKW12CP001
MKW12CP501
Seal Oil Pressure after DCSOP bar MKW13CP001
MKW13CP501
Seal oil differential pressure across duplex filter bar MKW21CP021
Seal oil Temperatures before coolers “C MKW11CT001
MKW11CT501
Seal oil temperature after filter °C MKW21CT001
“C MKW21CT011
“C MKW21CT021
MKW21CT031
Seal oil flow TE dm /s3
MKW31CF551
Seal oil flow EE dm 3 /s MKW32CF551
Seal oil pressure before shaft seals bar MKW31CP051
MKW31CP501
Ring relief oil volume flow TE dm 3 /s MKW35CF551
Ring relief oil volume flow EE dm 3 /s MKW36CF551
1) Data should be recorded during steady-state conditions after constant operation for several hours.

Date
1)
Operating values Unit Tag Number
H2 pressure at gas manifold MKG10CP001

bar MKG10CP501
H2 casing pressure MKG18CP001
bar MKG18CP501
H2 purity ( elecr. purity meter system ) % H2 MKG31CQ501
Temperature of CO2 flash evaporator MKG71CT001

°C MKG71CT501
Pressure at CO2 manifold bar MKG70CP501
(1) Data should be recorded during steady-state conditions after constant operation several hours.
(2) To be recorded only on failure of electrical purity meter system.

Operation Exciter Supervision

Tag Number
MKC61CT001
Cold air temperature to main exciter °C MKC61CT002
MKC61CT003
Cold air temperature to main exciter °C MKC61CT004
MKC65CT001
Hot air temperature after main exciter
°C MKC65CT002
Hot air temperature after main exciter MKC65CT003 .
°C MKC65CT004
Hot air temperature after rectifier wheel °C MKC66CT001
MKC66CT002
Hot air temperature after rectifier wheel °C
Bearing temperature °C MKD21CT014
Bearing temperature °C MKD21CT018

MKD21CY021
Exciter absolute vibration μm
MKD21CY022
Exciter shaft vibration

μm MKD21CY041
MKD21CY042
Cooling water Temperature Inlet to coolers °C MKD21CY041
MKD21CY041
Cooling water temperature at outlet of coolers °C
MKD21CY041
MKD21CY041
Temperature of Anticondensation heaters °C
MKD21CY041
MKD21CY041
Quadrature Axis Measuring Coil -
MKD21CY041
Rotor Earth Fault Detection Slipring - MKD21CY041
)
Data should be recorded during steady-state conditions after constant operation for several hours.

Turbogenerators Preparation for Starting
Operation Introduction
It is a prerequisite for startup of the turbine-generator displacement of the air prior to hydrogen filling and for
that continuous contacts be maintained between all plant immediate removal of the hydrogen from the generator.
sections directly or indirectly Involved In the starting
procedure.
Prior to startup, it should be ascertained that the 1.2.2 Hydrogen (H2)
following auxiliaries are in operation and will continue to The hydrogen gas quantity to be provided should
remain in service: suffice for displacing the CO2, for filling the generator to
operating pressure and to compensate for the H2 losses
Seal oil system
during operation [3].
Gas system
Cooling water supply
1.3 Cooling Water Supply
If auxiliaries were taken out of operation, the
The coolers to be placed in operation should be
operating media required to fill the auxiliary systems
filled with water. To do this, the cooler vents should be
should be made available.
opened~ Note: Continuous vents should remain open.
The vents should be kept open unfll the aIr on the water
1. Operating Media
side of the coolers has been completely expelled.
The operating media used, i.e.
Before startup, the operating staff should ensure
Turbine oil
that a sufficient cooling water supply Is available.
Carbon dioxide (CO2)
Hydrogen (H2)
2. Checking the Transmitters
must conform to the specifications [1] and [2].
Prior to startup, all connections should be rechecked.
This applies to piping as well as to cabling. When
1.1 Seal Oil System
checking the cabling, special attention should be paid to
The seal oil circuits should be filled with turbine oil.
testing the metering and signal cables. All alarm systems
The quantity of turbine oil required to fill the seal oil circuits
should be checked.
should be taken Into consideration when filling the turbine
All temperature measuring points should also be
oil tank.
checked. This applies to the local as well as the remote
reading thermometers. Unless temperature rises were
1.2 Gas System brought about by other preparatory work at the measuring
1.2.1 Carbon Dioxide (CO2) points, temperatures of approximately ambient or room
The carbon dioxide quantity to be provided should temperature should be indicated. When doubts exist
suffice for two complete generator fillings [3], i e. for regarding the electrical temperature measurement
calibration and/line compensation should be repeated.
Also refer to the following Information

[1] 2.1-1880 Oil Specification
[2] 2.1-1883 Gas Specification
[3] 2.3-4010 Gas Quantities

Turbogenerators Hints for Cooling Operation
Operation
1. General During this flushing procedure, the coolers should

The heat exchangers of the generator and its not be in service on their cooling water sides, i.e. bypass
auxiliaries have copper or copper alloy tubes. Admiralty arrangements must ensure that the flushing procedure
brass (CuZn28Sn) is primarily used for fresh-water can be carried out without passing water through the
applications, while aluminium brass (CuZn20AI) is coolers. Following the flushing procedure, cooling water
selected for seawater service. must be continuously passed through coolers with
Copper and copper alloy tubes must form a protective copper alloy materials for the longest possible period of
film on the cooling water side to ensure adequate time (four to eight weeks) to ensure the formation of an
resistance to corrosion attack. The formation and the effective protective film on the cooler tubes.
preservation of the protective film are essentially
dependent on the conditions during initial 5. Preventing Standstill Corrosion
commissioning and subsequent service. Depending on the cooler material and the kind and
properties of the cooling water, standby coolers through
2. Cooler Tube Materials which no cooling water flows for some period of time are
The coolers of the unit described have copper or subjected to all corrosive influences that can occur during
copper alloy tubes. an outage.
Details of the cooler tube materials are specified in This involves the risk that the micro-organisms on
the Technical Data section of this manual [1]. the tube walls will die due to the lack of oxygen resulting
Influences on the cooling water side can cause from the loss of fresh water supply and form decay
damage to the copper or copper alloy tubes of the products during decomposition, such as ammonia.
coolers, primarily in the form of erosion/corrosion and Depending on the material used, this may lead to
corrosion attack due to corrosion and/or stress corrosion. cracking.
Corrosion damage can only be safely prevented If
insufficient protective film formation the standby coolers are drained on their water sides,
excessive cooling water velocity cleaned, completely dried, vented, and maintained in a
localized, excessive cooling water velocity resulting dry condition.
from tube blockage by foreign bodies For cleaning, the coolers may be flushed with water
deposits on tubes caused by suspended material having a low salt content (CI content < 500 mg/l).
and/or remnants of micro-organisms which impair For drying, the medium to be cooled can be passed
the formation of a protective film and promote through the coolers via the filler and vent pipes. However,
corrosion, especially in (standby) coolers having no this measure cannot be always implemented in practice,
cooling water flow for some time. especially in the case of brief outages and because of
the need to maintain the cooler ready for operation.
3. Cooling Water Properties
If a cooler has to be maintained ready for service in
The cooling water used for the coolers must meet
filled condition (wet preservation), it should be flushed
the following requirements:
with the full cooling water volume flow for a brief period
The cooling water must be free from coarse twice every week. In addition, it is recommended to
impurities. perform a cooler changeover once every week so that
The amount of suspended material must be as the normal-service cooler and the standby cooler will be
small as possible. alternately in operation.
The growth of micro-organisms and, in case of
seawater installations, the growth of mussels must 6. Preventing Deposits in Cooler Tubes
be prevented. Deposits in the cooler tubes are best prevented by
Cooling water obtained from a closed secondary supplying the normal-service coolers with the full cooling
cooling water circuit mostly meets these requirements water volume flow.
provided that the necessary care Is exercised during initial If the temperature of the medium to be cooled is
operation, for example, by flushing the system without controlled by varying the cooling water volume flow, it is
passing water through the coolers. recommended to supply the normal-service cooler with
When using water direclly obtained from natural water the full cooling water volume for a brief period twice
sources, adverse influences should be minimized by suitable every week in order to flush away any deposits formed
treatment procedures (e.g. filtration, dispersant dosing, on the tubes due to insufficient cooling water velocIty.
chlorination and similar methods as specified in the During occasional outages of sufficient duration or
literature). during an overhaul it should then be checked whether in-
service flushing is sufficient or whether manual clearing
4 Initial Operation of Coolers is required. If frequent manual cleaning is necessary on
Prior to placing the coolers in operation for the first time, account of poor cooling water conditions, the installation
the cooling water system should be thoroughly cleaned of a high-velocity water cleaning system or of a cleaning
by flushing to remove Impurities and foreign matter. system using sponge rubber balls should be considered.

7. Special Measures for Wet Preservation 8. Cooler Changeover
If a cooler has to be maintained ready for service in Make sure to fill and vent standby coolers on their
filled condition, the water volume in the cooler must not water sides prior to changing over the coolers. Fully open
be hermetically sealed from the cooling water system or shutoff valves. After cooler changeover, which must be
from the surrounding atmosphere, respectively. Improper performed by experienced personnel, perform all mea-
cooler changeover would then result in heating and sures required for preservation of the cooler removed
excessive expansion of the cooling water volume, leading from normal service and now on standby.
to damage to the cooler, gaskets or piping due to To do this, close shutoff valves upstream and down-
excessive pressure. stream of the standby cooler, since the cooling water sys-
For wet preservation, always open a cooler vent on tem Is mostly designed only for supply of the cooling water
the water side or a shutoff valve by a small amount, flow through the normal-service cooler(s). Then open the
making sure to avoid a low-velocity water flow that would shutoff valve on the outlet side by a small amount to avoid
promote the entry of suspended material. the effects of a water expansion due to water heating.
A cooler changeover is necessary when, with the
Note: Standby coolers should be maintained ready for valves in the cooling water circuit fully open, the tempera-
operation In dry condition In preference to wet ture of the medium to be cooled is rising above the nor-
preservation. mal level or when required on account of abnormal
events (e.g. leakage).
Also refer to the following information

(1) 2.1.3-1830 Hydrogen Cooler Data
2.3-5003-0001/2
Turbogenerators Filling and Initial Operations
Operation of Seal Oil System
Preparatory Work
Caution: The seal oil system Is to be filled only with oil

complying with our specification [1].
1 Filling and initial operation
of seal oil system PrerequisIte for filling the seal oil circuits :
z Seal oil circuits were cleaned and flushed [2].

z Pump motors were checked for correct direction of
rotatIon.
z Bearing vapor exhauaters were checked for correct
direction of rotation and proper functioning.
2
Preparatory work
2.1
Adjust level detectors in liquid level detec- Carefully drain probe tank and reclose filler connections
tor rack with the probes immersed [3], [4] after completion of the functionaI tset.
2.2
Adjust level detectors for level detection
in seal oil system with the probes im-
mersed [3].
2.3
Check to ensure that regreasing device of axial
Check to ensure that bearing vapor
exhausters are ready for operation shaft seal is filled with a sufflcient quantity of grease.
Fill all existing loop seals in waste gas system with
turbine oil. Close drain valves.
2.4
Check valve positions for agreement Note: Pressure relief valves and seal oil pressure
with valve position list [5]. regulating valves have already been adjusted.
3
Start with filling of seal oil circuits
Also refor to tho following InformatIon

[1] 2.1-1880 Turbine Oil Specification
[2] 2.5-0320 FlushIng the Oil Piping
[3] 2.3-5510 Activating the Level Detector System
for Seal Oil System and Generator
Supervisory System
[4] 2.3-5520 Activating the Level Detector System
for Generator Supervisory System.
[5] 2.3-5108 Valve Positions in Seal Oil System for
Normal Operation

Turbogenerators Valve Positions in Seal Oil System for
Operation Normal Operation
Note : With normal cooling water conditions, one of the two seal oil cooler is in operation. The second cooler is on standby and
filled with oil on its oil side, but should be empty, clean and dry on its cooling water side to preclude standstill corrosion.
Name Tag Number Valve Position

Shutoff valve at seal oil storage tank MKW01 AA151 Open
Drain valve at seal oil storage tank MKW01 AA201 Closed
Drain valve, loop seal after seal oil storage tank MKW01 AA211 Closed
Control valve, bypass of level control valve MKW06 AA008 Closed
Shutoff valve after level control valve MKW06AA151 Open
Drain valve, loop seal MKW06 AA201 Closed
Shutoff valve, level detection in intermediate seal oil tank MKW06 AA301 Open
Shutoff valve, level detection in intermediate seal oil tank MKW06 AA331 Open
Level control valve, inlet vacuum tank MKW10AA001 Open
Control valve, bypass of vacuum tank MKW10AA011 Closed
Shutoff valve before vacuum tank MKW10AA101 Open
Shutoff valve, level detection in vacuum tank MKW10AA301 Open
Shutoff valve, level detection in vacuum tank MKW10AA331 Open
Pressure regulating valve after pump 1 MKW1 1 AA001 Set
Shutoff valve after vacuum pump 1 MKW11 AA011 open
Pressure relief valve, pump 1 MKW1 1 AA031 Set
Check valve after pump 1 MKW11 AA051 Open
Shutoff valve before pump 1 MKW11AA101 Open
Shutoff valve after pressure regulating valve MKW11AA181 Open
Shutoff valve to lube oil system ;
MKW11 AA185 Closed
Shutoff valve before vacuum pump 1 MKW11AA121 Open
Pressure regulating valve after pump 2 MKW12AA001 Set
Shutoff valve after vacuum pump 2 MKW12AA011 Closed
Pressure relief valve, pump 2 ;
:
MKW12AA031 Set
Check valve after pump 2 MKW12AA051 Open
Shutoff valve before vacuum pump 2 MKW12AA121 Closed
Pressure regulating valve after pump 3 MKW13AA001 Set
Pressure relief valve, pump 3 MKW13AA031 Set
Check valve after pump 3 MKW13AA051 Open
Over pressure regulator, governing oil MKW14AA001 Open
Check valve after governing oil MKW14AA051 Open
Pressure regulating valve at inlet of governing oil MKW14AA101 Set
Filler valve, coolers 1/2 MKW21 AA121 Open
Multi-way valve before seal oil cooler . MKW21 AA151 Set
Multi-way valve after seal oil cooler MKW21 AA152 Set
Multi-way valve before seal oil filter MKW21 AA157 Set
Multi-way valve after seal oil filter MKW21 AA158 Set
Drain valve at cooler 1, seal oil MKW21 AA201 Closed
Drain valve at seal oil filter 1 MKW21AA211 Closed
Vent valve at cooler 1, seal oil MKW21 AA251 Closed
Vent valve at seal oil filter 1 MKW21 AA261 Closed
Shutoff valve for differential pressure across filter MKW21 AA341 Open
Shutoff valve for differential pressure across filter MKW21 AA371 Open

Turbogenerators Valve Positions in Seal Oil System for
Operation Normal Operation
Name Tag Number Valve position
Drain valve at cooler 2, seal oil MKW22 AA201 Closed

Drain valve at seal oil filter 2 MKW22 AA211 Closed
Vent valve at cooler 2, seal oil MKW22 AA251 Closed
Vent valve at seal oil filter 2 MKW22 AA261 Closed
Differential pressure valve, seal pressure TE MKW31 AA001 Set
Shutoff valve before differential pressure valve MKW31 AA101 Open
Shutoff valve after differential pressure valve MKW31 AA111 Open
Shutoff valve, signal line for differential pressure valve MKW31 AA311 Open
Differential pressure valve, seal oil pressure EE MKW32 AA001 Set
Shutoff valve before differential pressure valve MKW32 AA101 Open
Shutoff valve after differential pressure valve MKW32 AA111 Open
Shutoff valve, signal line for differential pressure valve MKW32 AA311 Open
Control valve for volumetric flow rate control MKW35 AA001 Set
Control valve in by pass of volume flow control valve MKW35 AA011 Closed
Shutoff valve before volume flow control valve MKW35AA101 Open
Shutoff valve after volume flow control valve MKW35AA111 Open
Control valve for volumetric flow rate control MKW36 AA001 Set
Control valve in bypass of volume flow control valve MKW36 AA011 Closed
Shutoff valve before volume flow control valve MKW36AA101 Open
Shutoff valve after volume flow control valve MKW36 AA111 Open
Shutoff valve, signal line, casing pressure MKW39 AA301 Open
Shutoff valve, signal line for differential valve 1, casing pressure MKW39 AA311 Open
Shutoff valve, signal line for differential valve 2, casing pressure MKW39 AA321 Open
Vent valve at cooler 1 PGB61 AA551 Closed 1)
Vent valve at cooler 2 PGB61 AA552 Open 2)
Drain valve at cooler 1 PGB61 AA571 Closed 1)
Drain valve at cooler 2 PGB61 AA572 Open 2)
(1) Open, if cooler 2 is in operation

(2) Closed, if cooler 2 is in operation
(3) Set, if cooler 2 is in operation
BHEL, Hardwar 2.3-5108-7500/2

Turbogenerators Filling and Initial Operation
Operation of Air Side Seal Oil Circuit
Prerequisites for filling the air side seal oil circuit:

1 Filling air side
seal oil circuit
Preparatory work was completed.
Valves must have been set according to the valve
position list.
Shutoff valves before all pressure gauges and
pressure transmitters must be open.
Note: The seal oil cooler should be filled on its

water side and placed in operation only when
the seal oil temperature rises to >= 380C.
2
Open shutoff valves MKW01AA151 Fill seal oil vacuum tank with oil opening shut
and MKW10AA101
off valves MKW01AA151 and MKW10AA101.
3
Place vacuum pump and bearing Place one exhauster in operation electrically.
vapor exhausters in service Ensure that second exhauster is ready for startup.
4 With the seal oil tank filled, seal oil is available at

Start main seal oil pump the seal oil pumps after a short time.
Start seal oil pump 1 by manual control.
Note: The seal oil ‘pump is deenergized when the
level detector in the seal oil tank activates an alarm
for low oil level in seal oil tank. Seal oil pump is
automatically restarted when the seal oil tank has
been refilled to the required level (dry running
protection).
4.1
Observe formation of oil foam in seal oil tank When the oil foam rises above the observable
level in the oil sight glass in the seal oil tank, close
shutoff valve
MKW11AA121 (before vacuum pump)
and fully open control valve
MKW10AA 011 (in vacuum pump bypass).
Throttle control valve MKW10AA011 and reopen

shut off valve MKW 11AA121 as soon as seal oil tank
is free from oil foam. Repeat this procedure until the
formation of oil foam has ceased.

4.2
To do this, open valves
Fill and vent seal oil coolers
MKW21AA121 (filler valve, cooler 1/2)
MKW21AA251 (vent,cooler 1)
MKW22AA251 (vent,cooler 2).
Close vent valves as soon as oil - emerges from

vent valves without bubbles. Maintain filler valve
MKW21AA121 in open position.
4.3
Fill and vent seal oil filters To do this, first open filler valve at filters and then
open vent valves.
MKW21AA261 (seal oil filter 1)

MKW22AA261 (seal oil filter 2)
Close vent valves as soon as oil emerges from

vent valves. Maintain filler valve in open position.
4.4
Change over pumps Stop seal oil pump 1 by manual control. Then-
start seal oil pump 2 and standby seal oil pump. Stop
standby seal oil pump after a few minutes and change
over to seal oil pump 1 or 2.
4.5
Oil from the hydrogen side of the shaft seal will
Observe oil level in intermediate oil tank
continue to flow into intermediate oil tank
MKW06BB001, resulting in a rise of the oil level above
the sight glass. This is caused by the lack of pres-
sure in the generator.
5
Start with venting of seal oil circuit.
Seal oil circuit is filled

[1] 2.3-5113 Placing Vacuum Pump in Service
2.3-5110-0027/2
Turbogenerators Placing Vacuum Pump in Service
Operation
Placing the vacuum pump in service is required

whenever a seal oil pump is placed in operation.
1 Placing in service Check oil level in sight glass of vacuum pump.
Start vacuum pump Open gas ballast valve and close shutoff valve
MKW11AA21 to avoid the formation of moisture
condensatation as the pump is in cold condition.
3
Open shutoff valve after the pump has been put in
Open shutoff valve MKW11AA121
operation for approximately 30 minutes. Pump must be
warm to touch.
4
Use control valve MKW10AA011 to adjust vacuum
Adjust control valve MKW10AA011
in seal off tank to approximately-0.6 to -0.8 bar.
Vacuum Pump is in service

Turbogenerators Venting of Seal Oil Circuit
Operation
Prerequisite:
1 Venting seal oil circuit Seal oil circuit was filled and placed in service.
1.1
Keep venting screws open until the oil emerges
Vent pressure retaining valves downstream
of seal oil pumps without bubbles.
1.2
Fill and vent seal oil coolers Vent seal oil coolers by means of vent valves.
MKW21 AA 251 (seal oil cooler 1)

MKW22AA 251 (seal oil cooler 2)
Close vent valves when oil emerges from vent valves

without bubbles. Maintain filler valve in open position.
1.3
Keep vent valves MKW21 AA261 and MKW22AA261
Fill and vent seal oil filters
open until the oil emerges without bubbles. Maintain
filler valve in open position.
1.4
Vent all pressure gauges, except for MKW10CP001,
Vent pressure gauges
through the venting screws at the respective pressure
gauge shutoff valves.
1.5
Bypass of volume flow reglators
Briefly open regulating valves MKW35AA011 and
MKW36AA011 to fill pipe with oil and then reclose
regulating valves.
Venting of all components of seal oil

system is completed. Start with setting of the oil pressures.

Turbogenerators Setting of Seal Oil Pressures
Operation
Note: Seal oil units and seal oil valve rack were
subjected to a functional test at manufacturer’s works.
This included setting of seal oil pressures for operating
1 Setting Seal oil pressures
conditions to be expected.
Do not change any setting during commissioning
unless such a change is unavoidable.
2 Pressure regulating valves for seal oil pressures were

set at the manulacturer’s works. Any readjustments are
Seal oil circuit
normally only required after maintenance work or
replacement of the pressure regulating valves.
2.1
Adjust pressure retaining valves Pressure retaining valves

down-stream of seal oil pumps
MKW11 AA 001 (downstream of pump 1)
MKW12 AA 001 (downstream of pump 2)
MKW13 AA 001 (dcwnstream of pump 3)
were adjusted so that the delivery head of each pump

amounts to 13.5 bar when 50 % of the delivery flow is
discharged via the respective pressure retaining valve.
The seal oil pressure downstream of each pump is
adjustable by changing the spring pressure at the
associated pressure retaining valve. To do this, turn the
upper spring retainer in downward direction as
necessary.
2.2
Adjust pressure regulating valves

Pressure retaining valves
MKW31 AA 001 (for normal operation mode)

MKW32 AA 001 (for standby mode)
were adjusted with graded settings to prevent them from

responding simultaneously as far as practicable The
adjustments were make under due consideration of the
control characteristics of the valves [1].
Observe the following general requirements
With 100 % flow, (standby) pressure regulating valve

MKW 32AA001 should maintain the seal oil
pressure at the shaft seals at 1.0 bar above the gas
pressure in the generator.
The seal oil pressure obtainable with the above
setting at a volumetric flow rate of 20 dm3/min should
be equal to the seal oil pressure established by
pressure regulating valve MKW31 AA001 with 100%
flow.

Turbogenerators Setting of Seal Oil Pressures
Operation
Fig.1 Setting of Pressure Regulating Valves,

Schematic
Any required readjustment should be made as

follows:
Loosen lock nut at the respective valve stem

Turn adjusting nut to set the seal oil pressure
Retighten lock nut.
Set seal oil volumetric flow rate for seal Set seal oil volumetric flow rate for seal ring relief
ring relief by means of volume flow regulators MKW35AA001 and
MKW36AA001
Note: Final adjustment can only be made when the
generator is filled to rated pressure and operated at
rated speed. When making the final volumetric flow
rate setting, also check the turbine-generator vibration
levels, since an incorrectly set seal oil pressure for
seal ring relief may impair smooth running of the
generator.
Setting of the seal oil pressures is Start with setting and checking of alarm and
completed changeover device.

Turbogenerators Setting of Operating Values
Operation for Seal Oil System
Note: Seal oil units and seal oil valve rack were
subjected to a functIonal test at manufacturer’s works.
1 Setting of operating values This included setting and checkIng of all pressure
transmitters for operatIng conditions to be expected.
2
Alarm contacts at differential pressure indicator is
Differential pressure transmitters at set so that an alarm is activated when a predetermined
seal oil filters degree of fouling is exceeded.
3 Pressure transmitters for alarm and changeover

devices were set at the manufacturer’s works. Do not
Set pressure transmitters
change settings unless such a change is unavoidable.
Resetting is normally only required after replace-
ment of the pressure transmitters.
To do this observe the following procedure:
Close shutoff valve upstream of pressure

transmitter. Remove cap at test connection.
Connect a hand pump with pressure indicator to
test connection (if provided, open shutoff valve for
test connection).
Establish required pressure [1] by means of pump
and set contact.
Relieve pressure (if provided, close shutoff valve
for test connection).
Remove hand pump.
Refit cap to test connection.
4 Low vacuum in seal oil vacuum activates an alarm.

After the vacuum pump has been in operation for
Pressure transmitter for vacuum in seal
sometime, the vacuum in the system should be
oil vacuum tank approximately -0.4 to -0.45 bar.
To perform a leakage test of the seal oil tank, stop
seal oil pumps and close shutoff valves.
MKW11AA101 (upstream of seal oil pump 1)

MKW12AA101 (upstream of standby seal oil pump)

MKW10AA101 (oil inlet, seal oil tank)

MKW11AA121 (upstream of vacuum pump)
MKW10AA011 (in vacuum pump bypass)
Check to ensure that pressure in vacuum tank

remains constant for period of 24 hours. Then reopen
5 shutoff valves and start seal oil pumps.
Perform functional test of level detectors in
Note: This check Is only permissible when the
generator prechambers
generator is filled with air at atmospheric pressure.
Perform function test as follows:

Remove hex plugs near the level detectors on TE
and EE stator end shields.
Close shutoff valves MKW06 AA 151 and MKW 06 AA
008. The oil level in the seal oil circuit will rise up to
the generator prechambers within a short time.
The alarm is activated as soon as the oil level in the
generator prechamber reaches the level detectors.
After both level detectors have activated an alarm,
which should take place almost simultaneously,
promptly open shutoff valve MKW06AA151 and
secure in position to prevent valve closing.
1. Stator end shield

2. Level detector
3. Hex plug
Flg.1 Level Detector In Stator End Shield
Cancel the alarm after a short while.

Replace hex plug making sure that a gastight seal
is obtained.
If seal oil flows from the threaded holes without an

alarm being given, reopen shutoff valve MKW06 AA151
immediately and investigate and correct cause of level
detector malfunction. Repeat functional test.
6
Set limit-value cards for temperature monitoring Note: If shutoff valve MKW06AA151 is not opened
(1) and the seal oil pump stopped immediately, seal oil
may flow into the generator.

7
Start with measurement of seal oil volumeteric flow
Checking and setting of supervisory rates and setting of flow rates for TE and EE seal ring
equipment are completed relief.

[1] 2.3-4050 Setting and Operating Values

Turbogenerators Measurement of
Operation Seal Oil Volume Flows
Seal oil volume flows to shaft seals are dependent

on:
1 Measuring seal oil

volume flows clearance between seal ring and rotor shaft
seal oil temperature
generator casing pressure
generator speed
A comparison of the readings will provide

meaningful results only if the readings are taken under
equal steady-state conditions.
2
Measure oil volume flows for seal ring Note: Regulating valves MKW35AA 001 (TE seal ring
relief relief) and MKW36AA 001 (EE seal ring relief) for setting
the volumetric flow rates were set and checked at
manufacturer’s works. Settings were made under due
consideration of operating conditions to be expected.
Do not change any setting unless such a change is
unavoidable.
3
Measurement of seal oil volume flows is Start with functional testing of pumps and exhausters.
completed

Turbogenerators Activating the Measuring
Operation Device for Vacuum in Seal Oil
Vacuum Tank
1 Activating measuring device If a zero adjustment should be necessary, e.g. as a

result of improper handling, follow the procedure de-
scribed below.
2
Calibration of measuring device Only Barton cells with indicator module can be cali-
brated, since the calibration can only be performed at
the indicator module. Never make any adjustments on
the Barton cell itself.
A calibration will be required to adjust the indicator
module for a torque tube shaft rotation of 8° + 10 %. In
addition, a linearity correction should be made to elimi-
nate any linerarity errors of the cell and indicator mod-
ule.
The calibration should preferably be performed by
comparing the indication with the reading obtained by
means of a U – tube (mercury or water column) con-
nected to the system. The choice of mercury or water
column depends on the measuring range.
When using a mercury column for calibration, make
sure that no mercury will enter the cell.
Exercise utmost care when setting up the instru-
ment on a calibration stand.
Perform the calibration with dry air, making sure
that there is no water in the cell. Remove the bottom
screw plugs before starting with the calibration proce-
dure in order to drain any moisture condensate, etc. from
the cell.
Insert a screw plug on the high-pressure side for
tight sealing. Check to ensure that low-pressure side is
open. Then apply test pressure.
To calibrate measuring transducers with used cells.
Clean the cells before starting with the calibration.
1 Compressed air connection.

2 Precision instrument, e.g. U-tube gauge.
3 Differential pressure gauge
Fig. 1 Arrangement of Metering Connections
Note: Liquid columns in the legs of the U-tube

gauge must be at the same level.

3
To perform a zero check, equalize the pressure be-
Zero check tween the high-pressure and low-pressure sides and
isolate both differential pressure transmission lines
(Open equalizing valve. Close shutoff valves). Use a simi-
lar-procedure on pressure and
vacuum measuring systems. Check zero drift at built -in-
indicator or at a similar facility.
In the case of meter systems with suppressed zero,
apply an appropriate pressure to the high-pressure side.
Correct zero drift on indicator module and not on the cell
itself.
Zero drift may be due to improper mounting of the
Barton cell, inclined position of traps, defective equaliz-
ing valve, fouled shutoff valves, fouled pressure cham-
bers in cell, etc. Remove cause.
Trace fault in Barton cell as a last step. The Barton
cell has a high zero constancy.
4
The pointer can be removed from the pointer axle for
Adjustment of indicator a coarse zero adjustment.
Use zero setter in housing bottom for vernier adjust-
ment. A range correction is only required if the actuating
lever was removed from the torque tube shaft, and a
subsequent linearization is only necessary if the Barton
cell was replaced.
The indication can be adjusted by turning the cor-
recting spindle. Clockwise turning shifts the pointer to
the right-hand side.
Linearity can be corrected by cautiously enlarging the
upper slot of the calibration device for a positive deviation
and the lower slot for a negative deviation,
4.1
Connect precision instrument and Connect instrument to a pressure transmitter (see
compressed air feed line Fig.1)
Disconnect pipes between shutoff valve and Barton
cell.
Connect a U-tube pressure gauge or another preci-
sion instrument to the high-pressure side of the
Barton cell.
Remove cover, pull off pointer and remove dial.
Attach calibration dial. It is recommended to use a
standard dial with a 60 mm dia. hole in the center,
affording access to the calibration facilities and en-
abling readings to be taken.
Set pointer to 0 % mark at zero pressure and make
vernier adjustment
Open shutoff valve for compressed

Open shutoff valve for compressed air until U-tube
air carefully gauge or precision instrument indicates full scale value
of indicator.
Apply 100 % pressure and correct full scale indica-

tion if necessary.
Apply 50% pressure and correct possible deviations
by way of a linearity correction.
Recheck 0%and 100% indications and correct again
if necessary.
2.3-5165-0001/2
Repeat calibration procedure until correct 0%,
50%and 100% indications are obtained.
Remove pointer and replace dial and then set
pointer to zero mark as precisely as possible.
Remove U-tube gauge or precision instrument and

reconnect metering lines.
Setting of limit contacts Limit contact settings are not visible from outside.
They should be checked and, if necessary, corrected.
Opening the housing is not required.
The operating points can be adjusted with a
screwdriver at the left-hand and right-hand setting
spindles in the indicator module.
Example: Limit contact C, positive contact; at
connector II, terminals 4,5 and 6, for maximum value
monitoring with rising characteristic, can be adjusted
by turning the upper setting spindle in the left-hand
side wall of the housing (looking on indicator module
from front).
To check the setting, connect a continuity tester,
e.g. ohmmeter. etc., to fixed contact and to one of the
moving contacts (NC or NO contact) and perform
status check. Apply pressure to be monitored to
measuring system. Check limit switch for proper
response and operation.
If the limit switch fails to operate as necessary,
correct setting for the required pressure by turning
the setting spindle. To obtain an optimum setting,
turn setting spindle several times beyond the switch
point in both directions and then approach switch point
position from the higher-pressure side for maximum
contacts and from the lower-pressure side for
minimum contacts.
If the limit switch fails to operate as necessary,
correct setting for the required pressure by turning
the setting spindle. To obtain an optimum setting,
turn setting spindle several times beyond the switch
point in both directions and then approach switch point
from the higher-pressure side for maximum contacts
and from the lower-pressure side for minimum
contacts.
This procedure accounts for the smaller effect of
the switch contact at the switch point. No variation in
the indication occurs before or beyond the switch
point.
Measuring device is ready

for measurement
2.3-5165-0001/3
Turbogenerators Functional Testing of
Operation Pumps and Exhausters
1 Perform functional test
Check standby seal oil pump for proper

operation
Check pumps for automatic operation
When a seal oil temperture more than

40 ° C has been reached, turn on the
cooling supply to cooler selected
for operation so as to obtain the specified
heat removal capacity
5
Measure vacuum in bearing compartments with a
Check bearing vapor exhausters for U-tube manometer while the bearing vapor exhauster is
proper operation
in operation. The vacuum should be between
approximately 5 to 10 mbar.
Filling and startup procedures are completed

Begin normal running routine

Turbogenerators Startup of Seal Oil System
Operation
Prerequisite:
1 Startup of seal oil system Seal oil circuits must have been filled with oil.
Instructions for placing the seal oil system in service

after a shutdown involving draining of the seal oil circuits
are given elsewhere in this manual [1] .
Check valves for correct positions [2]
3
Activate controls of bearing vapor exhausters,
Place bearing vapor exhausters, vacuum
pump and seal oil pump in operation vacuum pump and all seal oil pumps.
Check seal oil circuits for proper venting

[3]
Seal oil circuits are new in operation Start will normal running routine.

[1] 2.3-5100 Filling and Initial operation
2.3-5163 of Seal Oil System
[2] 2.3-5108 Valve Positions in Seal Oil System
for Normal Operation
[3] 2.3-5130 Venting of Seal Oil Circuits

Turbogenerators Activating the Level Detector System
Operation for Seal Oil System and Generator
Supervisory System
Prior to activating the level detector system check

Activating level detector system wiring for compliance with circuit arrangement and
1
connection diagrams.
Check power supply voltage.
2
Make adjustment with the probe immersed. Remove
Adjustments
level detectors in seal oil system from their normal
location and place them in a container filled with turbine
oil.
The level detectors in the level detector rack of tne
genrator supervisory system should be adjusted in the
probe tanks. To do this, fill tank with turbine oil via a
separate filler connection until the probe is immersed in
turbine oil. Then adjust level detector.
2.1
Adjust Level Switch 1. Shutt off valve before 3. Probe

level detector 4. Sight glass
2. Filter connection 5. Shutof valve after sight glass
1. Make sure switches have been properly connected

on the electronic unit.
2. Commission the switch as per the instruments

manuals for the level switch.

2.2
To perform a, functional test, drain turbine oil until
Perform functional test probe is no longer immersed in oil. Fill with turbine oil
via the filler connection. Check to ensure that an alarm
is activated as soon as the probe is immersed. Repeat
the adjustment if no alarm Is activated.
3
The level detector system is now adjusted After completion of adjustment, install level
and ready for initiating a level alarm detectors in seal oil system and then perform a functional
test.
Restore gastight sealing of filter connections in

level detector rack and, drain turbine oil from piping. Close
shutoff valves after sight glasses and open all shutoff
valves before the level detectors.

Turbogenerators Positions of Multi-Way Valves
Operation in Gas System
MKG15AA151 Multi-way valve after H2 pressure reducer
Position 1 : H2 from pressure reducer Position 0 : Valve closed Position 2 : H2 from pressure reducer
MKG 15 BY 001 MKG 16 BY001
MKG18 AA 101 Multi-way valve for gas filling and removal
Position 1 : H2 filling Position 0 : Valve closed Position 2 : H2 waste gas

Filling generator with H2 and Filling generator with air Filling generator with CO2
supplying make-up gas to generator
MKG30 AA410 Multi-way valve for H2/CO2 calibration and sampling
Position 1 : CO2 calibration Position 0 : Valve closed Position 2 : H2 Calibration

For CO2 calibration of H2/CO2 purity For H2 calibration of CO2/H2 purity
transmitter transmitter
MKG18 AA 101 Multi-way valve for gas filling and removal
Position 1 : CO2 filling Position 0 : Valve closed Position 2 : CO2 waste gas
Filling generator with CO2
or H2 and measuring H2 purity
in generator

Turbogenerators Valve Positions in Gas System
Operation for Gas Filling From CO2 and H2
Bottle Supplies

CO2 Fitting from H2 Filling from
Bottle Supply Bottle Supply
Shutoff valve after H2 bottle 1 MKG10 AA111 Closed Open 1)
Shutoff valve before pressure reducer MKG11 AA121 Closed Open
Shutoff valve after pressure reducer MKG11 AA151 Closed Open
Shutoff valve, intermediate pressure line MKG11 AA160 Closed Open
Shutoff valve before pressure reducer MKG12 AA121 Closed Closed
Shutoff valve after pressure reducer MKG12 AA151 Closed Closed
Shutoff valve before pressure reducer MKG15 AA121 Closed Open
Shutoff valve after pressure reducer MKG15 AA151 Position 0 (1) Position 0 (1)
Shutoff valve before pressure reducer MKG16 AA121 Closed Closed
Multi-way valve for gas filling and removal MKG18 AA101 Position 2 (1) Position 1 (1)
Shutoff valve for gas removal MKG19 AA155 Open Open /Closed
Shutoff valve before operating pressure system MKG21 AA160 Closed Closed
Shutoff valve, H2/CO2 sampling MKG30 AA401 Closed Closed
Multi-way valve H2/CO2 calibration and sampling MKG30 AA410 Positon 0 (1) Positon 0 (1)
Shutoff valve before puirty meter system MKG31 AA101 Open Open
Shutoff valve, inlet of gas drying system MKG69 AA101 Open Open
Shutoff valve at inlet of Drier-1 MKG69 AA504 Open Open
Shutoff valve at outlet of Drier-2 MKG69 AA508 Closed Closed
Shutoff valve at inllet of Drier-1 MKG69 AA501 Open Open
Shutoff valve at outlet of Drier-2 MKG69 AA509 Closed Closed
Shutoff valve after CO2 bottle 1 MKG70 AA111 Open Closed
Pressure relief valve before CO2 flash evaporator MKG71 AA031 Set Set
Shutoff valve before CO2 flash evaporator MKG71 AA131 Open Closed
Pressure relief valve after CO2 flash evaporator MKG75 AA035 Set Set
Shutoff valve after CO2 flash evaporator MKG75 AA036 Open Closed
Multi-way valve for gas filling and removal MKG78 AA111 Position 1 (1) Position 2 (1)
Regulating valve, compressed air supply MKG91 AA101 Closed Closed
Shutoff valve, compressed air to generator MKG91 AA105 Closed Closed
According to VDE, not more than two valves marked are allowed to be open at the same time when the Hydrogen is
obtained from the H2 bottle supply.
1)
One at a time Also refer to the following Information
[1] 2.3-6107 Position of Multi-way Valves Gas System

Operation for H 2 Operation
Shutoff valve after H2 bottle1 MKG10 AA111 Open*

Shutoff valve before pressure reducer MKG11 AA121 Open
Shutoff valve after pressure reducer MKG11 AA151 Open
Shutoff valve, intermediate pressure line MKG11 AA160 Open
Shutoff valve before pressure reducer MKG12 AA121 Closed
Shutoff valve after pressure reducer MKG12 AA151 Closed
Shutoff valve before pressure reducer MKG15 AA121 Closed
Shutoff valve after pressure reducer MKG15 AA151 Position 2 [1]
Shutoff valve before pressure reducer MKG16 AA121 Open
Multi-way valve for gas filling and removal MKG18 AA101 Position 1[1]
Shutoff valve for gas removal MKG19 AA155 Closed
Shutoff valve before operating pressure system MKG21 AA160 Closed
Shutoff valve, H2/CO2 sampling MKG30 AA401 Closed
Multi-way valve, H2/CO2 calibration and sampling MKG30 AA410 Position 0 [1]
Shutoff valve before purity meter system MKG31 AA101 Open
Shutoff valve before gas analyser MKG35 AA502 Open
Shutoff valve, inlet of gas drying system MKG69 AA101 Open
Shutoff valve at inlet of Drier 1 MKG69 AA504 Open
Shutoff valve at inlet of Drier 2 MKG69 AA508 Closed
Shutoff valve at outlet of Drier 1 MKG69 AA501 Open
Shutoff valve at outlet of Drier 2 MKG69 AA509 Open
Oil trap drain valve MKG69 AA112 Closed
Shutoff valve after CO2 bottle 1 MKG70 AA111 Closed
Pressure relief valve before CO2 flash evaporator MKG71 AA031 Set
Shutoff valve before CO2 flash evaporator MKG71 AA131 Closed
Pressure relief valve after CO2 flash evaporator MKG75 AA035 Set
Shutoff valve after CO2 flash evaporator MKG75 AA036 Closed
Multi-way valve for gas filling and removal MKG78 AA111 Position 2[1]
Regulating valve, compressed air supply MKG91 AA101 Closed
Shutoff valve, compressed air to generator MKG91 AA105 Closed
Non return, bypass line of blower MKG107 AA002 Open
* According to VDE-0530, not more than two valves marked (*) are allowed to be open at the same time.
Also refer to the following information:
[1 ] 2.3-6107 Position of Multi-way valves Gas system
Turbogenerators Gas Filling
Operation Replacing Air with CO2
Never use fire or an open flame (welding, flame-

cutting, smoking, etc.) in the vicinity of the generator
1 Hints and preparatory and the hydrogen system at any time, even when starting
work with the preparations for generator filling.
Filling and emptying the generator should be
performed with the generator at rest or on turning gear.
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,
For this reason, do not perform any filling or purging
operations with the generator at higher speeds than
during turning gear operation
The seal oil system and the bearing vapor exhauster
must be in operatlon and will positively remain in service
prior to starting with the gas filling procedure.
CO2 flash evaporator was filled with heat transfer
Iiquid up to lower edge of the riser.
Ensure that the hose between compressed air filter
and regulating valve MKG91AA101 is not connected at
the bayonet fitting. Making this connection should only
be done when compressed air from the station air
system is required for removing the carbon dioxide
(CO2) from the generator or for performing a leak test.
Check to ensure that all shutoff and three-way valves
are closed.
1.1
Open all pressure gauge shutoff valves
1.2
Turn range selector to position I Set range selector switch in CO 2 /H 2 purity
transmitter to position I (0-100% CO2 in air)
2
All lines carrying gas during this procedure are
Fill generator with carbon dioxide (CO2)
represented by yellow lines on the mimic diagram of
the H2 supply unit.
2.1
Switch on heater of CO2 flash evaporator. Observe
Switch on heater of CO2 flash evaporator temperature rise of heat transfer liquid at temperature
gauge. Wait until thermostat switches off the heater at
the preset temperature.

2.2
Set shutoff and multi-way valves accord- Adjust shutoff and multi-way valves as specified in
ing to valve position list [1] column CO2 Filling.
2.3
Terminate filling with carbon dioxide (CO2) Filling with CO2 may be terminated when a purity in
excess of 95% CO2 in air has been reached.
Switch off heater of CO2 flash evaporator. Close
shutoff valves MKG70 AA111 to 118 after CO2 bottles and
shutoff valve MKG71AA131 for high-pressure CO2.
2.4
Prior to starting with H2 filling, check to ensure that a
Check if sufficient CO2 is available for next
sufficient amount of CO2 is available for the next generator
generator filling operation
filling procedure.
3
The generator is filled with carbon dioxide Start with H2 filling.

[1] 2.3-6307 Valve Positions in Gas System for Gas Filling

Turbogenerators Gas Filling
Operation Replacing CO2 with H2
All lines carrying gas during this procedure are

1 Fill generator with H2 to 0 Bar reepresented by red lines on the mimic diagram of the
H2 supply unit.
1.1
Set shutoff and multi-way valves according
Adjust shutoff and multi-way valves as specified in
to valve position list [1] column H2 Filling.
1.2
Set pressure reducers MKG15 BY001 and Check to ensure that H2 pressure reducers adjust
MKG16BY001 to operating pressure and the required pressures.
pressure reducers MKG11 BY001 and MKG12 Note: Pressure after pressure reducers in H2 bottle
BY 001 to intermediate pressure rack must be approximately 8 bar. Pressure after
pressure reducers in H2 supply unit must be set to gas
pressure.
H2 filling should be performed by opening the H2
bottles separately.
2
Set range selector switch in CO 2 /H 2 purtiy
Set range selector switch to position II and
transmitter to position II (0 to 100% CO2). The increase
measure H2 purity
in H2 purity can be seen at the indicator, since the purity
meter system continues to measure the waste gas purity.
2.1
Observe H2 purity indication (80%) and set

When the indicator at position II shows a H2 purity
range selector to position III of less than 20% CO2 in H2, set range selector switch to
position III. (100 to76% H2 in air).
Continue H2 filling until indicator gives a reading of
approximately 98% H2 in air.
Check measuring gas volume flow at volume
flowmeter and if required, correct measuring gas volume
flow.
2.2
Contrary to the valve position list (1) the shutoff valve
Close shutoff valve MKG19 AA155 in waste
should be closed.
gast line

3
When shutoff valve MKG18AA155 is closed the
Fill generator with hydrogen to operating
generator is automatically filled to operating pressure
pressure [1]
via a H2 pressure reducer.
Filling the generator to operating pressure may also
be performed during operation at rated speed.
5
The generator is filled with H2 ; start with
normal running routine
[1] 2.3-6307 Valve Positions in Gas System for Gas Filling

Turbogenerators Turning Gear Operation and Runup
Operation of Generator
1. General control valves only to the extent required to adjust a

The generator should be operated on the turning cold air temperature of <= 40°C in the exciter. In
gear and brought up to speed in accordance with the addition, adjust the two control valves so that equal
turbine startup diagrams. cooling water outlet temperatures are obtained
downstream of the cooler sections (measured by
2. Turning Gear Operation means of the thermometers in the outlet lines).
Prior to operating the generator on turning gear, After load pickup, adjust control valves for a cold
the shaft lift oil pump and the bearing oil system must air temperature of <= 40 °C.
be placed into operation.
The seal oil system for lubrication and sealing of 5. Runup
the shaft seals must be placed into operation. During runup to rated speed, the bearing oil inlet
The oil flow to the bearings and shaft seals should temperature should not be less than 35 °C but not
be checked prior to turning gear operation to ensure higher than 45 °C The oil inlet temperature at the shaft
an adequate flow. In addition, drains should be seals should not be less than 38 °C
inspected for proper operation Note: Do not run up generator to rated speed and
Note: The generator may be filled with hydrogen voltage as long as generator casing pressure [1] is
prior to or during turning gear operation provided not at rated value.
that leakage tests have been performed and the During runup, the critical speed ranges should be
seal oil system is in operation. passed through quickly and at a uniform rate.
Smooth running depends on several factors. Even
3 Generator Cooling Gas Temperatures minor temperature differences of 1-2 degC between
The hydrogen coolers should be placed into opposite sides of the rotor may result in rotor distortion
service on their cooling water sides as soon as the which could load lo inadmissible vibrations due to
generator is filled with hydrogen and on turning gear. unbalance
The H2 coolant temperature control system should be During runup, the bearing and oil temperatures
changed over from the Automatic to the Manual should be read and recorded at short intervals.
mode. Use manual mode to adjust a cooling water To prevent these thermal unbalances during
volume flow through the hydrogen coolers of runup, the turbine-generator should be run on turning
approximately 5 to 10 % of the nominal flow rate. gear. If the generator is run up following prolonged
This results in a lower dew point temperature in turning gear operation, no restriction regarding the
the generator interior due to the condensation of rate of runup need be observed other than those
moisture contained in the gas on the cooler tubes and required for the turbine.
fins.
The cooling water volume flow through the 6. Generator Air Operation
hydrogen coolers should not be increased as long as Besides the above mentioned operating
the H2 cold gas temperature is not at rated value. conditions, it may be necessary in certain exceptional
cases to operate the generator without hydrogen, i.e.
4 Exciter Temperatures during inital runup of the unit to check the bearings
and vibrations and for clean-up. In view of the high
The exciter coolers must be filled with water and
windage losses and the resulting high temperature rise
vented. The shutoff valves in the lines upstream of the
of the air such air operation is only permissible for
coolers are open, and the control valves in the lines
brief periods and only with generator non-excited.
downstream of the coolers are closed.
The cold air temperature downstream of the
During runup of the turbine-generator, the cold
coolers should not exceed 40 °C. At higher cold air
air temperature requires particular attention. Open
temperatures the hydrogen coolers should be placed
control valves in cooling water outlet lines as soon as
into service.
the cold air temperature has risen to >= 40°C. Open
During generator air operation, the supply of seal
oil to the shaft seals must be ensured as well.

[1] 2.1-1850 Reactive Capability Curve

Turbogenerators Generator Startup Diagram
Operation
1 Command : Start up generator Actual Condition
Bearing vapor exhausters in operation
Exciter drying system in operation
Seal oil system in operation
Seal oil inlet temperature t = approx. 380C
Generator hydrogen pressure p= rated gas pressure

Hydrogen purity
> 96%
Measuring devices and supervisory equipment in operation
Gas drying system in operation
Hydrogen Coolers in service with reduced flow (approx 10% of nominal flow)
Exciter cooler
filled with water and vented, control valves closed
Coolant temperature control in operation
Automatic voltage regulator ready for operation
2 Command: Run up generator
Drying system n>=4 s-1 out of service

Heating system n>=4 s-1 out of service
Bearing vibration normal

Bearing metal temperature normal
Exciter cold air temperature cold air temperature >=40 0C, adjust cooling water
flow required for removal of loss heat [1]
Speed n = appox. 90 %

Actual condition
Field circuit breaker closed
Set point for rated voltage set
Speed n = rated speed

Primary Water volume flows set
Bearing vibration set seal ring relief oil pressure for shaft seals
3 Synchronizing, paralleling and loading
Synchronizing
Paralleling
Loading to requirad load, only within the region of

capability curve

[1] 2.3-8010 Turning Gear Operation and Runup of Genera-
tor
2.3-8011-0013/2
Turbogenerators Permissible Synchronizing Criteria
Operation

Turbogenerators Permissible Load Limits of Generator
Operation
1 Load Limits 4. Load Restrictions

For permissible generator loading, refer to the During the service lite of the generator, operating
reactive capability curve [1]. The following conditions are conditions may arise at the generator which require the
required: generator to be operated at reduced load in order to avoid
damage to the unit. The following restrictions should be
Generator Is filled with hydrogen up to rated observed for the limits indicated:
pressure and all hydrogen cooler sections are in
operation.
Generator Is operated at rated frequency. Operation With Hydrogen Coolers Out of Service In
Generator is operated at rated voltage. the event ot a failure ot one or two hydrogen cooler
sections, operation of the generator is only
Any desired load setting is possible within the limits permissible at a reduced load. The percentage of
of the reactive capability curve: rated load still permissible depends on the location
Note: Load operation of the generator without hydrogen of the failed sections [3).
(e.g. with air or CO2) Is not permissible.
Note: The transmitters for the hydrogen temperature
control are located downstream of sections A/B and
2. Rate of Loading upstream of sections C/D. If the section Is out of
During operation, load variation is permissible within service, change over control system from AUTOMATIC
the limits of the reactive capability curve. The permissible to MANUAL. The necessary corrections must be
rate of loading depends on the condition of the winding performed manually.
insulation. Generators with a Mlcalastlc stator winding
insulation and a rotor winding of silver-alloyed copper
with glass laminate insulation can be suddenly loaded Deviation From Rated Voltage and Rated Frequency
and unloaded if an automatic coolant control system is Loading of the generator with deviations from the
provided and fully operational. rated generator voltage and/or frequency is only
permissible up to the limits shown in the attached
diagram [4].
3. Unbalanced Load Deviation From Rated Hydrogen Pressure
The continuously permissible unbalanced load as If the specified hydrogen pressure cannot be
specified [2] must not be exceeded under any operating maintained because of lack of gas or high gas
condition. Unbalanced load is defined as the ratio of losses, the generator must be shut down as soon
negative phase sequence current to rated current, with as the pressure has dropped by 0.4 bar. The cause
the rated current [2) not being exceeded in any of the of the gas loss should be identified and corrected.
three phases.

[1] 2.1-1850 Reactive Capability Curve
[2] 2.1-1810 General and Electrical Data
[3] 2.3-8184 Generator Capability With Hydrogen
Coolers Out of Service on Water Side
[4] 2.3-8181 Permissible Loading at Rated P.F.During
Voltage and Frequency Deviations

Operation Permissible Loading at Rated P.F. During
Voltage and Frequency Deviations.
De

Turbogenerators Generator Capability With Hydrogen
Operation Coolers Out of Service on Water Side
Continuous Operation Short-Time Operation

(Permissible only for cooler cleaning) **
1234
1234Cooler Out Of Service
Cooler In Service
** Operation with less coolers or higher output than shown above is not allowed.

Turbogenerators Genertor Capability vs.
Operation Cooling Water Temperature
Generator Capability vs. Cooling Water Temperature
260
250
240
Generator output in MVA
230
220
210
200
190
180
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
Cooling Water Temperature in deg. C

Turbogenerators Unbalanced Load Time Curve
Operation
Time t in sec
Per Unit negative sequence current
BHEL, Haridwar 2.3-8187-7500 / 1

Operation Current Overload Capability

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

Turbogenerators Generator Shutdown Diagram
Operation
1 Command : Unload generator Actual condition
Generator load S<0.05 SN
Turbine trip manual turbine trip
Generator main circuit breaker automatic trip through reverse-power protection
Speed approximately 90%
Excitation field circuit breaker tripped
Turning gear operation see Turbine Instruction Manual
Exciter dryer n < = 3.5 s-1 in operation

Anticondensation heating system n <= 3.5 s-1 in operation
Coolant temperature controls deactivated, manual control
Hydrogen cooler in service with reduced flow

(approx 10% of nominal flow)
Exciter cooler out of service [1]
Seal oil system in operation
Gas system in operation
speed n= 0 s-1 at room temperature
shutdown procedures completed

[1] 2.3-8310 Shutdown of Generator

Turbogenerators Supervision of Generator During
Description Standstill
General
1. Generator at Standstill With the Seal The scope of the preservation work required
Oil and Gas System in Operation depends on the duration of the shutdown, on the
overall conditions in the vicinity of the unit and on the
Due to operational conditions, it may become extent to which checks and inspections are possible
necessary to shut down the generator for a short during such period.
period. When the unit is at standstill, the bearing oil After removal of the hydrogen from the generator,
system can be taken out of service. In the absence of it is recommended to open the generator by removing
any operational needs, e.g. inspection or faults on two manhole covers and to connect a dryer or hot air
generator, the hydrogen should remain in the generator blower for continuous drying or circulation of the air in
in order to retain the most favorable prerequisites for the generator. Care should be taken to ensure that
a dry condition. All observations required for a this equipment is connected in such a way that a
generator partly taken into service should be circulation through the entire generator interior will be
performed, such observations being essentially accomplished.
limited to seal oil and gas systems. The hydrogen, exciter and seal oil coolers should
Normally it can be assumed that the generator be drained on their water sides and dried in a suitable
was operated with the gas dryer during the preceding manner.
service period. In the absence of any special fault These measure are intended to prevent any
(e.g. leak) requiring special measures, the generator condensation in the generator interior even under
interior will thus be in a dry condition. different environmental conditions, including the risk
Care should be taken to ensure that no standstill of stress corrosion cracking of the austenrtic rotor
corrosion damage will occur in the tubes of the retaining rings.
hydrogen and exciter coolers. During a brief outage It will be necessary to request the services of
the coolers should be supplied with a small water trained BHEL personnel for the preservation of a
flow. In addition, the coolers should be flushed with turbogenerator. If it is intended to shut down the
full water flow twice weekly. generator for a longer period, the competent BHEL
In the case of prolonged outages, the coolers should Office should be informed, when requesting the
be drained on the water side and dried. services of BHEL personnels, how long the units is to
be shutdown, on the conditions prevailing in the vicinity
2 Generator at Standstill With the Seal Oil of the unit during the outage and whether customer’s
personnel will be available for any required checks.
and Gas System Out of Operation
The necessary preparations for the preservation will
Preservation measures will have to taken when
then be made in all details by the competent BHEL
the generator is to be shut down for a period
Office. The services of BHEL personnel should again
exceeding two months with the seal and gas systems
be requested if a preserved unit is to be
to be taken out of operation.
recommissioned. The preservation measures will
then be abolished by the BHEL personnel. For
recommissioning, the same procedure should be
followed as during initial startup.

Turbogenerators Supervision of Generator During Standstill
Operation Coolers
Suitable measures will have to be taken on all coolers to supply the coolers with a small water flow and to
taken out of service to prevent standstill corrosion in the flush them with the full water flow twice weekly.
cooler tubes [1]. In the case of a prolonged outage, the coolers should,
In the case of a brief outage, it will mostly be sufficient however be drained on their cooling water sides & dried.

[1] 2.3-5003 Hints for Cooler Operation

After gas removal from the generator, the seal oil monitoring of the generator must be continued. All seal
system can be taken out of operation, and monitoring of oil pressures and temperatures should be recorded at
the generator is no longer required. the previous intervals, and attention should be given to
However, if the seal oil system remains activated, all special occurences.

Turbogenerators Shutdown of Seal Oil System
Operation
Caution: Taking the seal oil system out of service is only

permissible with the generetor at standstill (n–0s-1) and
filled with air at atmospheric pressure.
1 Shutdown of seal oil The seal oil system should thus be taken out of
system service only after occurrence of major faults or for a
prolonged shutdown of the generator.
2
Shutdown turbine-generator
3
Remove H2 gas from generator After lowering of the H2 gauge pressure in the generator
remove hydrogen from generator by admitting CO2.Then
purge CO2 by means of compressed air.
4
Stop seal oil pumps, vacuum pump and
bearing vapor exhausters
5
Terminate normal running routine
6
Partial or complete draining of the seal oil system
Seal oil system is out of service; start with will only be necessary for work requiring an empty
corrective actions, e.g. replacing defective system. Refill piping or branch circuits with oil prior to
valves and fittings restarting the seal oil system.
If the cooling water supply is stopped for more
than three days, the seal oil coolers should be drained
and dried on their cooling water sides.
If operation can be expected to be resumed after
three days, the coolers may remain filled with cooling
water provided that the cooler tubes are free of deposits
If deposits are detected, the cooling water should be
drained and the tubes cleaned and flushed with clean
water. Water channels should remain open until the
system is restarted.
During brief outages (< three days), it is permissible
to maintain the system in operation at low cooling water
velocities (slow-motion flow) in order to avoid deposits
in the tubes.

Turbogenerators Draining Seal Oil Circuit
Operation
1 Draining seal oil circuit

Prerequisites:
Turbine-generator was shut down

Generator rotor at standstill (n < 0 s-1)
Generator is filled with aIr
Seal oil pumps are out of operation
Vacuum pump is out of operation
Emergency seal oil supply is out of operation
2
Drain seal oil tank
2.1
Close shutoff valves MKW21AA151 (Three-way valve at the inlet of coolers)
2.2 .
Open shutoff valves MKW06AA008 (after intermediate oil tank)
MKW11AA185 (after seal oil pumps)
2.3
Start seal oil pump MKW11AP001 and
Deactivate level detector MKW10CL002.Start
vacuum pump MKW11AN001
pumps. The pumps should be kept in operation only
until the seal oil has been removed from seal oil tank
MKW10BB001. Stop the pumps immediately afterwards.
Close shutoff valve MKW11AA185.
The remaining seal oil can be drained through the
drain plug in bottom of seal oil tank
3
Drain intermediate oil tank The remaining oil can be drained through drain plug
MKW06BB001 of intermediale oil tank.
4
Drain seal oil coolers and piping

4.1
Open cooler drain and vent valves on oil MKW21AA251 (seal oil vent valve, cooler 1)
side MKW22AA251 (seal oil vent vaIve, cooler 2)
MKW21AA201 (seal oil drain valve, cooler 1)
MKW22AA201 (seal oil drain valve, cooler 2)
The seal oil circuit should be drained via the two

drain valves.
4.2
Close cooling water inlet valves.
Open cooler drain and vent valves on water After draining on their water sides, the coolers
side
should dried to prevent standstill corrosion of the cooler
tubes.
5
Draining of seal oil circuit is complete Start with draining of signal line.

It is recommended to leave the hydrogen in the The gas must, however, be removed from the generator
generator and to reduce the hydrogen pressure if the if the seal oil system is taken out of service or for carrying
generator is to be shut down for a period up to two months. out welding work within the range of the gas supply system
It should, however, be observed that all alarm devices or work on the generator. If the generator is filled with air,
must be set to the new operating values. Monitoring of the seal oil system can be taken out of service.
the gas system must be continued as during normal
operation.

Operation for Gas Removal

Lowering CO2 Filling Air Filling
H2 Pressure
Shutoff valve after H2 bottle 1 MKG10 AA111 Closed Closed Closed
Shutoff valve before pressure reducer MKG11 AA121 Closed Closed Closed
Shutoff valve after pressure reducer MKG11 AA151 Closed Closed Closed
Shutoff valve, intermediate pressure line MKG11 AA160 Closed Closed Closed
Shutoff valve after pressure reducer MKG12 AA151 Closed Closed Closed
Shutoff valve before pressure reducer MKG15 AA121 Closed Open Open
Shutoff valve after pressure reducer MKG15 AA151 Position 0 (1) Position 0 (1) Position 0 (1)
Multi-way valve for gas filling and removal MKG18 AA101 Position 2 (1) Position 1 (1) Position 1 (1)
Shutoff valve for gas removal MKG19 AA155 Open Open Open
Shutoff valve before operating pressure system MKG21 AA160 Closed Closed Closed
Shutoff valve, H2/CO2 sampling MKG30 AA401 Closed Closed Closed
Multi-way valve, H2/CO2 calibration and sampling MKG30 AA410 Positon 0 (1) Positon 0 (1) Positon 0 (1)
Shutoff valve before puirty meter system MKG31 AA101 Open Open Open
Shutoff valve before gas dryer MKG69 AA101 Open Open Open
Shutoff valve after gas dryer MKG69 AA104 Open Open Open
Shutoff valve after CO2 bottle 1 MKG70 AA111 Closed Closed Closed
Pressure relief valve before CO2 flash evaporator MKG71 AA031 Set Set Set
Shutoff valve before CO2 flash evaporator MKG71 AA131 Open Closed Closed
Pressure relief valve after CO2 flash evaporator MKG75 AA035 Set Set Set
Shutoff valve after CO2 flash evaporator MKG75 AA036 Open Closed Closed
Multi-way valve for gas filling and removal MKG78 AA111 Position 2(1) Position 1 (1) Position 2 (1)
Regulating valve, compressed air supply MKG91 AA101 Closed Closed Closed
MKG91 AA105 Closed Closed Closed

Turbogenerators Gas Removal
Operation Lowering Hydrogen Gas Pressure
in Generator
Prior to removing hydrogen (H2) from the generator

1 Preparatory work housing, the generator must be at standstill (n =0 s-1) or
on the turning gear.
Carbon dioxide must be available in sufficient
quantity. Check to ensure that the CO2 flash evaporator
is filled with heat transfer liquid up to lower edge of riser.
1.1
Check zero setting of CO2/H2 purity transmitter
1.2
Set shutoff valves and three-way valves ac- Set valves as specified in column Lowering H2
cording to valve position list [1] Pressure.
1.3
Lower the gas pressure in the generator to
Lower gas pressure in generator
approximately 0.1 bar when shutoff valve MKG19 AA155
is open and when multi-way valve MKG18AA101 is in
position 2 (H2 waste gas).
2
Generator is ready for filling with CO2

[1] 2.3 -8608 Valve Positions Gas System for Gas Removal

Operation Replacing H2 with CO2
1 Filling generatorwith carbon dioxide All lines carrying gas during this procedure are
represented by yellow lines on the mimic diagram on
the H2 supply unit
1.1
Set range selector switch to position II Set range selector switch in CO 2 /H 2 purity
transmitter to position II (0 to 100% CO2 in H2).
1.2
Switch on heater of CO2 flash evaporator Switch on heater of CO2 flash evaporator. Observe
temperature rise of heat transfer liquid at the temperature
gauge. Wait until the thermostat switches off the heater.
1.3
Set shutoff and multi-way valves according Set valves as specified in column Air Filling.
to valve position list (1)
1.4
CO2 filling can be terminated when the indicator
Terminate filling with CO2
shows a purity reading in excess of 95% CO2 in air.
Switch off heater of CO2 flash evaporator and close
shutoff valves MKG70AA111 to MKG70AA118 after CO2
bottles and shutoff valve MKG71AA131 for high-pressure
CO2.
2
Generator is filled with CO2 Start with air filling.
Alao refer to the following information

[1] 2.3-8608 Valve Positions in Gas System for Gas Removal

Operation Replacing CO2 with Air
1 Filling generator with air All lines carrying gas during this procedure are
represented by blue lines on the mimic diagram of the
H2 supply unit.
1.1
Set range selector switch in C0 2 /H 2 purity
Set range selector switch to position I
transmitter to position I(0 to 100% CO2 in air)
1.2
Establish hose connection between compressed
Establish hose connection
air filter MKG91BT101 and regulating valve MKG91
AA101.
1.3
Set shutoff and multi-way valves according Set valves as specified in column Air Filling.
to valve position list [1] Ensure that compressed air is clean and dry. ie.
neither oil nor water should be entrained in the air. Adjust
the compressed air pressure by means of regulating
valve MKG91 AA101 so that the pressure in the generator
will not exceed 1 bar.
1.4
Terminate filling with air When the indicator gives a readlng of 0% CO2 in
air, the carbon dioxide has been driven out of the
generator.
Open shutoff valves downstream of the liquId Ievel
detectors and close multi-way valve MKG78AA111 for
purging the main lead range and the pipes to the level
detectors. After purging, switch multi-way valve MKG78AA
111 to position II (CO2 Waste Gas) and close shutoff
valves downstream of liquid level detectors
Close shutoff valves MKG91AA101 and MKG91
AA105 afler purging.
1.5
Remove hose connection
Remove hose connection between compressed
air title MKG91BT101 and regulating valve MKG91 AA101.

1.6
After approximately 15 minutes, close all shutoff
Close shutoff valves and multi-way valves
valves of the gas supply that are still open, except for the
pressure gauge shutoff valves and valves MKG35 AA341,
MKG35AA381 MKG78AA111 (position II, CO2 Waste Gas)
and MKG19 AA155.
With the generator rotor at standstill (n=0s-1), the
seal oil supply to the shaft seals may also be shut down.
2
Stop normal running routine of gas system

[1] 2.3-8608 Valve Positions in Gas System for Gas Removal
2.3-8630-0015/2
Turbogenerators Supervision of Generator During
Description Standstill
Exciter
With the unit on turning gear or at standstill, the Slightly contaminated filters should be blown out
exciter dryer and the anticondensation heating system with clean compressed air from the air inlet side or
must be in operation and absorb the moisture’ from washed in water of approximately 30°C, adding Prilor
the air inside the exciter enclosure. another neutral expansion agent.
Air drawn from the power house via an air filter is Depending on the operating conditions, the ball
dehumidified in the dryer and then delivered into the bearings of the fan and gear motor should be packed
exciter enclosure. with new grease at intervals of two to three years.
The filters should be checked for contamination The brushes of the ground fault detection system
at regular intervals and cleaned or replaced as should be removed to prevent the formation of rust on
necessary [1]. the sliprings. In the case of a prolonged outage, a
Caution: Never place exciter dryer into service protective coating should be applied to the measuring
without makeup air filters. sliprings.

Turbogenerators Fault Tracing
Trouble-Shooting General
The details given herein on faults, their possible corrective measures can be taken in accordance with
causes and the corrective measures cannot be the following instruction, the turbine-generator should
considered complete in every respect, since all be shut down and the services of the manufacturer
possible troubles cannot be covered in advance. In should be requested. In most cases, however,
most cases, the operator will have to decide on the sufficient details will be found in the Turbogenerator
measures to be taken. The individual measures Manual.
required depend on the mode of operation. Unless

Operation Stator and Generator Supervisory Equipment
Fault/Cause Remedy
Differences in slot temperatures of stator winding The embedded RTD’s should be checked when
different slot temperatures are indicated while stator
currents are of equal magnitude in the three phases. Such
check should only be made with the generator at rest
and in non-excited condition. The check should include
resistance measurements as well as testing of the
detector leads, the measuring point selector switches and
the indicators. 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. In many
cases, a fault can be cleared by recalibration of the RTD’s.
High hot gas temperature

and/or
High cold gas temperature
The cause will usually be an insufficient cooling water A rise of the cold water temperature will require a
volumetric flow or a higher cooling water higher cooling water volumetric flow for removal of the
temperature. heat loss. The cooling water volumetric flow should be
increased. In addition, the cooler should be vented via
the vent valves. If the cold gas temperature downstream
of the cooler cannot be reduced to the permissible
operating value [1], the generator load should be reduced.
Note: The temperature transmitters for the

generator mechanical equipment protection and for
the coolant temperature control are located upstream
and downstream of cooler sections a/b.
Change over temperature control system to
MANUAL prior to cleaning the cooler section with the
actual-value transmitter.
An equivalent circuit with fault Indication Is
established when cleaning the hydrogen cooler
section with the transmitters for the generator
mechanical equipment protection.
Loss of cooling water flow. Restore cooling water flow immediately. If this should
not be possible, the generator should be unloaded and
shut down.
Liquid in generator
Due to a leaking or defective H2 cooler tube. The liquid in the generator casing should be
inspected to determine its origin, i.e. defective cooler
section, bearing oil or moisture condensate.
Very small water quantities are indicative of moisture
condensate. The gas dryer should then be placed in
operation. The hydrogen gas should be examined in a
laboratory to determine its moisture content.
Larger amounts of water points to a leakage cooler
section, in which case the measures outlined in [2] will
have to be taken.

Fault/Cause Remedy
Unbalanced load due to unequal phase loading of If the generator is operated with unbalanced load
the system connected to generator due to particular system conditions, care must be taken
that the continuously permissible unbalanced load is not
exceeded [3]. The unbalanced load is defined as the ratio
of negative sequence current to rated current. The
permissible rated stator current should not be exceeded
in any stator phase. When the unbalanced load is higher
than the continuously permissible unbalanced load, steps
should be taken for bringing about a uniform system load.
The generator should be shutdown if it is impossible to
distribute the system load more uniformly over the three
phases.

[1] 2.3-4020 Operating and Setting Values-
Generator and Supervision Equipment
[2] 2.3-9440 Hydrogen Coolers

Trouble-Shooting Rotor
Fault/Cause Remedy
Sudden deterioration of rotor running condition Check whether the deteriorated running condition
originated due to the turbine or whether the rotor bearings
are damaged. A deterioration of the running condition
may be caused by a change in the balancing condition
or by a rotor wiinding short. Unload and shotdown 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, it is advisable to
obtain the help of manufacturer's product service
personnel.

Trouble-Shooting Coolers
Fault/Cause Remedy
Liquid In Generator
This fault is due to a leaking or defective H2 cooler Identify the defective cooler section. First, close
tube. cooling water outlet of this cooler section and then the
cooling water inlet.
Close shutoff valve before the level detectors that have
initiated the alarm. Drain the liquid by means of shutoff
valves after the level detectors. Repeat this procedure
until no liquid is drained through the shutoff valves. This
procedure ensures that no hydrogen can escape from
the generator through the shutoff valves.
Shut down generator and remove the hydrogen with

carbon dioxide. Fill generator with air to a gauge
pressure of approximately 0.5 bar (7psig). Remove
the return water channel. Ensure that gaskets are not
damaged.
After removal of the cover of the return water
channel, the defective tube can be easily identified
since air bubbles emerge from this tube. Mark defective
tube and drain cooling water. Detach cooling water
lines, seal cap and inlet/outlet water channel. Ensure
that gaskets are not damaged. Plug the defective
tube at both ends. Insert plugs by light hammer

Trouble-Shooting Bearings
Fault/Cause Remedy
Generator bearing temperatures vary Temperature variations at the generator bearings

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

Operation Bearings Vapor Exhausters
Fault/Cause Remedy
Bearing vapor exhauster 1 failed

Fuses or thermal overload device have tripped main Bearing vapor exhauster 2 automatically takes over
contactor resulting in failure of bearing vapor venting of generator bearing compartments. Verify that
exhauster 1. voltage is available. Check fuses and thermal overload
device. Examine bearing vapor exhauster 1 for proper
electrical and mechanical condition.
Check operating points of vacuum transmItters.
Bearing Vapor Exhauster 2 failed
Fuses or thermal overload device have tripped main Bearing vapor exhauster 1 automatically takes over
contactor, resulting in failure of bearing vapor venting of generator bearing compartments. Verify that
exhauster 2. voltage is available. Check fuses and thermal overload
device. Examine bearing vapor exhauster 2 for proper
electrical and mechanical condition.
Check operating points of vacuum transmitters.
Bearing vapor exhauster 1, loss of control voltage

Fuse has blown Identify cause of blown fuse (overcurrent or short in
cable). Replace defective fuse and prepare exhauster for
operation.
Bearing vapor exhauster 2. loss of control voltage

Fuse has blown Identify cause of blown fuse (overcurrent or short in
cable). Replace defective fuse and prepare exhauster for
operation.

Fault/Cause Remedy
Seal oil pump 2, loss of control voltage

Fuse has blown, resulting in loss of control voltage Identify cause of blown fuse (overcurrent or short in
cable). Replace defective fuse and ensure that seal oil
pump 2 can be restarted.
Standby seal oil pump, loss of control voltage

Fuse has blown, resulting in loss of control voltage. Identify cause of blown fuse (overcurrent or short in
cable). Replace defective fuse and ensure that standby
seal oil pump can be restarted.

[1] 2.3-9561 Oil Level in Seal Oil System
[2] 2.3-8620 Replacing H2 with CO2
[3] 2.3-8630 Replacing CO2 with Air

Operation Seal Oil Pumps
Fault/Cause Remedy
Seal oil pump 1 failed

Fuses or thermal overload device have tripped the In the event of a failure of seal oil pump 1, seal oil
main contactor, resulting in failure of seal oil pump 1. pump 2 automatically takes over the seal oil supply to
the shaft seals.
Check if voltage is available. Check fuses and
thermal over load device. Examine seal oil pump 1 for
proper mechanical and electrical condition.
Correct fault immediately so that seal oil pump 1
can be promptly restarted.
Level detector for low oil level in seal oil tank has See under Low oil level in seal oil tank in [1].
stopped seal oil pump 1.
Seal oil pump 2 failed

Fuses or thermal overload device have tripped the The standby seal oil pump automatically taxes over
main contactor, resulting in failure of seal oil pump 2 the seal oil supply to the shaft seals if seal oil pump 1
has failed as well.
Caution: If thes seal oil supply to the shaft seals has been
taken over by the standby seal oil pump, make all
preparations for shutdown of generator and gas removal.
Check if voltage is available. Check fuses and
thermal overload device. Examine seal oil pump 2 for
proper mechanical and electrical condition.
Correct fault immediately so that seal oil pumps 1
and 2 can be promptly restarted
Level detector for low oil level in seal oil tank has See under Low oil level in seal oil tank [1].
stopped seal oil pump 2. .
Standby seal oil pump failed

Fuses or thermal overload device have tripped the Sealing and lubrication of shaft seals with seal oil
main contactor, resulting in failure of the standby can no longer be maintained
seal oil pumps. Caution: Hydrogen flows into generator bearing
compartments via sealing gap and is extracted by
bearing vapor exhauster in service. Place all Power
House exhausters into operation immediately.
If another seal oil pump cannot be started
immediately, promptly de-excite and shut down generator
and remove hydrogen gas. Close shutoff valve MKG 11
AA 160 and open shutoff valve MKG 19 AA 155 for vent
gas.
As soon as the hydrogen gauge pressure of the
generator has been reduced to atmospheric level, the
generator may be filled with CO2 [2] and afterwards with
air [3].
Seal oil pump 1, loss of control voltage

Fuse has blown, resulting in loss of control voltage. Identify cause of blown fuse (overcurrent or short in
cable). Replace defective fuse and ensure that seal oil
pump 1 can be restarted.

Operation Seal Oil Pressures and Temperatures
Fault/Cause Remedy
Low seal oil pressure. TE/EE
DRRV1/DPRV2 no longer controls to operating Check setting of DPRV1/DPRV2

value.
Pressure collapses during pump changeover. Trace and correct cause of pump changeover.
Seal oil filter in service is contaminated. For remedial measures, see below.
High differential pressure across seal oil filter
Seal oil filter MKW21AT001 or MKW22AT001 is con- Change over to standby filter with changeover valve
taminated assembly. Deactivate contaminated filter by means of
the other changeover valve assembly.
Low vacuum in seal oil tank
Vacuum bypass valve MKW10AA011 is open. Remove contaminated filter and clean filter. Fill filter
housing with turbine oil prior to reassembly. Prepare filter
for operation.
Shutoff valve MKW11AA121 is closed. Throttle vacuum bypass valve MKW10AA011
Vacuum pump MKW11AN001 has failed. Opon shutoff valve MKW11AA121
Screw caps on relief valves M KW11AA031 and For remedial measures, see [1 ]
MKW12AA031 are missing.
High seal oil temperature after cooler

Cooling water Flow is too low or cooler is contami- Refit screw caps to ensure that vacuum pump cannot
nated. draw any air via the relief valves.
Verify that correct relationship exists between cooling
waters volume flow and seal oil temperature. If cooling
water flow is too low, increase the cooling water volume
flow by opening the shutoff valves in cooling water outlet
pipes. Failure of seal oil temperature to decrease is
Indicative of a dirty cooler.
Place standby cooler in operation by means of rotary
transfer valve.
Ensure that cooler is properly vented on its oil and
water sides. Throughly clean cooler taken out of service
on its water side.
Varying pressure gauge indications
Entrapped air in pipes. Variations in oil pressure are usually, due to

entrapped air in regulating valves or oil delivery lines.
Thoroughly vent all lines and regulating valves.
Transmission of Mechanical vibrations Check whether mechanical vibrations transmitted to

movements are due to lines or foundation.1)
[1] 2.3-9526 Vacuum Pump

Operation Oil Level in Seal Oil System
Fault/Cause Remedy
High oil level in TE/EE prechambers
Shutoff valve MKW06AA151, which must always be Open shutoff valve MKW06AA 151.
open and secured against closing, was opened
without authorization after removal of lock. (Shutoff
valve MKW06AA151 should only be opened for
setting of level detectors MKA06CL001 and MKW07
CL001 in generator prechambers.)
Float-operated valve MKA06AA001 does no longer If the fault is due to failure of float-operated valve
operate properly. The valve remains fully closed or MKW06AA001, the fault cannot be cleared without
opens insufficiently. removing the float-operated valve.
The indication is given when the oil level in the seal
all drain Iines has risen to such a height that level
detectors MKA06CL001 and MKA07CL001 in the
generator prechambers are immersed in seal oil. Open
regulating valve MKW06 AA008 so that the oil level will
drop. When the oil level in intermediate oil tank MKW06
BB001 has fallen to such an extent that level detector
MKW06CL001 is no longer immersed in seal oil, the
indication Low oil Ievel in Intermediate oil tank is given.
Then close regulating valve MKW06AA008.
Caution: if the regulating valve Is open, the complete
oil volume contained In the intermediate oil tank is
forced Into the seal oil storage tank and hydrogen
flows Into the seal oil storage tank.
If the cause of the trouble is not removed, the oil
level In the seal oil drains lines starts to rise again and
the procedure described above is repeated. Removal of
fault is only practicable following shutdown and emptying
of generator and lowering of oil level in intermediate oil
tank.
Emergency operatlon for brief periods is possible
with manual control of regulating valve MKW06AA008.
Make sure that oil level remains visible in oil sight glass.
Low oil level In Intermediate vacuum oil tank
Oil level In Intermediate oil tank MKW06 BB001 has For remedial measures, see: High oil level in TE/EE
dropped to such an extent that level detector MKW06 prechambers
CL001 is no longer immersed In oil.
Make sure that regulating valve MKW06AA008 is
closed.
High oil level in seal oil vacuum tank

Oil level In seal oil tank MKW10BB001 has risen to Close shutoff valve MKW10AA101 and reopen
such a height that level detector MKW10CL001 is it only when the seal level becomes visible in the sight
immersed in seal oil. The oil level is no longer visible glass of seal oil tank MKW10 BB001. If the oil level starts
in the sight to glass of seal oil vacuum tank MKW10 rising again, throttle oil supply to seal oil tank MKW10
BB001 since it has risen above the upper edge of BB001 by means of valve MKW10AA101 so that
the sight glass. Level detector MKW10CL001, approximately normal oil level is maintained.
covered with seal oil, switches off the operating

Fault/Cause Remedy
vacuum pump MKW11 AN001 so that it can draw no Operation of the generator can be continued without
seal oil. Level detector MKW10 CL001 automatically removing the fault. The fault should, however, be cleared
restarts the vacuum pump when the level detector Is no during the next outage.
longer immersed in oil.
Float- operated valve MKW10AA001 does not close
even if the oil level in seal oil vacuum tank MKW10 BB001
continues to rise above its normal level.
Low oil level in seal oil vacuum tank
Oil level in seal all tank MKW10 BB001 has dropped

to such an extent that level detector MKW10 CL002
is no longer immersed in oil. (Oil level is no longer
observable in sight glass of seal oil tank MKW10
BB001.)
Shutoff valve MKW10AA101 was closed. Open shutoff valve MKW10AA101.
Shutoff valve MKW01AA151 in the connection Open shutoff valve MKW01AA151.

between the seal oil storage tank and the seal oil
system was closed.
Float-operated valve MKW10AA001 in binding. If the fault is due to a failure of float-operated valve
MKW10AA001 set control switch for standby seal oil
pump MKW12AP001 to off position. Seal oil pump
MKW11AP001 automatically switched off by level detector
MKW10CL002. The pump is automatically restarted
when the level detector is immersed in seal oil.
After stopping of the seal oil pump, B valve MKW13
AA001 takes over the seal all supply to the shaft seals
without any interruption. Stop the vacuum pump and open
vacuum bypass valve MKW10AA01 to break the vacuum.
Low oil level in seal all storage tank
Level detector does no longer function properly. Check level detector and probe.
Leak in seal oil storage tank. In the event of a leak In the seal oii storage tank,
the seal oil pump can no longer draw oil for supply to the
shaft seals. Shutdown generator and remove gas
immediately.

Operation C02 Flash Evaporator
Fault/Cause Remedy
CO2 flash evaporator heater Off

Built-in temperature transmitter has switched off Heater is switched on again as soon as the
heater due to excessive temperature of heat temperature of the heat transfer liquid falls below
transfer liquid. The cause of the temperature rise the alarm level.
is mostly an insufficient CO2 flow rate.
Isolate supply of liquid CO2. Check level of heat
transfer liquid in CO2 flash evaporator and. if required,
add heat transfer liquid until it is observable in
expansion vessel.
CO2 flash evaporator is iced

Level of heat transfer liquid inCO 2 flash Check electric heater. If heater rods have failed,
evaporator is too low or heater capacity is operation of the CO2 flash evaporator can be continued
insufficient due to failure of heater rods. Icing of with a reduced CO2 flow rate (replace defective heater
CO2 flash evaporator is caused by a lack of heat rods after CO2 filling).
of vaporization and impairs the CO2 flow. As soon as the normal operating temperature of
the CO2 flash evaporator has been restored continue
CO2 filling of generator by opening the respective
shutoff valves.
CO2 flash evaporator, loss of control voltage

Loss of heater control voltage. If CO 2 flow Isolate supply of liquid CO2. Remove cause of
continues no heat of vaporization will be supplied failure. Replace defective fuses and activate CO2 flash
after a short time, resulting in icing of the CO2 evaporator for operation. Continue CO 2 filling of
flash evaporator. generator when normal operating temperature has
been restored.

Operation Gas Pressures and Volumetric
Flow Rates
Fault/Cause Remedy
Low H2 bottle pressure
H2 bottle connected and open is empty. Close valves as necessary to isolate the empty H2
bottle from the gas system. Then connect a new H2 bottle
ready for operation.
Note: Record connection of a new bottle and
analyze gas consumption for continuous assessment
of tightness of entire system. If a major gas loss due
to leakage is suspeced, identify leaks immediatel [1].
Caution: Reduce load as soon as gas pressure

has dropped below the required operating pressure
by 0.4 bar. Unload and shutdown generator when
pressure continues to drop.
Low H2 casing pressure
H2 supply is distrubed Check hydrogen flow path and correct cause of fault.
Setting of H2 operating pressure reducer in H2 supply Check setting of H2 operating pressure reducer MKG16
unit incorrect. BY001.
In the event of a failure of the H2 operating pressure
reducer, perform changeover to H2 filling pressure reducer
MKG 15 BY001. To do this, set multi-way valve MKG15
AA151 to position 1 [2] and then open valve MKG15
AA121. Set filling pressure reducer to operating value.
Close shutoff valve MKG16 AA121 to check or replace
the defective pressure reducer.
Caution: An inadmissibly high H2 volume flow

escapes from the leak.
Shutdown unit immediately by activating a turbine trip.
High leakage at generator or within range of gas Ensure that power house is adequately ventilated.
system. Gas pressure cannot be maintained inspite Remove the hydrogen from the generator unless the
of the addition of make-up gas. leak is repaired immediately.

[1] 2.5-0310 Leakage Tests
[2] 2.3-6107 Positions of Multi-Way Valves in Gas System

Operation Gas Purity Meter System
Fault/Cause Remedy
Low H2 Purity
Seal oil system was in operation without vacuum Corrective action as described in [1].
treatment of the seal oil for a longer period time, i.e.
the air entrained in the seal oil will escape into the
generator, resuling in a deterioration of the H2 purity.
The supply of measuring gas to CO 2/H 2 purity Check the complete meter system for CO2/H2 purity
transmitter MKW31CQ001 has been interrupted, transmitter MKW31 CQ001 as per instructions manual
resulting in faulty indication of the instrument or for H2/CO2 gas Analyser.
malfunction.
Warning: Isolate all H2 carrying lines prior to

opening gas flow path to prevent mixing of gases.
Do not perform any work on Analyser other than
that described in the instruction manual.

Operation Fuses on Rectifier Wheels
Remedy
Fault I Cause
Note: After operation of one or several fuses, it may
Fuse indicator operated be necessary to observe the respective operatlng
limitations [1], [2].
Failure of one or several diodes. If the number of blown fuses per bridge arm and
rectifier wheel has reached the maximum admisslble
value, it is no longer permissible to continue on-load
operation of the generator. The number of blown fuses
indicates a severe fault in the excitation system, the cause
of which must be identified and removed. To do this. the
turbine-generator must be shut down immediately.
Work on the exciter should be performed with the
field ground fault detection system shut down and the
measuring brushes lifted off the sliprings. Remove the
exciter enclosure and half of the enclosure over the
rotating rectifier wheels. Rotate entire shaft assembly of
turbine-generator until defective fuse is brought to an
accessible position. While rotating the shaft. visually
check all fuses in both wheels. To remove defective fuse,
detach contact splice strap of the heat sink by unscrewing
lock nut. Unlock and unscrew the screw attaching the
fuse to the wheel on front side. A continuity test of the
fuse will indicate whether fuse failed due to an electrical
or mechanical fault. A mechanical fault is unlikely.
If fuse failed electrically, the cause of the fault
(defective diode) should be located by megger test. To
do this disconnect flexible lead from the three-phase
power lead. In cases where two diodes are mounted in
each heat sink, both flexible leads must be
disconnected. A controlled DC voltage source of not less
than 1000 V with constant output voltage must be
available for the measurements. Apply DC voltage to
diode in reverse direction. Use another connection to tie
the rectifier wheel to the voltage potential. Connect a
micro-ammeter for determination of reverse current in
circuit between the voltage source and the diode
connection.
To obtain the blocking characteristIc of a diode,
increase applied voltage in steps up to e maximum level
of 1000 V and determine the reverse current for each
step. At least three measurements are necessary for
pIotting the characteristic, the recommended voltage
steps being 500 V, 750 V and 1000 V. The maximum
permissible reverse current at 1000 V amounts to 500
μA. If this limit is exceeded, the diode must be repIaced.
If the shaft assembly cannot be shut down for
several hours, e.g. because cooldown of turbine is still
in progress, the measuring setup described above can
probably not be implemented. ln such a case, the shaft
should be stopped for brief period only to enable a
replacement of the diode(s) in the respective branch
circuit. Plotting the blocking characteristic and assessing
the reusabilily of the diode(s) can then be done while
the unit is running. The defetive diode(s) should be
cautiously unscrewed from the heat sink using the special
diode wrench.
Before installing new diodes and fuses, the
following checks must be made:
After cleaning the heat sink, the insulation
resistance

Operation Fuses on Rectifier Wheels
Fault I Cause Remedy
between isolated heat sink and wheel must be

measured using a 500 to 1000 volt megger. Insulation
resistance should be more than 10 MΩ.
Fuses and diodes are both individually tested at the
supplier factory. Checking the characteristic data before
installing new diodes and fuses will thus not be required.
Only make sure that each replacement diodes is of the
same type as the defective diode (observe forward
direction).
Before installing any replacement diodes, apply a
labricant (Teflon spray) to the threads and coat diode/
heat sink contact surface with a contact agent (silicone
paste). Diodes should be screwed into the heat sink by
hand and then torqued to 10 kgm.
Use self-locking nuts for attaching the flexible leads
to the three-phase power lead.
Be sure that the contact surface (front face) of fuse
bears flush against the contact surface of wheel. After
the fuse has been properly screwed to the wheel and
strap of the heat sink, check clearances between fuse
and wheel using a feeler gage. If a distance of more
than 0.1 mm is measured between fuse and wheel,
fuse should be remounted after any required retouching
work e.g. refiling of bore in fuse strap. Finally, the front-
side set screw should be locked if several fuses and
diodes are to be replaced, this procedure should be
repeated.
No replacement of fuses or diodes must take place
without checking.
Running behaviour of the exciter will not be affected
by an exchange of diode and fuses because of small
differences in the weights of replacement parts.
Prior to re-assembly to the exciter enclosures-
insulation resistance of exciter, including rotor winding,
should be checked. If measured by a megger applying a
measuring voltages of 500 volts, insulation resistance
must not be below 1MΩ.
After installation of the enclosures and re-activation
of field ground fault detection system the generator may
again be placed in service.

[2] 2.4-4910 Maintenance and Supervision
Fuses on Rectifer Wheels

Operation Exciter Temperatures
High hot air temperature at main exciter

and/or
High hot air temperature at rectifier wheels
The cause is a change in the cooling water conditions. With a rise in cold water temperature, higher cooling
waterflow is required for removed of the loss the heat.
Increase cooling water flow.
High cold air temperature

The cause is an insufficient cooling water flow. Increase cooling water volumetric flow rate up to the
maximum permissible limit.
Trapped air has accumulated in cooler. Vent cooler by means of vent screws.
Cooler is fouled on water side. If the cold air temperature continues to rise above the
permissible level, the generator should be operated at a
reduced load.
Unload & shutdown the generator at the next possible
occasion.
Remove the exciter enclosur, isolate the cooling
water supply and detach return water channel for cooler
cleaning.
Thoroughly clean individual cooler tubes with a tube
cleaning brush. If this should not lead to the desired result,
the coolers should be disassembled and cleaned by
hydraulic or chemical means [1].
Use new gaskets for refitting water channels.
We recommend cleaning the exciter coolers on the
air side as well.
For this purpose, cover main exciter, rectifier wheels
and ploit exciter with a tarpaulin. Blow out coolers with
clean and dry compressed air. After careful cleaning, the
tarpaulins should be removed and the exciter enclosure
placed in position over the exciter. Check to make sure
the seals are tight around the exciter enclosure to prevent
the exciter from drawing unfitered air into the enclosure.

[1] 2.5-9440 Exciter Cooler

Operation Exciter Coolers
Liquid in exciter
The cause is a leak or a tube rupture at the cooler Unload and shutdown turbine-generator.
tube bundle. Identify the defective cooler section. Close cooling
water inlet and outlet of this cooler section.
Drain the water from the cooler. If the defective cooler
tube cannot be identified by a simple visual examination,
disassemble the cooler section, remove water inlet/outlet
and return water channels. All cooler tubes must be
separately subjected to a leakage test.
Leakage Test of Individual Tubes
To perform the leakage test, 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. See
Fig.1.
1.Container 5. Cooler Section

2. Water 6. Tube
3. Hose 7. Seal Plug
4. Hollow Plug 8. Tubesheet
Fig.1 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.
For checking purposes, a pressure gauge can be

installed in the line, which will indicate a pressure drops
even for minor leaks after a short time.
If the leakage test in performed without pressure

gauge a visual examination on the air side must be
possible.
Leakage Test With Air in Water
Dry the individual tubes by blowing air through the

tubes. Plug all tubes of the cooler section at one end and
place cooler section in a water basin. Each tube can now
be leak tested with air at 0.5 bar, max. During the leakage
test, air bubbles will escape from the tube(s).
Note that isolated air bubbles may rise from

accumulations of trapped air in the cooler section which
have nothing to do with the leak to be identified.
Note: If several defective tubes air identified, it must

be decided right away whether the heat removal
capacity remaining after plugging of the defective
tubes is sufficient for emergency operation.

1. Plug
2. EE Tubesheet
3. Cooler tube
4. TE Tubesheet
Fig.2 Plugging a Defective Cooler Tube
Plug the defective tube at both ends as shown in

Fig.2. Remove all plugs from the remaining tubes. Then
bolt on water inlet/outlet and return water channels and
perform a leakage test of the cooler section at the
specified test pressure. If no leak is detected, the cooler
section should be installed, filled with water and vented.
The cooler section may remain in operation until the next
inspection or outage, at which time the cooler section
should be replaced.

Operation Stroboscope
Type LX5 (220 V)
Stroboscope defective
Check to ensure that supply voltage is available at
Pins 2 and 9 on plug board 2 are interconnected for a pins 1 and 9 on plug board 2. If no voltage is available,
supply voltage of 220 V. check cable and fuse.
Note: Voltages specified below may vary within a
tolerance range of + 15%.
Printed Circuit board 1 defective

Verify that following voltages are available:
Supply voltage of 220 V is available at pins 3 and 8.
Ground/pin 12 abt. 310 V DC
Plug boad 1, printed circuit board viewed from below Ground/pin 6 abt. 23 V DC
Ground/pin 7 abt. 5V AC
1 2 3 4 5 6 7 Ground/pin 11 abt. 24 V AC
0 0 0 0 0 0 0
Replace printed circuit board if, on pressing the on
0 0 0 0 0 0 pushbutton (hold pushbutton if relay fails to pick up) the
8 9 10 11 12 13 supply voltage is available at pins 2/3 and 8/9 and is not
available at pins 6, 7, 11 and 12. If one of the voltages
measured at these pins greatly deviates from the specified
value, the cause may be a short on another printed circuit
board. Extract printed circuit boards 2 to 4: voltages at
the pins must now reach or exceed the specified value.
Switch off stroboscope and insert one printed circuit board
Printed circuit board 2 defective
after the other until voltage at the respective measuring
Supply voltage of 220 V is available at pins 1 and 9. point collapses. Replace printed circuit board identified
in this manner.
Plug board 2, printed circuit board viewed from below.
1 2 3 4 5 6 7
Relay d1 must pick up on depressing the on
0 0 0 0 0 0 0
pushbutton. If the relay drops out again on releasing the
pushbutton, the pushbutton should be pressed again and
0 0 0 0 0 0 held in position. Measure voltage at pins 11 and 5 with
8 9 10 11 12 13 respect to ground (15 V DC). If no voltage is available,
replace printed circuit board 3. If voltage is available,
replace printed circuit board 2.
Printed Circuit board 3 defective
Plug board 3, printed circuit board viewed from below Ground/pin 13 abt. 23 V DC
1 2 3 4 5 6 7 Ground/pin 11 abt. 5 V DC
0 0 0 0 0 0 0 Ground/pin 9 abt. 6-9 V DC
0 0 0 0 0 0
8 9 10 11 12 13 If no voltage is available at pin 7 or with 15 V or 0 V
at pin 9, replace printed circuit board provided that voltage
is available at pins 13 + 11.

Defect on plug board 4

Verify that the following voltages are available:
Plug board 4, printed circuit board viewed from below
1 2 3 4 5 6 7 Ground/pin 11 abt. 310 V DC min.
0 0 0 0 0 0 0
Ground/pin 9 voltage should not exceed 280 V but
0 0 0 0 0 0 must not be zero. Replace printed circuit board if above
8 9 10 11 12 13 voltages are not obtained.
If only one flash tube functions properly, the cause

One flash tube failed of the malfunction is the flash tube and not the control
unit. Replace failed flash tube.
Functional check: Interchange the flash tube

connectors.

Operation Exciter Drying System
Overheat protection has switched off the exciter Open door in exciter enclosure behind which the
dryer. In most cases, the cause is no or an insufficient dryer is located from the operating floor. Following a short
air flow. cooldown period, the overheat protection automatically
returns the dryer to service.
Check whether air is drawn in via the intake parts
on both side of the air diyer.
If yes, the air flow passage is obstucted. Inspect
prefilter in door for contamination.
If air is drawn only, via one intake part, the free flow
of dry air or regeneration air is obstructed. Restore free
flow conditions.
If no air is drawn in via both intake parts, the ventilator
motor in the dryer has failed. The exciter dryer should be
deenergized, disassembled and returned to the
manufacture’s work for repair. A 2 kW heater-blower
should be used inside the exciter enclosure for dehumidifi-
cation as long as the dryer is not available due to repair.

Operation Ground Fault Detection System
in Exciter Field Circuit
Ground fault detection system disturbed

Carbon brushes have poor or no contact with Install carbon brushes and plug-in brush holders
measuring slipring strictly in accordance with maintenance instruction [1].
Exciter voltage response takes longer than 5s. Fault alarm is automatically extinguished after
removal of cause.
High-resistance groundfault in exciter circuit Immediately investigate cause of ground fault alarm.
Ω)
(RE <80 kΩ Measure insulation resistance in exciter circuit if the
generator can be disconnected from the system and de-
excited [2].
If an insufficient insulation resistance is measured,
operation of the generator should be continued only after
consultation with the manufacturer to avoid possible
major damage.
Low-resistance ground fault in exciter circuit
Ω)
(RE <5 kΩ At RE <5 kΩ, a TUSA trip is activated by the electrical
generator protection, and the generator is disconnected
from the system and de-excited.
If the insulation resistance measurement confirms
the ground fault, the generator must be removed from
service. The manufacturer should be notified and
entrusted with the fault removal.
If no ground fault can be identified by the insulation
resistance measurement, check system once more for
ground faults and rated speed before exciting the
generator again.

[1] 2.4-4990 Maintenance and Supervision of Ground
Fault Detection System
[2] 2.5-3300 Insulation Resistance Measurements on
Rotor and Exciter Windings

Turbogenerators Maintenance and Supervision
Maintenance Introduction
The turbogenerator and its auxiliaries require continuous-

maintenance and supervision to assure reliable operation
and serviceability of the complete plant. Maintenance and
monitoring are required both during operation and when the
unit is at standstill.
Some maintenance work should preferably be performed
with the unit is at rest, e.g. in the case of any special
conditions being noted in the operating log, while other
maintenance work may be carried out during normal
operation.
The maintenance work required on the generator
described herein is specified in detail in the following
section.

Turbogenerators Survey on Maintenance and Supervision
Maintenance
Maintenance Intervals
Every 3 months
Every 6 months
See
Work Required
Instruction
Annually
Monthly
Weekly
Daily
Check sight glasses after level detectors for liquid level x 2.4–4210–......
Check gas consumption x 2.4–4610–......
Check hydrogen cooler vents x 2.4–4240–......
Check shaft grounding brushes x 2.4–4210–......
Check seal oil cooler in operation for proper venting x 2.4–4540–......
Check seal oil supply lines and shutoff valves for leakages x 2.4–4540–......
Check degree of contamination of seal oil filters x 2.4–4550–......
Change over seal oil pumps 1 and 2 x 2.4–4520–......
Perform functional check of standby seal oil pump x 2.4–4520–......
Change over vapor exhausters 1 and 2 x 2.4–4520–......
Check EE generator bearing insulation x 2.4–4250–......
Check EE shaft seal insulation x 2.4–4250–......
Measure insulation resistance x 2.4–4310–......
Check shutoff valves for free movement x 2.4–4610–......
Check shutoff valves with magnetic drive for function and gastight x 2.4–4610–......
Check gas supply lines and shutoff valves for leaks x 2.4–4610–......

Maintenance Stator
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Check shaft grounding brushes x
Check sight glasses after level detectors for liquid level x

1. Monitoring the Temperature of Components is measured separately for each cooler section by means
It is Important that all temperatures remain within of a temperature gauge in the cooling water outlet line
the specified upper and lower limits. If a temperature downstream of each cooler section.
deviation is observed the cause must be determined
immediately and the original temperature restored.
If there exists the danger of overheating, load should
be reduced, accordingly.
The temperatures between the top and bottom bars
of the stator winding are measured with resistance
temperature detectors (RTD’s).
The RTD’s are embedded in the winding and
distributed uniformly over the three phases. The RTD’s
in the stator winding should transmit identical values for
identical currents in all three phases. If different
temperatures are indicated with identical currents in the
three phases, a check should be performed to determine
if the slot RTD’s are correctly calibrated and/or
compensated. Differences in the temperature indication
up to 5 K may be due to tolerances in the slot RTD’s,
compensating resistors and tolerances caused by
differences in the contact at the measuring point selector
switch. Other small temperature differences may be due
to different mounting conditions of the RTD’s.
2. Monitoring the Cooling Gas and Cooling

Water Temperatures
The temperature of the cooling gas in the generator
is measured with one RTD upstream and downstream
of each cooler section. The RTD’s installed behind the
coolers indicate the temperature of the gas used for
generator cooling. The cooling water supply to the
individual cooler sections should be adjusted so that the
gas outlet temperatures at all cooler sections are identical.
The setting of the cooling water volume flow should be
performed by changing the adjustment of the control
valves in the cooling water outlet lines only. The shutoff Fig. 1 Level Detector Rack
valves in the cooling water inlet lines should be fully
opened. 3. Hydrogen Pressure in Generator
To prevent undue stressing of the generator, it is On-load running should always be performed at
desirable to maintain a constant temperature in the specified hydrogen pressure, since it results in minimum
generator by controling the cooling water volume flow. thermal stresses within the generator.
In addition to the gas temperatures, the cooling water If the specified hydrogen pressure cannot be
temperature are also measured. The cooling water inlet .maintained (e.g., lack of gas, high gas losses), the
temperature is measured with temperature gauges in the generator should be unloaded and de-excited as soon
cooling water inlet lines. The cooling water outlet temperature as the rated pressure has dropped by 0.4 bar (5.7 psig).

4. Stator Liquid Detection During operation, the useful length of each individual
Liquid entering the generator housing is sensed by carbon brush can be determined by visual inspection.
level detectors. Sight glasses located before and behind For limits of wear, see Description [1].
the level detectors, permit any leakage to be readily The carbon brushes should be replaced against new
detected before the liquid level has risen up the level ones having contact faces which match the rotor shaft
detectors. contour.
Note: Ensure to Insert the grounding brushes so that
5. Shaft Grounding Brushes .
the carbon layer is followed by a silver layer when
The carbon brushes should be checked at regular
looking In the direction of rotation of the rotor shaft.
intervals.
1 Brush holder
2 Grounding brush (Design A)
3 Grounding brush (Design B)
4 Brush spindle
5 Insulation
6 Rotor shaft
Fig.2 Brush Holder With Grounding Brushes

[1] 2.1–1820 Mechanical Data

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


Maintenance Bearings
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Check EE genertor bearing insulation x
Check EE shaft seal insulation x
1. General reduction may be indicative of damage in the area of

During normal operation. no service or maintenance contact surface, the bearing babbitt, leaking supply pipes,
work is required on the bearings of the generator, or defective pressure limiting and check valves.
however, bearing vibrations, bearing temperatures, oil The temperature of the lubricating oil supplied to
temperatures and oil pressures should be continuously the bearings is controlled by the cooling water flow to
monitored. the bearing oil cooler. The temperatures of the generator
The generator bearings require particular attention sleeve bearings are displayed in the control room.
during each new startup following a brief shutdown.
Careful monitoring will also be necessary within the first 2. Checking the Shaft Seal and Bearing
few minutes after runup until the normal operating values Insulation
are restored. If the operating values prevailing after a The shaft seal and bearing insulation can be checked
restart exceed the permissible limit values. the unit should during operation [1] by measuring the shaft voltage of
be shut down immediately. the excited generator. The voltage measuring points are
The lift oil pressure for the shaft journals should be accessible from the outside of bearing. Ammeters can
adjusted so that the shaft is lifted by not more than 50 % be used to check the effect of the insulation of the shaft
of the bearing top clearance. To prevent any damage to seal carrier and bearing. The ammeter bridges the oil
the bearings the shaft lift oil system must be in operation film between shaft seal carrier or bearing and measures
at speeds as specified in the turbine instruction manual. the current across the insulating element. The
At higher speeds, the lift oil pressure will settle at 40 manufacturer must be notified if this current should
to 80 bar. The oil pressures should be recorded in the exceed 50 mA (AC).
operating log. If a lower oil pressure is observed, the
respective bearings should be checked. Such pressure
Fig. 1 Generator Bearing and Seal Insulation Also refer to the following information
[11 2.5-0300 Checking the Bearing and Seal Insula-
tion

Maintenance Barton Cell (Vacuum Indication)
Work required
Every 3 months
Every 6 months
Annually
Monthly
Weekly
Daily
Check zero x
Normally the Barton cell-requires no maintenance. With contaminated working fluids, it may become
In the event of a disturbance, first inspect the pres- necessary to remove the pressure caps on the high-
sure transmission lines and the other fittings for pressure and low-pressure sides for inspection and
possible faults. cleaning of the diaphragm bodies. To do this, loosen
If unauthorized opening of the center plate unit or and remove clamping bolts Cautiously lift off pres-
damage to the diaphragm bodies has resulted in sure caps to avoid damaging the diaphragm bodies
draining of the liquid, the -system must be returned if a large amount of dirt has accumulated. Dirt. tar or
to the manufacturer’s works for refilling under other foreign matter deposited on the diaphragms
vacuum. should be removed by means of a soft brush, using
suitable solvents.
Note: Barton cells with incompletely filled dia-
phragm bodies are not capable of withstanding high Note: Never use a wire brush, knife or other
static pressures.
tools which are likely to damage or perforate
Inspect lower parts of pressure caps for deposits
the diaphragm bodies.
of solids, crystals, high-viscosity condensate (e.g.
tar) at regular intervals. To do this, disconnect Barton Remounting the pressure caps:
cell from measuring point and remove bottom screw
plugs. • If necessary, replace gaskets prior to remounting
the pressure, caps.
Note that over-range protection of Barton cell is
only designed for short-lived operational troubles as • Remount pressure caps.
these can normally be corrected within a short time.
Note: Do not damage diaphragm bodies.
Relieve damping valve at regular intervals to avoid
sticking of the O-ring seal due to prolonged over- • Lubricate screw and nut threads and nut contact
loading To do this, close shutoff valves and open faces with Molykote paste
equalizing valve assembly until system is restored
to zero. It is recommended to perform this Zero check • Fit screws and torque to 8 kpm (torque wrench)
at intervals of three months.

Maintenance Rotor
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Measure insulation resistance x
1. Monitoring Rotor Vibrations correcting any problems.

The vibrations of the generator rotor should be
monitored and any change should be carefully observed. 2. Measuring Insulation Resistance
Should a change in vibration characteristics be noted, The insulation resistance of the rotor winding toward
it is recommended to have the manufacturer's product ground should be measured once a year [1].
service personnel determine the cause and assist in

[1] 2.5-3300 Insulation Resistance Measurements
on Rotor Winding

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

Maintenance Seal Oil Coolers
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Perform cooler changeover x
Check seal oil supply lines and shutoff valves for leakages x
1. General The rotary transfer valve set should be changed

During normal operation, one of the two seal oil over by turning the common handwheel, which actuates
coolers is on standby and should be filled with water both valves simultaneously. The changeover procedure
and ready for operation. This cooler should be flushed does not result in an interruption of the oil flow. A stop is
with the full cooling water flow twice a week for a short provided so that the rotary transfer valve set cannot be
time in order to prevent corrosion damage. In addition, turned to a position where the oil flow would be interrupted
the coolers should be changed over approximately once or passed through both coolers simulteneously. The
a week so that they will be alternately in service. water flow for the cooler taken into service should be
throttled so that the specified oil outlet temperature is
2. Cooler Changeover obtained.
When changing over the coolers, the standby cooler
should first be taken into operation on its water side with 3. Cooler Cleaning
care being taken to ensure that the cooler is properly
vented on both the water and oil sides. The seal oil cooler removed from service should be
cleaned with tube brushes. The use of Perlon brushes
ensures both a careful treatment of the tube wall and
good cleaning results. To ensure through tube cleaning,
the tube interior should be wet, since dry dirt deposits
are more difficult to remove. After completion of cleaning
and refitting of the upper water channel, the cooler should
briefly be flushed with the full water flow for complete
removal of any residual dirt deposits. Deposits which can
not be removed by mechanical means may require
chemical cleaning. If there is insufficient experience and
equipment available, it is recommended to have this
cleaning work performed by a suitable qualified
contractor.
1. Multiway valve before cooler 5. Seal Oil Vent

2. Cooling Water Vent 6. Multiway Valve
3. Spindle for cooler changeover after cooler
4. Lever for changeover 7. Seal oil drain
Fig. 1 Seal Oil Cooler

Maintenance Seal Oil Filters
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Check degree of contamination of seal oil filters x
The degree of contamination of the seal oil filter can

be seen at the differential pressure indicator. As the
differential pressure across the seal oil filters increase,
corresponding to an increase in contamination of the
filters, a larger portion of the indicator dial appears red.
When the dial is completely red, the standby filter
should be placed in service and the contaminated filter
removed from service by means of the changeover valve
plug.
Drain the seal oil from the filter housing via the drain
plug and remove the filter housing. The screen filter should
be removed and cleaned thoroughly. Prior to reassembly,
the filter should be flushed with turbine oil to remove any
solvent residue. The filter housing should be filled with
turbine oil and mounted to the valve. Vent the filter. Clean
the filters during each inspection.
1. Differential pressure indicator 3. Drain

2. Vent 4. Pressure Equalising
Valve
Fig.1 Seal Oil Filter

Maintenance Gas Consumption
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Check gas consumption x
Check shutoff valves for free movement x
Check gas supply lines and shutoff valves for leaks x
1. General The total gas consumption consists of the hydrogen

quantities escaping both controlled and uncontrolled.
Caution: The CO2 bottle rack should be equipped with The gas quantity escaping under control is com-
full bottles so that a sufficient quantity of carbon posed of the hydrogen flowing outcontinuously via the
dioxide is available for any required displacement of purity meter system for measuing the gas purity in the
the hydrogen. generator, and the gas removed from the generator
A sufficient number of full hydrogen bottles should through the seal oil and discharged into the waste gas
be kept in stock at all times taking into consideration the line.
gas consumption rate of the unit and the availability of Gas quantities escaping uncontrolled are those lost
new hydrogen. through leaks in the generator and gas system.
According to section 4.6 e in VDE 0530, Part 3, not If an undue gas loss occurs on the unit, the location
more than two standby H2 bottles should be open during of the leak must be determined [1].
normal operation. Since this leakage gas may present a danger to the
On occurence of a leak and the resulting higher gas environment, it should not amount to more than 12 m3
consumption, only the open H2 bottles would be emptied (s.t.p.) during 24 hours. In the event of the gas leakage
at a faster rate. In addition, an alarm is activated to alert losses exceeding 12 m3 (s.t.p.) during 24 hours, leak tests
the operator in due time. should be performed and the gas losses reduced below
To improve the operating reliability. It is this limit. If such measures are not successful, even on
recommended that only the hydrogen bottles in service reduction of the gas pressure in connection with a corre-
should be connected to the hydrogen bottle rack, while sponding load reduction, the unit should be shut down
the other connections should be isolated by means ofthe and the hydrogen removed from the generator (see sec-
shutoff valves at the H2 bottle rack manifold. tion 4.6 d in VDE 0530. Part 3).
The connection of new gas bottles should be entered
in the operating logs.
2. Gas Consumption
During operation, the loss of hydrogen gas must be

monitored continuously on the basis of the daily gas
consumption.


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

[1] 2.1-1810 General and Electrical.Data
(2) 2.5-9000 Excitation System

Maintenance Make-up Air Filters in
Exciter Enclosure
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Check make-up air filters x
1. Cleaning Air Filters agent to drain. Air filters are now ready for operation and
The air filters should be cleaned with Purinol air filter can be reinstalled.
cleaning fluid available from DELBAG-Luftfilter GmbH. The cleaning and wetting fluids are available from
The air filters should be removed and slightly beaten
to remove loose dust. For cleaning in a Purinol bath,
pour Purinol into the cleaning tank and add water about DELBAG-Luftfilter GmbH
as thick as a finger to prevent the cleaning fluid from Schweidnitzer Str. 11-15
evaporating. Depending on the degree of contamination, D-1000 Berlin 31
the air filters should be vigorously rinsed out in the or
cleaning fluid several times until the dirt layer has been DELBAG-Luftfilter GmbH
removed. Heerdterbuschstr. 9
Then set up filter pads for drying. Immerse clean air D-4000 Dusseldorf-Heerdt
filters in Viscinol air filter wetting agent and allow wetting West Germany

Maintenance Exciter Coolers
Work required
Every 6 months
Every 3 months
Annually
Monthly
Weekly
Daily
Check exciter cooler vents X
1. General 2. Exciter Coolers

Special measures should be taken to prevent During normal operation, the cooling water flows
corrosion damage to the cooler [1]. Cooler sections through the cooler sections. Since the coolers are
having no cooling water flows for some time may be designed for 100% capacity at maximum cooling water
subject to standstill corrosion. In addition to many other temperature, the condition may arise that the coolers
corrosive influences, such as the different elements of are supplied with smaller cooling water flows for long
the cooling water, locally differing deposits, raw periods. Depending on the purity of the cooling water,
materials, etc., there exists the danger that micro- this may result in deposits due to the lower water
organisms on the tube walls may die and decay due to velocity in the cooler. To prevent cooler damage, it is
a loss of fresh water supply (lack of oxygen). Ammonia therefore recommended to rinse the coolers with the
is formed from such decay which may lead to stress full water flow during short outages. In addition, the
corrosion cracking. Corrosion damage can only be coolers should be frequently cleaned with brushes.
properly prevented if the cooler is drained on the water For heavy cooler contamination and if operational
side, cleaned, completely dried and maintained in a. restrictions and shutdowns are undesirable, it is
dry condition. With the generator in commercial recommended to install a continuous cooler water
operation, such measures are often unfeasible, purification system.
particularly in cases of short outages. In such cases,
special measures should be taken.
Fig. 2 Purification Brush
Fig. 1 Exciter Cooler


Turbogenerators Introduction
Inspection
Reliable operation of the turbine generator will be restarted in the same way as during initial startup.
ensured only if inspections and overhauls are carried out The assignment and number of BHEL product
at regular intervals so that any faults can be detected service personnel required for an inspection should be
and corrected before they result in costly failures. planned well in advance to enable BHEL to make the
Following each inspection, the next inspection should be necessary arrangements. In addition, the period available
scheduled. for execution of the inspection should be indicated.
Provided that commercial tools can be used and The spare parts stored for repairs and overhauls
that no special skills are required for the dismantling and should be checked at regular intervals. Components
erection work, the inspections can be performed by skilled packed in plastic sheeting mostly contain a desiccant
power station personnel. In all other cases, however, such which must be replaced of reactivated from time to time.
as for the inspection of the shaft seals and their auxiliaries,
the services of experienced BHEL product service Danger:
personnel will be required. Rotating components. These may cause
The shutdown of a turbine generator for inspection injury to persons. When working on generator
should be made in exactly the reverse order of startup. It or auxiliary equipment ensure that this is elect-
should be noted in particular that the hydrogen must be rically isolated and cannot accidentally be reconnected.
removed from the generator housing with carbon dioxide In single shaft configurations, do not open the
only. Should opening of the gas system or of the generator generator frame and do not start any work on the rotor
proper be required during an inspection, it is necessary or the bearings until the gas turbine and the steam turbine
to replace the carbon dioxide with air. as well as the generator have come to a complete
Following an inspection, the generator should be standstill.

Turbogenerators Determination of Dewpoint Temperature
Inspection
Example: Relative hunidity of ambient air=50% and room temperature=+20 0C result in a

dewpoint temperature (DT) of +9 0C, corresponding to an absolute humidity of 8.6 g/m3.

Turbogenerators Packing, Transport and Storage
Inspection of Generator Rotors
Note ing the effects of moisture on the rotor and especially on

the rotor retaining rings which may be endangerd by the
Generator rotors are high-grade components which effects of moisture and for protection against mechanical
are sensitive to moisture. For this reason, they must be damage during transport and transshipment procedures.
protected against corrosion and mechanical damage
For protection against the effects of moisture, the
during transport and storage.
rotor retaining rings and the rotor body are packed in
The packing precautions and the organizational
sealed plastic sheeting covers, adding materials for
measures for protection during transport and storage are
moisture absorption. This sealed packing is protected
described below and summarized in [1]. This description
with a second plastic sheeting cover. In the case of sea
contains all details required for restoring the standard
transport, a third plastic sheeting cover is provided for
packing provided by BHEL for delivery of the rotor. If a
the rotor retaining rings and the rotor body. This cover
rotor is to be returned to the manufacturer's works for
forms a second additional barrier against the diffusion of
overhaul or in the case of a prolonged outage of the
moisture into the innermost plastic sheeting cover.
generator involving a separate storage of the rotor, the
requirements specified in the following must be met for The metallically bright shaft ends (shaft journals and
protection of the rotor.
Any deviations from the standard packing due to couplings) are protected with a hard wax coating.
special circumstances shall be subject to the approval
The rotor is then placed on a skid with closed bottom
of BHEL.
and secured in position for protection against mechanical
damage. For land transport not exceeding one month,
Contents
this unit is protected against external influences by a
wooden enclosure resting on the bottom frame of the
1. Basic Makeup of Packing skid. This enclosure must be removed prior to each
transshipment to hitch the rotor with a lath grid in place
2. Definitions at the middle of the rotor body.
2.1 Land Transport
2.2 Sea Transport In the case of land transport exceeding one month
and with sea transport, the enclosure forms an integral
3. Summary of Rotor Packing Requirements part of the skid. The hitch should then be taken directly
at the skid. The complete cargo is covered with tarpaulins
4. Sealed Packing for protection from the elements.
4.1 Appliances and Packing Materials
4.2 Protection of Metallically Bright Shaft Ends
4.3 Making Plastic Sheeting Covers 2. Definitions
4.4 Desiccant
2.1 Land Transport
5. Skid and Outer Protection
The packing provided for this mode of shipment
5.1 Land Transport (Less Than One Month)
affords sufficient protection for land transport under
5.2 Land Transport or Sea Transport
moderate climatic conditions and for a scheduled transit
of Longer Duration
period of not more than one month. This provides a
reliable protection for short-distance transport.
6. Protection of Packing During Transit
6.1 Organizational Measures This type of packing also ensures adequate
6.2 Loading protection during subsequent storage in a covered hall,
6.3 Receiving Inspection e.g. power house. Following the receiving inspection, the
insulation resistance of the rotor winding and the condition
7. Storage of the desiccant should be checked at intervals of one
7.1 Storage Area month and the desiccant reactivated, if necessary.
7.2 Checks During Storage Period
7.3 Removal From Storage 2.2 Sea Transport
The packing provided for this mode of shipment

affords protection during shipment by sea, during
1. Basic Makeup of Packing unavoidable outdoor storage and for transport periods
and under conditions exceeding those under Item 2.1.
The packing precautions and organizational measures The additional packing, as compared to land transport,
during transport and storage are intended for reliably prevent- consists of a third plastic sheeting

1. Moisture-proof plastic sheeting
2. Desiccant pouch
3. Moisture indicator
Fig. 1 Sealed Packing of Rotor Retaining Ring
cover and a closed, seaworthy outer packing. The 4. Sealed Packing

desiccant included in the plastic sheeting covers is
sufficient for the scheduled transport period, but for not The obtain a reliable and long-lasting corrosion
more than six months. protection, both suitable production appliances and
The inspections required during storage are the same materials and appropriate methods of packing are
as specified for land transport under item 2.1. required. The basic prerequisites are:
Dry Condition of Rotor Prior to Packing

3. Summary of Rotor Packing Requirements
The summary [1] contains information on the makeup The rotor must be dried if it is expected to be in a
of the packing and on the procedures required to maintain wet condition due to operational faults. To do this,
the packing in sealed condition. A detailed description is the rotor and especially the rotor retaining rings and
given in the following section. end winding portions should be dried with dry air by
means of an air dryer.

Weather-Protected Packing Area To protect the aluminum foil from being damaged by
Packing and unpacking is only permissible in a the handling ropes, a canvas-reinforced rubber mat, 3 mm
weather-protected area, preferably in a hall. thick and approximately 2500-3600 mm (98-142 in.) wide
(dependent on overall length of rotor) should be placed
No Delays in Packing Procedure around the center of gravity of the rotor. This rubber mat
Care must be taken to ensure that after its removal consists of individual sections, each having a length
the rotor will not suffer any moisture condensation corresponding to the rotor body diameter +100mm (3.94
or accidental wetting. Packing the rotor should in) and arranged with an overlap of not less than 100 mm.
therefore be performed immediately after withdrawal All overlap seams should be sealed with wax-coated
of the rotor and any required drying procedure in canvas bindings. Axial overlap seams should be
order to minimize any uncontrolled phases. additionally secured with steel bands. The overlap
seam at the top on the circumference is to be secured in
4.2 Protection of Metallically Bright Shaft Ends axial direction by a wooden lath, 80x40 mm (3.15x1.57
The metallically bright shaft ends should be cleaned in.), which is also held in place with steel bands.
and de greased and protected with a hard wax coating Finally, a lath grid (hardwood laths attached to fabric
(e.g.Tectyl 506) of sufficient thickness (dark-brown). In mat or fabric tape) should be placed in position for hitching.
addition, the areas of support in the skid should be The grid should cover not less than the lower half two-
wrapped with two layers of wax-coated bindings (e.g. thirds of the rotor body circumference and be adequately
Denso binding) and a 3 mm thick canvas-reinforced secured with steel bands. The wooden laths must be on
rubber mat. All other areas contacting the skid should the outside and arranged so that the rubber mat is
also be covered with 3 mm (0.12 in.) thick rubber board. approximately 150mm (6 in.) wider at each end of the rotor.
The range between the wax-protected shaft portion and the
4.3 Making Plastic Sheeting Covers
end of the rotor body should then be wrapped with polythene
The polythene sheeting covers are made directly on
sheeting which is to be sealed tightly with waxcoated canvas
the components to be protected. To protect the plastic
bindings at the rotor body and free shaft portion.
sheeting cover from damage, any contact with sharp
Experience has shown that in the case of larger rotor
edges must be avoided. Edges should be padded with
body diameters (> 1300mm, 51.2 in. ), the aluminum foil
layers of rubber board or foam rubber. The use of
cannot be wrapped around the rotor with sufficient
excelsior, corrugated cardboard, felt or other hygroscopic
tightness and may thus be omitted. In such cases, the
materials is not permissible. Care should be taken to
above mentioned poly-thene sheeting should extend
ensure that the plastic sheeting cover remains intact
beyond the rubber mat at the middle of the rotor body
during the subsequent packing procedures. Even
and should be wrapped tightly with wax-coated canvas
pinpricks and minute tears in the plastic sheeting will
bindings at these points.
render tight sealing ineffective. Within the range of rotor
The precautionary measures specified under Items
support in the skid and of other contact points (upper
4.2 to 4.3.1 provide for the minimum packing
shipping saddles), the polythene sheeting should be
requirements and are sufficient for land transport not
inserted between two rubber boards of sufficient size for
exceeding 20 hours. In the case of rotors provided with
protection against damage. In the retaining ring area,
aluminum foil within the range of the rotor body, sealing
each plastic sheeting cover is provided with a 500 mm
of the rubber mat at the middle of the rotor body will not
dia. opening for connection of a plastic sheeting hose
be required for short-distance transport.
having the same diameter and a length of approximately
1 m. After checking the cover for tight Sealing the 4.3.2 Second Plastic Sheeting Cover
desiccant is added via this hose, which, is then closed In addition to the first plastic sheeting cover described
by heat-sealing. under Item 4.3.1, a second polythene sheeting cover of the
To maintain the sealed range in a dry condition, desiccant same type should be provided between the shaft ends and
(see Item 4.4) is added to each plastic sheeting cover. the rubber mat at the middle of the rotor body. To separate
After heat-sealing and tight wrapping with wax- the two plastic sheeting covers, a 5-10mm (0.2-0.4 in.) thick
coated bondings, each plastic sheeting cover should be layer of foam material should be placed over the top half
checked for tight sealing. To do this, one corner of the circumference of the rotor retaining rings and rotor body.
plastic sheeting hose should be cut for insertion of a Two plastic sheeting covers are required for land
vacuum cleaner hose (discharge end) and tightly sealed transport and storage as defined under Item 2.1 .
with a binding. If the cover remains inflated during the
following two hours, the cover is properly sealed. 4.3.3 Third Plastic Sheeting Cover
Following this check, the air should be drawn oft.
For sea transport and outdoor storage as defined
4.3.1 First Plastic Sheeting Cover under Item 2.2, an additional diffusion barrier should be
As a first step, the entire rotor body should be provided. This third polythene sheeting cover protects the
wrapped with wax-coated aluminum foil with 50- 20 mm entire range of the rotor between the shaft journals at
(2-2.8 in.) overlap, with the wax coating facing the rotor either end. It is placed over the plastic sheeting covers
body. Seams and overlapping portions should be sealed according to Items 4.3.1 and 4.3.2 and is to be made in
airtight by melting the wax coating with an electric iron. the same manner.

The plastic sheeting is placed over the rotor before the pouches do not come into contact with metal parts. The
rotor is supported on the skid. Within the range of rotor opening in the plastic sheeting cover should then be
support, the plastic sheeting is inserted between two rubber resealed with a heat-sealing unit.
mats of 3 mm thickness each. After the rotor has been
supported on the skid, its upper half por1ion (rotor body and 5. Skid and Outer Protection
retaining rings) should be covered with a 5-10mm (0.2-0.4
in.) thick layer of foam material outside the lath grid area, BHEL generator rotors are delivered in box type
and then the plastic sheeting cover should be heat sealed. shipping containers, consisting of a skid and an
4.4 Desiccant enclosure. Fig. 4 and 5 depict typical examples. It is
4.4.1 Type and Application recommended to keep this shipping container for future
The desiccant consists of silica gel in dust-free and air- needs.
permeable pouches. It should be inserted into each plastic 5.1 Land Transport (Less Than One Month)
sheeting cover via the plastic sheeting hoses. at the two For land transport, the rotor should be supported on
retaining rings. The desiccant must be placed so that it a skid similar to Fig. 4. The points of support should be
can be easily replaced when this becomes necessary padded with rubber mats for protection of the plastic
and that it does not come into contact with steel or winding sheeting covers. At the shaft ends, the rotor should be
components (danger of corrosion). If necessary, cover attached to the skid by means of upper saddles and se-
contact area with polythene or rubber sheeting. cured in axial direction.
All pouches must be tied together with a hemp rope, For loading operations, the hitch should be taken
and, when used, they must be in an active, i.e. absolutely either at the middle of the rotor body (lath grid) or at the
dry condition. rotor ends.
During transit, the rotor should be protected against
extemal influences by a wooden enclosure resting on the
4.4.2 Desiccant Quantities bottom frame of the skid. Both long sides of this protective
The desiccant quantities [1] are proportioned to enclosure should be clearly stencil-marked with the
accommodate highly adverse climatic conditions. The following note:
maximum quantity is sufficient for a transport period not Caution: Remove protective enclosure for rotor
exceeding six months. transshipment.
The complete cargo should be covered with a lashed
4.4.3 Checking and Reactivation tarpaulin.
The moisture absorption capacity of the desiccant 5.2 Land Transport or Sea Transport of Longer Duration
must be checked after arrival at site, after interruptions For land transport exceeding one month and for sea
in transit involving a storage period of more than one transport, the rotor should be packed in a closed, self-
month and during normal storage at the site (see Item supporting container. The setup for two-pole rotors
7.2). corresponds to Fig. 4.
The container bottom should have openings with
Make sure that sufficient replacement desiccant or
perforated-plate covers for ventilation and to prevent the
the necessary drying facility for reactiv:p.tion is available.
accumulation of water. In addition, inspection openings
After opening, the plastic sheeting cover should be
with covers should be provided on the long sides for
provisionally resealed, but must not be left In this
access to the desiccant pouches via the plastic sheeting
condition for more than 20 hours. hoses. An inspection opening at the exciter end should
For reactivation, the pouches should be dried in provide access to the contact pins on the exciter-end
a drying oven at a temperature of 110°C (230°F) end cover of the rotor for measurement of the insulation
for 12hours. If a drying oven is not available, the resistance of the rotor winding.
desiccant should be removed from the pouch spread out Prior to closing the container, the rotor should be
in a thin layer on a metal plate and dried at 110-130°C covered with 3mm (0.12 in.) thick pressboard panels and
(230-266°F) for several hours until the weight of the polythene sheeting, taking care to avoid the formation of
desiccant remains constant. The desiccant should then troughs in which water might accumulate. The container
be filled back into the pouches which are to be closed lid should be covered with tar board sanded on one side
and reinserted into the plastic sheeting covers as quickly and folding down over the edges not less than 200mm
as possible. Care should be taken to ensure that the (7.87 in.).
The total weight and the dimensions of the cargo
All circles pink: danger of corrosion 50 should be marked on the container. In addition the
hitching range should be color-marked. The complete
cargo should be covered with a tarpaulin for protection
Two circles pink: replace desiccant 40
against the elements.
Four-pole rotors requiring prolonged land transport
One circle pink: warning 30 or shipment by sea should be set up on a skid as
illustrated in Fig. 5. In contrast to the example shown in
Fig. 4. the hitch should be taken at a steel sleeve at mid-
Fig.3 Moisture Indicator length of the rotor. The lower half of the steel sleeve
(Exact Location Identification to be Entered in Handwriting)
should be connected to the skid.

6. Protection of Packing During Transit During shunting operations, the car must never be
allowed to pass over a hump. A corresponding note
6.1 Organizational Measures should be included in the waybill and affixed to the car in
Proper packing of the rotor will prevent both the a well visible location.
ingress and the condensation of moisture during transit,
unless the sealed packing is damaged by improper 6.3 Receiving Inspection
loading procedures or customs inspections. This should After arrival of the rotor, the consignee should
be avoided by suitable precautions, enabling a quick examine the packing for extemal damage. The condition
restoration of the dry condition of any damaged sealed of the desiccant can be ascertained. In addition, the
packing. These measures include: insulation resistance of the rotor winding should be
checked. The date of the receiving inspection should be
On the Cargo: entered in the respective section on the inspection hole
Instructions for correct handling. covers. The results of the receiving inspection should
Reference to Sealed Packing on shipping container. be recorded in the check lists [2], copies of which should
Indication of desiccant quantity inserted into each be forwarded to the consignor.
individual plastic sheeting cover behind inspection If the packing is found in damaged condition, it
hole cover. should be resealed as soon as possible.
Attaching this instruction 2..5-0030. The same requirement applies if the seals were
opened by the customs authorities.
In the Accompanying Documents: If the moisture absorption capacity of the desiccant
Reference to Sealed Packing. is no longer sufficient, the desiccant should be removed
Reference to arrangements for customs clearance from the plastic sheeting cover, with the shipping
al place of installation. container protected from the environment, and reactivated
Request for immediate drying in case of transport (see Item 4.4.3). If the rotor is unpacked immediately
damage with moisture penetration. after delivery, it may become necessary to bring it to
Check list relating to condition of desiccant [2]. ambient temperature level for protection against moisture
Check list relating to insulation resistance of rotor condensation. If the rotor temperature is equal to or higher
winding. than the room temperature, there will be no need for
raising the temperature of the rotor to the level of the
6.2 Loading ambient temperature. The rotor temperature can be
If a flatcar is used for transport, the cargo should be measured at the accessible rotor ends using a
loaded so that it can slide on the car, i.e. the skid must temperature measuring instrument. If the rotor
not be secured in position and must be free to move in temperature is lower than the ambient temperature, steps
both directions of running. Provision should be made for must be taken to ensure that the rotor temperature will
a sliding distance of approximately 1.5m (59 in.) at either be 5 K (safety margin) higher than the dewpoint
end. temperature of the ambient air [3].
Planks, approximately 50mm (2in.) thick, should be In the case of outdoor units, the rotor assembly
nailed to the long sides adjacent to the battens. phase should be timed so that the unpacked rotor will
If a deep well wagon is used for transport, the skid- not be exposed to extreme changes in temperature as
mounted rotor should be secured in position at both ends this will involve the risk of moisture condensation.
of the loading bridge. The bridge trough should be sealed
with boards for protection against stones.

7. Storage In addition, the stored item should be blocked up on the
solid ground for protection against moisture. Enough
The precautionary measures during storage provide space must be left between the boxes to permit
for maintaining the dry condition of the rotor in the sealed inspections and checks.
packing without any interruptions until commencement
of the assembly. 7.2 Checks During Storage Period
To this end, certain minimum requirements must be Following the receiving inspection, surveillance of
observed, which are dependent on the condition of the the equipment should be conducted by repeat checks at
storage area. In addition, the condition of the packing intervals of four weeks. The checks required are the same
and of the desiccant contained in the packing must be as specified for the receiving inspection under Item 6.3.
checked at regular intervals. To obtain additional The dates of the repeat checks should be recorded on
verification, the insulation resistance of the rotor winding the outer packing below the date of the receiving
should be measured. inspection and in the check lists [2].
7.1 Storage Area 7.3 Removal From Storage

Sufficiently ventilated and dry storage rooms for If the storage area and the place of installation are
stable support of the parts in a fully accessible location not located in the same room (power house or
are favorable preconditions for storage. If outdoor storage workshop). the rotor temperature may be below the
cannot be avoided, a heavy-duty outer packing of the dewpoint level on transfer of the rotor from a cool storage
seaworthy type must be provided. The outdoor storage area to a warm power house. To protect the rotor from
facility must be set up in such a way that the stored item moisture condensation, it should be left in its sealed
is protected against rainfall and moisture from the ground. packing for several days and allowed to assume the
This would include placing a waterproof shelter over ambient temperature prior to removing the packing for
the shipping container which affords sufficient ventilation. immediate assembly.

[1] 2.5-0031 Preventive Measures for Transport and Storage
of Generator Rotors (Summary)
[2] 2.5-0032 Checking Desiccant in Generator /Rotor Packing
[3] 2.5-0019 Determination of Dewpoint Temperature

Turbogenerators Preventive Measures for Transport and
Inspection Storage of Generator Rotors
Summary
Preventive Measures
Protective Materials and Setup
Purpose/
Phase Component
Land Transport Sea Transport
Short Distance, Shipment by Sea or
Transport Period Less Than One Month Transport Period More Than One Month
A
Corrosin Shaft Hard wax coating (e.g. Tecty1506) of sufficient thickness (dark-brown color). Additionally
protection of journals (1) protect areas of support in skid with two layers of wax-coated bindings and one layer of
shaft ends Couplings 3mm (0.12in.) canvas-reinforced rubber mat.
C Place wax-coated aluminium foil over entire range of rotor body (only for rotor body diameters
Rotor body (2) < 300 mm < 11.8 in.), due to difficult handling).
First pack-
ing of rotor Piace 3mm (0.12 in.) canvas-reinforced rubber mat, 2500 -3600 mm (98 -141 in.) wide
retaining (3) (dependent on length of rotor) around center of gravity; seal overlap seams with wax-
rings and coated bindings and steel bands; secure axial overlap seam with wooden lath.
rotor body Place lath grid on fabric mat, about 300mm (11.8 in.) narrower than (4), around two-thirds
(4)
in plastic of rotor circumference and secure at top.
sheeting
Retaining, (5) Place 0.2 mm (0.08 in.) polythene sheeting between shaft ends (1) and body ends (3) and
cover rubber mat (4), respectively; seal joints with wax-coated brindings at both ends; heat-seal
rings
(sufficient Fans seams.
for short- (waterboxes) Check plastic sheeting cover for tight sealing by inflation with air and recheck after two
(6)
distance hours.
transport up
to 20 hours Add desiccant per m2 (1 m2=1.2sq.yd.) of sheeting surface: shipping time up to 1 month:
500g (1.1 lb.); up to 3 months: 1000 g (2.2 lb.); up to 6 months: 1500 g (3.3Ib.). Plus 280g
and imme-
(7) (0.62Ib.) for each kg of wood and 35g (1.230z.) for each kg of foam material within plastic
diate instal- cover. Moisture indicators for relative humidity> 30 %, > 40 %, > 50 %.
lation)
(8) Place 0.2mm (0.008in.) polythene sheeting between shaft ends (1) and rubber mat (4)
D Rotor body over a 5.10 mm (0.2-0.4 in.) foam mat around top half circumference of rotor retaining
Protection and rings and rotor body.
of first pack- retaining
(9) Check heat-sealed and tightly wrapped plastic cover (9) for tight sealing as under (7).
ing C by rings
second
(10) Add desiccant as under (8).
plastic sheet-
ing cover
(11) Not required for land transport Place 0.2 mm (0.008 in) ploythene sheeting
E over a foam mat and cover entire rotor bet-
Rotor body
Protection ween shaft ends as under (9). With four-
and
of packings pole rotors, foam mat is split within range of
retaining
C and D by lath grid; insert plastic sheeting between
rings 3 mm (0.008 in) rubber boards. Check for
third plastic
sheeting tight sealing as under (7). Add desiccant as
under (8).
cover
F (12) Tightly sealed rotor (1) to (11) on skid with Tightly sealed rotor (1) to (12) in closed
Tightly
closed bottom under enclosure and self-supporting shipping container under
Transit sealed rotor tarpaulin. tarpaulin.
protection
Hitch point on rotor at lath grid in center of Hitch point on shipping container, in the case
G Complete (13) gravity after removal of enclosure. of four-pole rotors on steel sleeve at
Loading cargo midlength of skid.

Preventive Measures
Protective Materials and Setup
Purpose/
Phase Component
Land Transport Sea Transport
Short Distance, Shipment by Sea or
Transport Period Less Than One Month Transport Period More Than One Month
H Complete Check outer packing. Replace desiccant, if necessary. Return check list with details
(15) on condition of packing and insulation resistance of rotor winding to consignor.
Receiving packing
of Cargo and rotor Prior to unpacking the rotor in a weather-protected location, a cold rotor must have
winding (16) ambient or dewpoint temperature plus 5 K safety margin to prevent moisture
condensation.
J Storage With packing for land transport, only in a hall kept at a moderate temperature. For
Storage area (17) outdoor storage, seaworthy packing plus additional precautions are required: storage
on well tamped and suitable reinforced ground and set on blocks for protection
against moisture, case under protective roof.
Complete During storage (including interruptions in transit), check outer packing for damage
packing (18) and tight sealing, insulation resistance of rotor winding.
and rotor
winding
K Rotor Maintain tight sealing of packing as long as possible until rotor is installed. Protection
(19)
Removal against condensation hazard by preventive measure (16).
from
storage

Turbogenerators Checking Desiccant in
Inspection Packing of Components
Desiccant Checking Requirements The results should be recorded in the table below. The
The absorbent capacity of the desiccant must be desiccant must be removed and replaced or reactived
checked after shipment has been completed and at inter- by drying, if necessary.
vals of one month during any subsequent storage period.
Job Name: Sl. No.: Type:
Moisture Indicator
outer packing
Location blue of pink? Weight of

condition of
condition of
Shipping Replacement
component
identification Desiccant
Company
or of
storage of moisture in packing reactivation
Bottom Bottom Bottom
Name
phase indicator in kg. of desiccant

circle circle circle
Date
(1 kg=2.2 ib.)
(30%) (30%) (30%)
Prior to TE 1
shipment
TE 2
TE 3
TE 1
TE 2
TE 3
TE 1
TE 2
TE 3
TE 1
TE 2
TE 3
TE 1
TE 2
TE 3
TE 1
TE 2
TE 3
TE 1
TE 2
TE 3
TE 1
TE 2
TE 3
TE 1
TE 2
TE 3
TE 1
TE 2
TE 3
BHEL, Haridwar 2.5-0032-0001

Turbogenerators Preparation of Machinery Parts
Inspection
1. General dimensions of the extemal and internal threads may be

taken from the respective drawings. Use dry compressed
The machinery parts to be assembled are deliv- air to blowout the rethreaded tapped holes.
ered ready for mounting, unless certain portions must Where no taps are available cleaning of the tapped
be protected during transport against corrosion or dam- holes may also be carried out with the aid of the original
age. screws. At first, the screws should be cleaned by means
Normally all machined surfaces including journals of solvent and a brush. The cleaned screws should then
are provided with a protective coating. In addition, com- be dipped into a solvent and immediately afterwards be
plete assemblies are sealed in plastic sheeting. screwed into the holes for thread cleaning.
If required, this procedure should be repeated
2. Removal of Protective Coating several times until the threads are free from protective
coating.
The protective coating applied at the manufacturer's
work should be carefully removed prior to installation. 3. Remedying of Minor Carnage
The surfaces to be cleaned should be washed with pe-
troleum or a similar agent. When using trichlorethylene,
Damaged machinery parts should be reconditioned
the cleaned surfaces should be carefully dried and after-
as dictated by the extent of the damage and the
vards a thin oil film should be applied. Non-observance
operational requirements unless the nature of the
of this requirement implies the danger of corrosion.
damage does not warrant such remedying.
Particularly thick layers of protective coating should Seriously damaged parts should be returned to the
be softened by applying one of the above-mentioned manufacturer's works together with a damage or failure
cleaning agents and then be removed by means of a report.
hardwood board (approx.10cmx10cmx1 cm, The machinery parts and the fixjng and locating
3.94in.x3.94in.xO.4in.). element should be checked for burrs and compression
marks, and such imperfections should be removed by
Caution:Never use scrapers, finishing trowels or sheet means of a smooth-cut file. Fine-finished surfaces should
metal stiips for removing the protective coating from only be polished by means of an oilstone. :
highly sensitive machinery parts (journals, etc.). Caution: Burrs and compress/on marks on bearing
Cleaning of internal and external threads should be metal surfaces should only be removed by means of
done by chasing, using suitable taps or cutting dies. The a spoon scraper or flat scraper.

Turbogenerators Checking the Bearing and Seal Insulation
Inspection
1. General expected that the total resistance will likewise be lower

than the lowest individual resistance measured before.
During operation of a generator, voltages are set up
along the rotor shaft due to magnetic unbalances. This 2.4 Pedestal Bearing of Exciter
shaft voltage would cause a destructive current to flow The insulation resistance between the bearing
through the bearing, shaft seal and other components if pedestal and base frame should be measured
the rotor were not insulated from ground at least at the immediately after mounting of the pedestal.
exciter end. For reasons of interchangeability, all stator With satisfactory insulation, a value in excess of 10
components coming into contact with the generator rotor megaohms is to be expected. Following this, bolt the
are insulated. associated oil pipe to the bearing pedestal being careful
to insulate it. It is also recommended to repeat the
insulation resistance measurenment after fitting of each
2. Checking the Shaft Seal and Bearing individual pipe. If a sufficiently high resistance value is
Insulation During Installation measured (five megaohms) proceed with fitiing of the
next pipe. Finally, measure the insulation resistance to
2. 1 Bearing Saddle the base frame of the bearing pedestal with the
Prior to inserting the rotor and supporting it on the connected pipework. If this value is higher than three
bearings, the insulation resistance of the built-in bearing megaohms, proceed with mounting of exciter rotor.
saddle should be measured separately by means of a
100 V megger applied between the bearing saddle and 2.5 Final Checking
the lower part of the stator frame. The values measured After the generator rotor has been inserted, a final
should be recorded. insulation check should be performed. The total insulation
With satisfactory insulation, a value in excess of 10 resistance must not be less than one megohm. Due to
megohms is to be expected. If an insulation resistance contact with the shaft, the measuring circuit covers in
value below three megohms is measured, the insulating parallel:
parts should be checked for moisture, contamination or
metallic contacts. If required, the insulation should be TE/EE bearings
dried at 80 °C maximum. . TE/EE shaft seals
The measurement should be repeated immediately Exciter bearing pedestal with pipework
after the rotor has been supported on the bearings.
Caution: With this measurement and the following 3. Checking the Shaft Seal and Bearing
checks both rotor bearings must be Insulated, and Insulation of the Assembled Unit
the generator rotor must not come into contact with
the turbine shaft through measuring devices or similar Checking the shaft seal and bearing insulation
parts, to prevent the generator rotor from being during operation may be done by way of the shaft voltage
grounded. prevailing with the generator running in an excited
Since, with the rotor Inserted, all individual condition. For this purpose, the potential of the insulated
resistances measured previously are now In parallel shaft seals and bearings is accessible external to the
in the measuring circuit, the total resistance will be generator. With the generator running, the components
slightly lower than the lowest individual resistance coming into contact with the shaft are separated from
value measured before. the shaft by an oil film, which has insulating properties.
Consequently, a non defined resistance value is set up
2.2 Inner and Outer Labyrinth Rings at the potential measuring points of the shaft seals and
Inner and outer labyrinth rings are insulated from bearing sleeves which is dictated by the magnitude of
other components. The insulation resistance of each the resistances of the oil film and insulating parts. The
individual labyrinth ring should be measured after following method permits the insulation to be checked
installation in order to preclude any lengthy search for without disassembly of components being required.
faulty mounting on measurement of a poor insulation Useful results are, however, to be expected only if the
resistance. Proceed with mounting of the next component turbine end of the generator rotor and the turbine shaft are
only after having identified and removed the cause of a grounded properly as defined during the measurements.
poor insulation resistance. After installation of all insulated Grounding must be maintained to discharge to ground any
components the total resistance will be slightly lower than static charges occurring continuously during operation due
the lowest individual resistance value measured before. to steam and oil film friction.
2.3 Shaft Seals 3.1 Checking the Insulation with the Generator
Both shaft seals are mounted such that they are insulated. in an Excited Condition
To check the insulation resistance, follow the same
procedure as outlined for the labyrinth rings. It is to be

Due to the rotor grounding arrangement at the turbine should first be connected to the potential measuring
end, the shaft voltage should be measured at the exciter terminal of the insulated component (bearing sleeve or
end. Since the result depends, however, on the function of shaft seal) at the exciter end by means of a cable. The
the rotor grounding system (carbon brush sliding on shaft), oil film of the component is thus bridged, with the
the shaft voltage should first be measured according to Fig. component assuming the shaft potential. With
1 with the generator running and excited. Normally, this will satisfactory insulation, the instrument will continue to
be an ac voltage of a few volts on which a small dc component indicate a shaft voltage of the original magnitude. In the
is superimposed. Measurement should be performed by event of insufficient insulation resistance, a current will
means of an AVO meter in the ac range. The voltage should flow through the insulation, which may be read at the
ammeter connected into the circuit. Bridging of the oil
film results in a reduction of the original shaft voltage or
in its complete collapse.
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.
3.2 Checking the Insulation With the Generator in

Non-Excited Condition
1. Voltmeter (ac range)

Fig.1 Measurement of Shaft Voltage With the Generator
in Excited Condition
be picked off the shaft through a sliding contact with an

insulated handle, which is connected to the meter by a cable.
The shaft voltage measured in this way should then be
compared with the voltage measured according to Fig. 2. If

2. Ammeter
Fig. 3 Measurement of Shaft Current with the
Generator in Excited Condition
3.2 Checking the Insulation With the Generator in

Non-Excited Condition

Fig. 2 Measurement of Shaft Voltage at Exciter End
with the Generator in Excited Condition
the two readings are not identical, the rotor grounding system
should be rectified first before taking any further readings to
check the insulation for shaft currents.
1. Bridge Instrument
If the shaft voltage can be exactly measured according
Fig.4 Measurement of Insulation Resistance With
to Fig. 2, the measuring brush on the shaft
the Generator In Non-Excited Condition

If the previous tests are conclusive, additional tests may connected in parallel with the measuring voltage. This
be performed in consultation with the manufacturer to measurement is not practicable with the generator at
locate insulation defects with the generator running and standstill, since a stable oil film providing for full
in non-excited condition. A bridge instrument must be insulation can only be fomled above a speed of
used. To measure the resistance of the insulated approximately 3.33 to 6.66 s-1.
component with respect to the shaft and ground. the In case of a low insulation resistance, it must be
bridge instrument should be connected between this assumed that the insulation is defective, requiring
component and ground. The resistances (Roil and Rins in detailed checking of the insulating parts. (Contact the
series) of the parts in contact with the shaft are then manufacturer.)

Turbogenerators Leak Tightness Investigations
Inspection
Safe generator operation without endangering the Possible leak locations:

environment (operating staff) and the unit essentially
requires that there are no unallowable gas losses of flange connections
generator and gas supply unit. Thus, before joints
commissioning, after inspections, when taking into screw unions
operation and in case of unallowable losses, thorough weld seams
leak tightness investigations are to be performed. h.v. bushings, etc.
1. Leak Tightness Test of the H2 System with Air are to be thoroughly investigated. In such a case the
Having sealed the generator and having taken the usage of Diprol or any other foaming agent which is to
seal oil supply into operation, the generator, including be applied to the leak location assumed is recommended.
the connected gas supply system has to be leak tested Bubbles will indicate the relevant leak.
with compressed air. Provide the compressed air supply If sufficient leak tightness is established when testing
via the appropriate compressed air connection. with air, the generator can be filled with CO2 and
The test pressure should be equivalent to the subsequently with H2.
generator operating pressure. Use a precision gauge of If in exceptional cases, leak tests are performed with
class 0.6. The leak test should last for at least 48 hours. hydrogen, due to the reduced density of hydrogen, the
The vacuum pump is out of operation during the leak test. allowable leak rate may be about four times as high as
The H2 system is to be regarded sufficiently tight, if with air. Leakages are determined in such a case with
the air loss is below 1.5 m3/24 h = 62.5 dm3/h (n.s.) by the gas leak detector.
this test.
Determine the air losses as follows: 2. Leak Tightness Monitoring of the H2 System
with Hydrogen
0.2694*24 (p1 + pB1 p2 + pB2 In operation. the gas loss has to be checked
V= .VG. - continuously with respect to the appropriate hydrogen
Z 273 +T1 273 + T2 consumption. The uncontrolled escaping hydrogen
Where: volume may amount to 12 m3 (n.s.)*/24 h. In such a
V = air loss in m3 (n.s.)*/24 h case, it has to be noted that only the uncontrolled
273K escaping gas volume should be taken as reference for
0.2694 = tightness considerations. Continuous controlled gas
1013.25 mbar losses, e.g. will escape the electrical purity measuring
unit. Losses will also occur due to gas being discharged
z = duration of leak tightness test in h via the seal oil.
VG = generator volume in m3
(see information at Mechanical Data) 3. Leak Tests by the Gas leak Detector
Leak tests have to be performed, if the gas loss of
p1 = overpressure in mbar within the system when the unit is unallowably high. Use the gas leak detector
starting the leak tightness test [1].
p2 = overpressure in mbar within the system when 4. Controlled H2 Losses in the Seal Oil Tank
finishing the test Deduct the controlled losses from the total amount
pB1 = barometric pressure in mbar when starting of losses to determine the uncontrolled ones. Quite large
the test controlled H2 losses come up due to degassing of the
seal oil in the seal oil tank.
pB2 = barometric pressure in mbar when finishing Determining the losses across the seal oil tank may
the test take place by air (pressure increase measurement) at
generator standstill or with hydrogen (delta p
T1 = intermediate temperature of the gas measurement) in operation. Close the shut off valve
atmosphere in the generator in °C ahead of the vacuum pump for measuring.
when starting the test Pressure increase measurements start at an initial
T2 = intermediate temperature of the gas pressure of 0 bar (relative). The air escaping the seal oil
atmosphere in the generator in °C results in a pressure increase. Measurements should only
when finishing the test take place up to an over pressure of about 0.1 bar, as
the oil level decreases in case of higher pressures. Any
lower oil level falsifies the measurements due to the
In case of air losses exceeding 1.5 m3 (n.s.)*/24 h, enlarged free volume in the seal oil tank; furthermore,
the leaks are to be determined. the lower level detector is activated in case of decreasing
oil levels. resulting in switching off the seal oil pump.

Delta p measurements start under vacuum. The hydrogen p2–p1 V.24
extracted from the seal oil in vacuum reduces the vacuum VVb= . .a [m3/24h(I.N.)]
t2–t1 Po
in the seal oil tank when measuring.
Vvb = loss volume flow rate in the seal oil tank
p [bar) p1 = pressure in mbar in the seal oil tank when
starting the measurements
p2 = pressure in mbar in the seal oil tank at t2.
p1 operating point determined by the tangent to the pressure
characteristics at operating point
measuring point t1 = time of measuring start in h
pressure characteristics with t2 = time of pressure p2 in h
switched off vacuum pumps V = free volume of the seal oil tank in m3
and closed valves
π.d2.h
V=
tangent line to the 4
pressure characteristics
at operating point d = diameter of seal oil tank
P2 h = height of vacuum chamber
Po = Atmospheric pressure in mbar
t1 t2 t [h] a = Volume ratio H2/air in the waste gas pipe.
Fig. 1 Measuring Chart end Tangent Line When measuring with H2: α = 0.6-0.8
Having recorded the pressure characteristics, t2 und When measuring with air: α = 1
P 2 can be determined by means of the tangent.
Fig. 2 Seal Oil Tank
* n.s.=in normal State at 00C and 0.013 bar acc : to DIN 1343

Determination of H2 Losses in the Seal Oil Tank
Unit No.: 12–................................. Date:........................
P in bar
Diameter of seal oil tank d : .................dm

Height of Vacuum chamber h : .................dm
H2/air-ratio α : .................
H2 loss volume flow rate : .................ltr/h

[1] 2.1-8469 Gas Analyzer for the Detection of Hydrogen Leakages
Turbogenerators Flushing the Oil Piping
Inspection
1. Measures to be Taken at Inspections, oil samples should be taken and analyzed to decide
Repairs or Checks whether the flushing oil charge can be used as ser-
When opening parts of the oil systems for inspection, vice oil change after treatment by the oil supplier.
repair or checking, make sure that no dirt is introduced Use of an oil grade intended for use as flushing oil
into the oil circuits. In the event of a contamination being only. Its properties, particularly its viscosity, are
unavoidable due to the work to be performed, take care matched to the special application. This oil charge
to reduce such contamination to a minimum and perform is completely drained on completion of the flushing
a thorough cleaning afterwards. procedure and replaced by a new service oil charge.
In case of more extensive inspections, it is The properties of the service oil and flushing oil must
recommended to drain the oil, to clean the oil coolers, be suitably matched.
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

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.
3. 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 1. Oil drain
contaminated oil is introduced between shaft and babbitt. 2. Bearing saddle
To do this, remove the upper half bearing sleeves and fit 3. Seal
tempotoary oil drain pipes to the inlet openings of the 4. Bearing sleeve
lower half sleeves. Remove the valve cones from the
permanently adjustable throttle valves before the bearings Fig. 1 Oil Drain at Generator Bearing
and insert the flushing fittings instead. Do not yet install
the flushing screens supplied with the throttle valves.
5. Flushing Procedure
Flushing all bearing oil lines and all shaft lift oil pipes
Make sure that the hoses of the shaft lift oil system are
of the generator should be performed in conjunction with
not connected to the bearings, as otherwise contaminated
the turbine according to the instructions issued for the
oil will be admitted to the bearing journal.
turbine.
During flushing, the oil lines should be hammered
4. Flushing Oil
regularly to remove dirt particles from the walls. During
The oil used for flushing must be provided by the
the last third of the entire flushing period. the screens
user and oil supplier as laid down in the generator
should be temporarily installed in the throttle valves up-
manufacturer's oil specification. In this connection, it may
stream of the bearings for checking the dirt accumula-
become necessary to consult the turbine manufacturer
tion.
too.
After draining of the flushing oil, remove any
The following methods are possible:
dirt deposits from the bearing compartments.
Use of the same oil grade for both flushing and Remove and clean all filters and screens. Remove
operation. On completion of the flushing procedure, 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. be replaced and/or cleaned as frequently as possible.
Assemble the bearings ready for operation. The hoses During commissioning, the oil should be checked for
of the shaft lift oil system should be connected to the contamination, e.g. via vent ports. In case of an extremely
bearings and checked for tightness. high dirt content due to carbon dust, construction work,
etc., special precautionary measures should be taken.
6. Supervision of Oil Circuits
After recommissioning, all screens and filters should

Turbogenerators Measures to Prevent Corrosion
Inspection During Inspections
During an inspection, the Individual components of The air dryer or fan-forced heater should be arranged so
the generator are exposed to the ambient conditions that the air will circulate through the stator interior in a
which may result in hazards to these components. It is closed circuit for ventilation of the entire internal space.
therefore strongly recommended to take suitable The rotor should be protected in such a manner that
measures for preventing any exposure to moisture, especially the retaining ring area can be kept dry and
especially rain, snow, liquids of any kind and above ambient temperature level. The air dryer or fan-
condensation. Covering the components will not afford forced heater should be arranged so that the air will
sufficient protection. circulate in a closed circuit.
To avoid the above-mentioned hazards, the The cooling water should be drained from the
assembly work during an inspection should be coolers. The coolers should be cleaned, dried and
accomplished under protection from weather conditions. maintained in dry condition by suitable measures.
The generator should only be opened if an uninterrupted Normally, a condensation hazard can be recognized
execution of the work will be ensured and provided that with the help of a dewpoint measuring device. In case of
the necessary protective measures can be taken. After doubt, however, it is recommended to dry the components
opening of the unit and withdrawal of the rotor, the stator on a continuous basis in order to achieve a markedly
openings should be promptly reclosed. The stator should low dew-point temperature on these components, i.e. to
be dried by means of a portable air dryer or fan-forced maintain their temperature above ambient temperature
heater and kept above ambient temperature level. level.

Turbogenerators Preventive Measures
Inspection to Avoid Moisture Condensation
Survey
Phase Keyword Precautionary Measures and Checks

Transport Packing: 1 Dry rotor retaining rings by blowing dry air into rotor end windings from
portable air dryers (e.g. Munters dryer) shortly before packing. Multiple
dry packing in sheetings with desiccant added.
Accompanying 2 Reference to special packing and request for restoration after opening
documents: due to customs or in-transit damage.
Damage to 3 Restore proper condition of dry packing immediately. For details, see
packing: 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.
Storage Condition: 5 Maintain dry packing until immediately before assembly.
Check: 6 Monthly functional check of dry packing and desiccant according

checklist.
Storage area: 7 Indoor storage in dry building; outdoor storage in seaworthy packing,
under shelter, protected against precipitation/ground moisture.
Installation Outdoor 8 Transport to jobsite in dry packing. Acclimatization in dry packing to

installation: avoid condensation after unpacking.
9 Installation under shelter. Removal of dry packing from retaining rings

(1 st layer) as late as possible.
Open generator 10 With danger of condensation (outdoor installations and open power
rotor Installed house) blow dry air from portable air dryers into rotor end windings
and slipring assembly.
Ready for Generator closed, 11 H2 cooled generators :

operation filled with Pass small cooling water flow through H2 cooler to ensure that cooler
(standstill is coldest component in the generator (condensation hazard!).
H2 gas:
or turning
Exciter unit in 12
gear RR Exciter Units:
enclosure
operation) Drying process with stationry or mobile air dryer
13 Generator closed: Measures as under Ready for operation.
Scheduled Outdoor
mainten. Installation: 14 Generator open: Shelters must prevent precipitation from entering
without
the generator; the retaining rings areas must be covered and kept dry
rotor
by supplying dry air.
removal
Scheduled 15 If rotor Is set down in dry power house with even temperature, it is
Indoor
mainten. Installation: sufficient if the entire rotor is covered against dirt and wetness. If danger
with rotor of condensation, the rotor area between the bearing joumals must be
removal provided with dry packing.
Outdoor 16 Set down rotor under shelter and provide rotor areas between bearing
installatlon: journals with dry packing.

Turbogenerators Inspection
Inspection Introduction
Preventive maintenance of generators serves to consideration of changes that are likely to occur after a
avoid major problems or damage while the unit is in relatively short service period.
service. The time periods given are guiding values.
Apart from its scope, the timing of an inspection is Depending on the scope of the planned work or inspection
important. To account for the deterioration and stresses findings, the inspection period is either shortened or
due to different modes of operation, the number of lengthened.
operating hours, the number of starts and the tuming
times are used as criteria in determining the intervals Influences
between the inspections. Scheduling of the Initial Inspection and of the
The intervals recommended in the following are the subsequent inspections mainly depends on the number
same as those indicated in the VDEW Recommendations of operating hours, the number of starts and the turning
for Intervals Between Generator Inspections [1] which times. The influences are considered according to VDEW
are based on the accumulated experience. This Foreword Recommendation for an equivalent operation time under
contains a large number of extracts from the VDE consideration of the machine output in four performance
Recommendations. groups.
The guiding values given in the VDEW Recommen-
dations are to assist the power plant owners/operators Tequlv = K1 .T1 + K2 .T2 + n.T3
in scheduling inspections, taking into account also own Tequiv t, Tequivr = Equivalent operating hours Subscript t
experience on the performance of their generators and K1 = Weighting factor for stress refers to total
that of sister machines. impact during normal operat. hours
operation since initial
Types of Inspection T1t,T1r = Operating time in hours commissioning
Depending on the scope, date and duration of the K2 = Weighting factor for
inspections, a differentiation is made between turning gear operation
T2t , T2r = Tuming gear operation Subscript r
Initial Inspection (II) time in hours refers to
Short Inspection (SI) (or Minor Inspection) nt, nr = Number of starts operat. hours
Intermediate Inspection (Inl) (or Medium Inspection) T3 = Weighted time equivalent belween two
Main Inspection (MI) (or Major Inspection) in hours per start main inspect.
Table 1: Types of Inspection, Features and Duration Table 2: Weighting Factors for the Different Power
Type Features Duration Output Ranges
II Maximal as Up to several
Main Inspection weeks Power
Rating K1 K2 K3
Output Range
SI Checks and measures required Days
based on observations during 1 SN> 600 MVA 1.0 0.5 20
operation and checks 2 250 < SN < 600 MVA 0.9 0.3 10
INI Like Short Inspections including A few weeks 3 50 < SN < 250 MVA 0.8 0.1 10
partial disassembly but without
4 SN < 50 MVA 0.7 0.1 5
removal of rotor
MI Like Intermediate Inspection but Several weeks
The recommendations given in the following apply
with removal of rotor
to normal operation without major disturbances.
The Initial Inspection is the first major inspection of Abnormal disturbances, such as close-in system faults,
the generator normally involving the removal of the rotor faulty synchronizing, asynchronous running and
and is an essential prerequisite for assuring high reliability inadmissibly high unbalanced load, may necessitate
on a long-term basis. shortening of the respective inspection interval or an
The removal of the rotor at the Initial Inspection immediate check.
Is not necessary for post-impregnated generator When scheduling inspections, also consider the
stators. An extensive visual Inspection through the following factors:
man holes Is urgently required. With these generators, Wear and deterioration of components
the extent of the Initial Inspection corresponds to the Deterioration of running behaviour
Intermediate Inspection. Frequency of load rejections associated with overspeed
The scope of work and checks to be performed should Earth faults or intertum faults in generator field circuit
be agreed upon with the manufacturer in good time. The Hydrogen, water or cooler leaks
date of the Initial Inspection should be determined under due Change in coolant flow rates .
Fouling of air-cooled generators
Deterioration of shaft insulation 50 hours per shutdown, but subject to an annual
Type specific experience. maximum of the difference between 8 500 h/year and
the operating time, In some circumstances this may result
With proper performance of the generator and In shutdown times of 1 000 hours per year for operating
provided that the inspection findings obtained by the modes A, B and E.
preceding inspections (s) have been favourable, the The recommendation of a generally binding
intervals between inspections may be lengthened within inspection interval of 40 000 to 60 000 equivalent
reasonable limits. operating hours between Main Inspections for a medium-
sized turbogenerator (power output range 2) at peak load
Recommendation for Inspection Intervals (operating mode D) will result in an interval of 6 to 10
The Initial Inspection (II) after an equivalent operation time years.
10000 h < Tequlv t < 20 000 h
Table 4: Determination of the Equivalent Operating
The Main Inspection (MI) after an equivalent operating time
Hours for One Calendar Year with Differing
40 000 h < Tequlv r < 60 000 h
Operating Modes and Ratings
It is recommended that one or more Short and
Intermediate Inspections are performed between Main Power Output 1 SN > 600 MVA
Inspections. This result in a sequence of Short, Operat.
Intermediate and Main Inspections which can be selected mode T1 T2 n T1XK1 T2XK2 noXT3 Tequtv
flexibly at different intervals.
A + E 7000 500 10 7000 250 200 7450
This point of time is not dependance to the technical
requirements of the generator, but also to the most B 5000 2500 50 5000 1250 1000 7250
generator dependent moments of shut down periods of C 3000 5500 150 3000 2750 3000 8750
the machine set. D 1000 7500 300 1000 3750 6000 10750
Recommendatlons
By the mathematical calculation of inspection Power Output 2 250 MVA < SN < 600 MVA
intervals based on the equivalent operating time Operat.
Tequiv = K1 .T1 + K2. T2 + n.T3 (from Table 2) will be included mode T1 T2 n T1XK1 T2XK2 noXT3 Tequtv
the turning gear operation hours in addition to the number
A + E 7000 500 10 6300 150 100 6550
of starts and by classifying four groups of power output
ranges with different weighting factors. B 5000 2500 50 4500 750 500 5250
In this way an equivalent operating time is C 3000 5500 150 2700 1650 1500 5850
determined for the various operating modes. It reflects D 1000 7500 300 900 2250 3000 6150
the diverse operating influence and corresponds well with
experience. The equivalent operating times are
determined and compared for one calendar year Power Output 3 50 MVA < SN < 250 MVA
considering different operational modes in the four power Operat.
output ranges. mode T1 T2 n T1XK1 T2XK2 noXT3 Tequtv
Regardless of the four power output ranges, in
A + E 7000 500 10 5600 50 100 5750
principle five operating modes can typify turbogenerators
(Table 3). For each operating mode typical values are B 5000 2500 50 4000 250 500 4750
given for the load ranges, the annual operating time, load C 3000 5500 150 2400 550 1500 4450
variations and the annual number of starts providing such D 1000 7500 300 800 750 3000 4550
a characteristic order.
Table 3: Typical Operating Modes
Power Output 4 SN < 50 MVA
Annual
Oper- Annual
Operating Load Operat.
ating Load Ranges No. T1 T2 n T1XK1 T2XK2 noXT3 Tequtv
time Variation mode
Mode of Starts
in h A + E 7000 500 10 4900 50 50 5000
A base load > 7000 small 10 B 5000 2500 50 3500 250 250 4000
B lower 4000-6000 large 50
C 3000 5500 150 2100 550 750 3400
medium load
C upper medium 2000-4000 large 100-200 D 1000 7500 300 700 750 1500 2950
load
D peak load < 2000 small 300
Regardless of the above recommendations to perform
E operation in
the Initial and the Main Inspections after having reached
industrial > 7000 large 10
equivalent operating hours totals of Tequiv t or Tequiv r , the
power plants
maximum time (operating time + turning gear time +
Examples of the equivalent operating hours in a standstill time) between two Main Inspections, and also
calendar year for each of the five typical operating modes between Short and Intermediate Inspections, should not
are shown in Table 4 for the four power output ranges. exceed the period specified in Table 5 because of harmful
The turning gear time in the Table has been taken as long-term factors.

Table 5: Maximum Total Time for Inspection Intervals
Power Output Range 1 + 2 Power Output Range 3 + 4
SI 2 years 3 years
Inl 5 years 6 years
MI 10 years 12 years
0 10 20 30 40 50 60 70 80
Fig.1 Typical Equivalating Hours of Turbogenerators Actual Operating Hours Tact ( 103 h )
Examples A,B,C,D to Table 2
Actual Operating Hours Tact per year

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

[1] "Recommendations for intervals between Turbogenerator inspections", VDEW-Publication, Edition 1991, ISBN 3-8022-0352-6

Turbogenerators Inspection Schedule
Inspection Stator
Initial Inspection")
Minor Inspection
Major Inspection
Work required
Measure insulation resistance of stator winding x x x

Implementation of insulation test 1)
x
Leakage test of H2 system x x x
Dismantle bushings and replace gaskets x 2)
Dismantle stator end shields and replace all gaskets x

Check stator winding condition x
Check condition of Stator core x
Check condition of seals between stator core and housing x
Replace all cable lead out plate gaskets x 2)
") Deleted, unless a main inspection has to be performed at an earlier time than scheduled due to findings of visual checks of the generator
interior of special occurrences in operation (system fauft, terminal fault, faulty synchronization etc.).
The scope of inspection will depend on the appropriate findings.
1) Dissipation factor measurement, charging and leakage current measurement, and, in particular cases, high-potential test.
2) Normally required only at every second major inspection.

Inspection Rotor
Initial Inspection")
Minor Inspection
Major Inspection
Work required
Perform runout check x

Withdraw and check rotor x
Check rotor wedges and retaining rings x
Check end winding and gas outlet ducts x
Measure insulation resistance of rotor winding x x x
Check bearing surfaces x
Check shaft seal contact faces x
Check rotor fan x
Check coupling flanges x
Check rotor alignment x x x
") Deleted, unless a main inspection has to be performed at an earlier time than scheduled due to findings of visual checks of the generator
interior of special occurrences in operation (system fauft, terminal fault, faulty synchronization etc.).
The scope of inspection will depend on the appropriate findings.
BHEL, Hardwar 2.5-1030-0007/1

Inspection Coolers
Minor Inspection
Major Inspection
Initial Inspection
Work required
General
Check cooling water inlet and outlet pipes, vent pipes, drain pipes and mountings of all coolers x x x
Check condition and performance of temperature and pressure measuring devices at all coolers x x x
Hydrogen Cooler
Clean H2 cooler on water side x x x
Check condition and, if required, recondition H2 cooler water channels x x x
Dismantle H2 cooler, check on water and gas sides, clean, if required, replace gaskets x
and perform pressure tests
Seal Oil Cooler

Clean seal oil cooler on water side x x x
Check condition and, if required, recondition seal oil cooler water channels x x x
Dismantle seal oil cooler, check on water and oil sides, clean, if required, replace gaskets x
Exciter Cooler
Clean exciterl cooler on water side x x x
Check condition and, if required, recondition exciterl cooler water channels x x x
Dismantle exciterl cooler, check on water and oil sides, clean, if required, replace gaskets x

Inspection Bearings
Minor Inspection
Major Inspection
Initial Inspection
Work required
Check and, if required, replace bearing insulation x x

Check bearing surfaces and babbitt bonding (dye penetrant and US*-test) 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
* US= uttrasonic test

Inspection Shaft Seals
Minor Inspection
Major Inspection
Initial Inspection
Work required
Check shaft seal insulation x x

Peplace 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 (dye penetrant test) x x
Check seal ring clearances x x
Check inner labyrinth rings and, if required, replace seal strips x x

Inspection Seals Oil System
Minor Inspection
Major Inspection
Initial Inspection
Work required
Perform functional check x x x

Check Coupling x x x
Seal oil pumps Regrease bearings of drive motors1) x x x
and Replace bearings of drive motors x x x
drive motors Replace gaskets of seal oil pumps x x x
Replace antivibration pads x x x*
Check control and safety valves (including float valves) x x x
Check control valve bellows x x x
Check all valves x x x
Replace gaskets in and at valves x x x
Replace complete flange gaskets x x x*
Check and clean seal oil filters, 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); 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 x x x
(at rated gas pressure and n=50 and n=0 s-1)
Overhaul vacuum pump x x x
* Normally required only at every second major inspection

1) Regrease bearings after 8000 operating hours at the latest

Inspection Gas System
Minor inspecttion
Major inspecttion
Initial inspecttion
Work required
Check condition and performance of all pressure reducers x x x

Check performance of all valves (leakage, operation) x x x
Replace valve gaskets / O rings x
Replace flange gaskets/ O rings x*
Replace PTFE sleeves in multi-way valves x*
Replace flange gaskets/ O rings of gas dryer x
Replace gaskets and coating of CO2 flash evaporator x
Check condition and performance of CO2 flash evaporator x x x
Replace dust filter in gas purity meter system x
Check complete gas system for leakages x x x
* Normally required only at every second major inspection.

Inspection Generator Supervisory Equipment
Initial Inspec-
Minor Inspec-
Major Inspec-
Work required
tion
tion
tion
Check condition and performance of temperature gauges and alarms x x x
Replace gaskets at temperature measuring points x x x*
Check condition and performances 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.

Inspection Excitation System
Major Inspection
Minor Inspection
Initial Inspection
Work required
Check radial bolts for H2 leakage1) x x x

Dismantle exciter x x
Check insulation resistances of windings x x x
Replace fuses x x x
Check condition and performance of rectifier wheels, check stator and rotor windings x x
Check coupling flange x x
Check contact pin and Multikontakt-strip and, if required, replace x x
Replace Multikontakt-strip x x x*
Check alignment x x
Check bearing and pipe insulation x x
Replace bearing and pipe insulation x x*
Check bearing surfaces and babbitt bonding x x
Check bearing clearances x x
Check seating of spherical portions of bearings x x
Check labyrinth rings and, if required, replace seal strips x x
Check air filter 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
* Normally required only at every second major inspection

1)
To be performed before H2 removal: using liquid leak indicators (e.g. DIPROL) is not permissible.

Turbogenerators Measures for Preservation
Inspection
Preservation measures will have to be taken when placed into operation once a week and the entire system
a adequately flushed with water-free oil. After activation of
hydrogen-cooled generator is to be shut down for a period the oil system, the shaft should be operated on the
exceeding two months. turning gear for approximately three to four hours.
The scope of the preservation work required
depends on the duration of the shutdown, on the overall The supply of water to the bending oil and seal oil
conditions in the vicinity of the unit and on the extent to coolers is not required during this period.
which checks and maintenance are possible during
such period. 3. Coolers
The preservation measures recommended in the All coolers should be drained on their cooling water
following are sufficient under normal conditions. High sides and dried by suitable measures. During the
relative humidity in combination with severe temperature outage, the drains and vents should be kept open.
changes involves the risk that the temperature of certain Caution: Never leave water-filled coolers standing idle
surfaces in the generator may drop below the dew point, for several weeks.
resulting in the possible formation of a moisture film For cooler drying, hot air or dry ambient air may be
due to condensation on these generator components. used which should be admitted by means of blowers
In such a case, special measures may be required for via the cooling water inlet/outlet flanges. A fan-forced
preservation of the rotor retaining rings [1] heater with a rating of 1 to 2 KW has proved satisfactory
for this purpose.
1. Generator Interior
The hydrogen gas should be removed from the 4. Bright Components
generator. The stator and rotor windings should then be All accessible bright components, e.g. exposed
protected against moisture by maintaining the generator shaft portions, should be protected with a suitable
interior at a moderate temperature or in dry condition by corrosion inhibiting oil or grease. e.g. Tectyl.
suitable means. This may, for instance, be achieved by
the provision of a hot air blower or dryer. The air should 5. Seal Oil and Gas Systems
be admitted and discharged via branches at the exciter Except for the work already mentioned, no
end and turbine end manhole covers. preservation measures are required on the coolers of
Prior to recommissioning the generator, the the seal oil system.
insulation resistances of the stator and rotor windings During the weekly activation of the seal oil system
should be measured and the windings dried, if required. for turning the shaft, the system should be inspected for
proper functioning by checking all operation values.
2. Bearings and Shaft Seals All valves in the gas system should be closed. No
No preservation measures are required on the additional measures are required.
bearings of the turbogenerator and on the H2 shaft seals.
However, the bearing and seal oil systems should be

[1] 2.5-0030 Packing, Transport and Storage of Generator
Rotors
Inspection
1. Insulation Resistance Measurement

After each shutdown, the insulation resistances
Attention
should be measured prior to carrying out the inspection
Even minimal-size metallic particles left InsIde
[1], [2], [3].
after work on the generator can iead to large-scale
2. Stator Winding damage during generator operation. To prevent
Depending on the scope of the inspection, the slot such damage to the generator and the stator wind-
wedges should be checked for tight fit, and the end ing, the following precautionary measures must
windings should be inspected for proper support. be taken.
After opening the generator, the interior should
always be inspected for contamination of any kind. If 1. Only persons assigned to such work may enter
contaminations are detected, its cause should be the interior of the generator.
determined and corrected in order to preclude any new
contamination. The generator interior should be cleaned 2. Persons assigned to such work must be in the
thoroughly.
possession of clear work procedures and have
3. Terminal BushIngs been informed of special features of the work scope
The bushings and expansion joints should be Involved and of the associated potential dangers.
inspected to ensure a proper connection between the
bushings and the phase connectors. The bushings should 3. All persons entering the interior of the generator
also be checked for proper connection to the bus bars must wear clean overshoes.
arranged external to the generator.
4. Before entering the generator interior; all persons
4. Cooler Wells must empty their pockets and remove all metallic
When dismantling of the hydrogen cooler sections objects worn (such as watches, chains, earrings
is required for inspection, the cooler wells in the stator etc.).
frame should be checked for cleanliness.
5. Tools required for work inside the generator may
5. Flanged Joints and Metering Connections only be transported within boxes, and must be re-
All stator flanges should be checked for proper turned to these boxes after use.
alignment and seating. The stator should be checked for
tight anchoring to the foundation. 6. After completion of work inside the generator; the
All metering connections should be checked for
completeness of tool kits should be verified agaInst
proper mounting and condition as far as practicable. This
should include both the electrical metering connections tool lists and the results of this check logged.
and the pipe connections to the measuring instruments.
7. All winding areas on which work is to be perfonned
Prior to recommissioning, the insulation resistance
of the stator winding should be measured and, if must be covered off carefully before work is started.
necessary, improved.
8. All parts to be installed or removed should be listed,
with details of their exact whereabouts.
9. Should a part be dropped despite all the above

precautionary measures, it is imperative that it be
located and removed. Site management should
be Informed in the case of any problems in this
context.
10.Generator openings should be closed off with the

original covers for the duration of any work breaks.
11.The use of the attached check list (2.5-2001) for

Also refer to the following Information works at the generator is strictly required.
[1] 2.5-2300 Insulation Resistance Measurements on Stator
Winding
[2] 2.5-3300 Insulation Resistance Measurements on Rotor Table 1 Precautionary Measures During Work Inside
{3] 2.5-2310 Drying the Windings the Generator

Turbogenerators Check List for Works on Generator
Inspection
Description of work to be carried out to be checked by Date Name/Signature
1 Work permit for works on generator
Area around generator to be barriered off (work

passes to be issued to individual workers) and
2 supervisor to be nominated for the period the
generator is open. Closing during breaks and
process interruptions to be assured.
3 Cleanliness check of area around generator.
4 Instruction of workers regarding working inside and

around the generator
5 Listing of all tools used for repair work inside of

generator. Tools to be marked
6 Checking of inside of generator immediately after

manholes are opened (first man inside generator)
7 All opening of generator, pipework and bearings to

be temporarily covered
8 Listing of all material removed from the generator

parts to be collected in separate boxes .
9 Checking of complete generator inside prior to

closing of manholes (last man inside generator)
10 Check of whereabout of tools used inside of

generator.
11 Checking the material removed from generator
12 Release of generator for start-up .
13 Return of work permit

Turbogenerators Cementing the Joints of Profiled Gaskets
Inspection
1. Sicomet 50 Adhesive cutting take care that the profile does not suffer any visible
distortion and that the pressure applied after pulling
Profiled gaskets should preferably be cemented together the parts to be mounted is exerted on the area
together by means of Sicomet one-component adhesive. of cut (see arrow in Fig. 1). The faces to be cemented
This adhesive meets all requirements, its only together should be well roughened.
disadvantage being the difficulties encountered in storage.
Sicomet should be protected from moisture, heat 2.2 Cementing the Joint
and sunlight and should therefore be stored in a dry, cool The adhesive should be applied in drops on the joint
and dark place. To prevent an increase in viscosity and areas to be cemented together, using a plastic or metal
discoloring of the adhesive Sicomet is best stored at a spreader for obtaining a thin film. Immediately afterwards
temperature of -10°C. If stored under these Conditions, the joint faces should be assembled and located in
Sicomet has an unlimited working life. Defrost Sicomet position. Because of the short curing time of 10 to 30 s
prior to use and bring to room temperature. any readjustment will be almost impossible. After curing,
Repeated freezing and defrosting does not affect the any cement residue should be removed from the outer
bonding properties. The maximum storage time at room surface of the bonded joint by means of emery paper.
temperature is six months. The adhesive not used up Warning: Sicomet should only be used In well
must be stored at a temperature of -10 0C immediately. ventilated work areas. Care must be taken to avoid
body contact. In the event of contact with the eye,
rinse immediately with ample amounts of distilled or
2. Preparatory Work and Application of Adhesive drinking water to dilute the adhesive. The eye should
then be treated to soothe any inflammation and a
2.1 Preparatory Work physician immediately consulted.
The exact length of the profiled gasket is determined
by inserting it in the center of the sealing groove, allowing 2.3 Breaking the Cemented Joints
30 to 40 mm in length for overlapping at the joint. The Cemented joints which are to be broken should be placed
joint faces could be cut so that the overlapping portion to in a bath of either dimethyl-formamide for a brief period
be cemented is approximately 30 to 40 mm long. When or of ethylacetate for a longer time, resulting in swelling.
Fig.1 Cementing of a Profiled Gasket

Turbogenerators Mounting of Inner Labyrinth Rings
Inspection
1. General Following this, the flat gaskets and insulating

The inner labyrinth rings are to prevent the seal oil rings should be matched[3].
leaving the shaft seals on the hydrogen side from entering
into the generator interior. 3. Installing Labyrinth Rings
For this reason, the assembly of these components (if labyrinth rings are assembled after rotor insertion)
should be performed with utmost care. Place lower half labyrinth rings on rotor in their proper
axial positions for normal operation. If required, use the
crane.
The fitting device protecting the labyrinth ring from

dropping when being shifted in position should be
assembled from the lower side. Then shift the labyrinth
ring on the rotor by turning it through 180°.
1. Labyrinth ring
2. Oil baffle
Fig. 1 Labyrinth Ring and Oil Baffle
The labyrinth rings must be mounted after insertion 1. Lower half labyrinth ring
of the generator rotor and installation of the lower half 2. Bolted Joint
bearings, but before to installing the upper half end shields 3. Finning device
and baffle ring carrier. At first, the ring should be attached
to the lower half end shield only. After complete assembly Fig.2 Shifting Lower Half Labyrinth Ring in Position
of the upper half end shield, the inner labyrinth ring should
be bolted in position. Shift the lower half labyrinth ring in axial direction
At this stage, the generator rotor is not yet coupled against the flange of the end shield. Attach it provisionally
to the turbine rotor, and the hydrogen cooler sections by means of the two bolts at joint level, permitting the
are not yet installed. fitting device to be detatched afterwards.
When placing the upper half labyrinth ring in position,
To avoid contact with the shaft and the resulting flow make sure that the joints are not displaced and the taper
of shaft current the labyrinth rings must be insulated from pins can be easily inserted.
the end shields at the flanged points. Attention should The joint bolts, nuts and lock washers should then
be given to careful fitting of the insulation. After be inserted and uniformly tightened.
completion of the assembly work, the insulation of the Remove the two bolts provisionally inserted at the
labyrinth rings should be checked [2]. labyrinth ring end shield joint and shift labyrinth ring in
axial direction away from the flange up to the collar. With
2. Preparatory Work the labyrinth ring in position, insert the gasket and the
The labyrinth rings should be cleaned with a suitable insulation.
solvent. Clean the groove for the gasket and all fixing 4. Mounting Gaskets and Insulation
holes and oil drain holes in the lower .half labyrinth rings Prior to connecting the labyrinth ring to the end
with compressed air. shield, the insulation and gasket should be checked,
The mating upper and lower half labyrinth rings are marked replaced (if necessary), and placed in the proper position
TE and EE close to the joints and should be mounted [3].
accordingly. 5. Assembling Labyrinth Rings
The labyrinth rings should be provisionally assembled Shift labyrinth rings upto the flange of the end
and the length of the gasket determined and prepared[3]. shield. provide mounting bolts with insulating sleeves,

insulating washers, washers and lock washers. Insert by computing the mean value of the measured lateral
bolts from the bearing compartment side via the through labyrinth ring clearances.
holes of the end shield and screw them into the tapped The bottom clearance must always amount to 0.05 mm.
holes of the labyrinth ring. In case the clearance distribution should not
Fit the centering devices. Tighten the fixing screws correspond to Fig. 4, a readjustment should be made by
uniformly and lightly, but do not yet secure the screws. reworking or using new centering devices in order to
Measure the insulation resistance and compare with obtain the specified clearance distribution.
the value measured previously [2]. If the actual clearances do not correspond to the
required clearances, reworking of the labyrinth ring will
be necessary. In case of excessive clearances, new seal
strips will have to be fitted [4].
7. Readjusting Labyrinth Rings

The centering devices should be removed and
marked for identification of their mounting position. The
mounting bolts of the labyrinth ring should then be slightly
loosened and the labyrinth ring shifted by means of a
mounting iron and wooden block in order to obtain the
specified clearance distribution. When inserting the
mounting iron be sure not to damage any parts.
Retighten the mounting bolts when the specified
1 2 3 clearance distribution has been obtained and check the
1. Labyrinth Ring clearances again after tightening.
2. Lower Half End Shield Check the centering devices for reusability (after
3. Rotor Shaft slight reworking) or mix-up and reinstall them with tight
fit. If this should not be practicable, manufacture new
Fig. 3. Mounting of Labyrinth Ring at End Shield centering devices.
6. Checking Labyrinth Ring Clearances 8. Reworking Labyrinth Rings

The labyrinth rings are adjusted during assembly at The labyrinth rings must be removed for performing
the manufacturer’s works and located in position by this work.
means of insulated centering devices. Determine the steps to be performed on a lathe on
To check the radial clearances, measure the gap the basis of the actual clearances. Use the actual
between the caulked seal strips and the shaft at two clearances also as a reference for judging whether a
opposite points each of the horizontal and vertical readjustment of the labyrinth ring and new matching of
centerlines. the centering devices will become necessary after
Use air gap gauges or feeler gauges (0.02 mm completion of the reconditioning work.
steps) for making the measurements. The clearances
measured should be plotted in a coordinate system and 9. Fitting New Seal Strips
compared with the reference dimensions. In case of excessive actual clearances, new seal
See the specific drawing Axial and Radial Rotor strips must be fitted. To do this, remove the old seal strips
Clearances for the required labyrinth ring clearances. and insert new seal strips [4]. New seal strips are available
Normally, these dimensions correspond to the from BHEL Works.
bearing clearances in the following configuration:
The actual top clearance is determined by adding 10. Final Assembly of labyrinth Rings
the measured top and bottom labyrinth ring clearances After assembly of the labyrinth rings with the
and deductmg 0.05 mm. The actual lateral clearance is specified clearances, check the insulation and compare
determined the results with those of previous measurements. If the
Bearing top clearance -0.05 mm results correspond to the specified minimum values, place
the upper half end shield in position.
Bolt the labyrinth ring to the upper half end shield
1/2 bearing top clearance 1/2 bearing top clearance only after the upper half end shield has been completely
attached to the stator frame and bolted to the lower half
at the joint. When bolting the labyrinth ring, check
0.05 mm insulating sleeves, insulating washers, washers and
lock washers for correct location.
Finally, check all flange bolts again for uniform tightening.
Then check again the insulation resistance of the
labyrinth ring insulation.
With satisfactory insulation, secure all bolts on the
Fig.4 Distribution of Labyrinth Ring Clearance in circumference as well as the joint bolts and nuts. Check
Circumference the insulation resistance again.

11. Mounting Oil Baffles If the actual clearances do not correspond to the required
After final assembly of the labyrinth ring, fit the split clearances, readjustment. reworking or fitting of new seal
oil wiper ring. The required radial clearance relative to strips will become necessary in the same way as in case
the shaft is specified on the specific drawing. Distribute of the labyrinth ring.
the radial clearance on the circumference in the same
way as in case of the labyrinth ring (see Fig. 4).
1. Stator end shield

2. Inner labyrinth ring
Fig.5 Assembled Inner Labyrinth Ring

[1] 2.5-3100 Rotor insertion
[2] 2.5-0300 Checking the Bearing and Seal insulation
[3] 2.5-6110 Insulation and Sealing of shaft currents
[4] 2.5-2163 Fitting New Seal Strips to Labyrinth Rings
Turbogenerators Generator Drying System
Inspection
1. General The moisture adsorbed by the dryer wheel is

A dryer (dehumidifier) should be connected to the removed in a regeneration section by a stream of hot air
generator to avoid the formation of moisture condensate directed through the wheel in the opposite direction of
inside the stator frame housing with the turbine-generator the inlet air and then discharged to the atmosphere.
at rest after removal of the hydrogen gas or during After regeneration, the dryer wheel material is again
overhauls. The dry air inlet and outlet connections are capable of absorbing moisture.
located in the stator end shields. The adsorption of moisture and regeneration of the
dryer wheel material take place simultaneously, using
For connection of the dryer, the covers in the upper separate air streams, which ensures a continuous drying
half end shields should be removed and replaced by the of the air.
covers comprising the dryer connection branches. The
dryer should be connected with flexible hoses and then
3. Operating Principle of Adsorption Dryers
placed into operation.
Dehumidification takes place in a slowly rotating
dryer wheel (approximately 7 revolutions per hour). The
honeycomb dryer wheel consists of a magnesium silica
alloy containing crystalline lithium chloride. 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. Regeneration air outlet 5. Filter

2. Dryer wheel 6. Dry air outlet
3. Heater 7. Shutoff valve, motor driven
4 Ventilator
Fig.2 Schematic Diagram
4. Adsorption Section of Dryer

1. Stator frame 3 End shield
2. Cover The air to be dehumidified passes through the
Fig. 1 End Shields adsorption section of the dryer wheel, with part of the
moisture contained in the air being removed by the
adsorbent material, i.e. lithium chloride. The moisture is
2. Mode of Operation of Dryer removed as a result of the partial pressure drop existing
The dryer dehumidifies the air within the stator frame between the air and the adsorbent material.
housing. The dryer whee! is made of a nonflammable
material. On its inlet side, the wheel is provided with a 5. Regeneration Section of Dryer
system of tubular ducts, the surfaces of which are
impregnated with a highly hygroscopic material. In the regeneration section of the dryer wheel, the
accumulated moisture is removed from the dryer wheel
The tubular ducts are dimensioned so that a laminar by the heated regeneration air.
flow with low pressure loss is obtained even at high air Continuous rotation of the dryer wheel ensures
velocity. continuous dehumidification of the air.

Turbogenerators Fitting New Seal Strips to Labyrinth Rings
Inspection
1. General
During initial installation or inspection of the unit the
radial clearances between the caulked-in seal strips of
the labyrinth rings and the shaft should be measured.
For required labyrinth ring clearances, see the binding
drawing Erection and Setting Clearances. If the actual
clearances are excessive, new seal strips should be
fitted to the labyrinth rings. To do this, the old seal strips
should be removed and replaced by new ones. New
seal strips are available from stock at BHEL Works.
2. Tools
The tools shown below are required for removal and
fitting of seal strips.
Fig.2 Driving Out Seal Strip
1. Scraper
2. Sharpening tool
3. Smooth file
Fig.3 Pulling Out Seal Strip
4. Caulking tool
5. Pincers
6. Turn-out tool
7. Drift key
8. Hammer
Fig.1 Tools Required for Fitting New Seal Strips to

Labyrinth Rings
3. Removing Seal Strips

For removal of the old seal strips, a chisel, screw-
driver or similar device should be sharpened so that it
fits into the labyrinth ring groove. Apply auxiliary tool to
the seal strip at the abyrinth ring joint and drive out seal
strip by light hammer bIows until the turn-out tool can be
applied. The machined slot in the turn-out tool should be
pushed over the caulked seal strip ind the seal strip
pulled out by turning the turn-out tool. Fig.4 Seal Strip, Pulled Out

4. Cutting New Seal Strips to Length
The new seal strips to be fitted are delivered in the
form of a coil approximately 300 mm (11.8in.) in diameter.
From this coil the required length including a sufficient
allowance for one groove of the half labyrinth ring should
be cut by means of pincers. Bend seal strip by hand so
that its diameter matches the diameter of the labyrinth
ring. Cut seal strip to required length with an allowance
of 2 to 3cm (0.8-1.2in.). Using this strip as a sample. the
half rings required for the remaining number of grooves
should be cut from the coil and bent as described above.
5. Caulking New Seal Strips

Insert seal strip into groove at bottom center of
labyrinth ring and gradually drive seal strip into the groove
over its full length by applying light hammer blows to the Fig. 6 Cutting Projecting Seal Strip Ends
caulking tool.
Fig. 7 Finishing Seal Strip Ends by Means of a Smooth

File
Fig. 5 Driving in Seal Strips
Note: Joint surface is super-finished and must not be
damaged.
Note: Never drive home seal strip to slot bottom
After all seal strips have been caulked in and finished
immediately as this may result In lateral distortions
at the joint, the joint surface should be checked by means
of the seal strip.
of a bar for colorprint control and, if required, reworked
Starting again at the bottom center, proceed to drive
with a scraper.
in the seal strip lightly in direction towards the labyrinth
ring joint. It is recommended to move the caulking tool
along the seal strip several times in opposite directions,
applying light hammer blows until the seal strip beds
against the groove bottom. With the strip in this position,
the caulking tool touches the inner diameter of the
labyrinth ring. Avoid hard hammer blows, as otherwise
the caulked-in seal strip will be unduly squeezed. In
addition, this would necessitate remachining of the groove
prior to inserting a new seal strip.
6. Finishing Seal Strips at Labyrinth Ring Joint

After caulking of each seal strip, the strip end
projecting from the joint should be cut by means of
pincers. The remaining 1 to 2 mm (0.04-0.08in.) should
be carefully removed by means of a smooth file after Fig.8 Checking the Joint with a Bar for Color Print
caulking of all seal strips. Control

Fig. 10 Sharpening Seal Strips
8. Sharpening Seal Strips
Fig. 9 Rescraping Joint Surface. Turning the inside diameter of the labyrinth rings
results in blunt seal strips The seal strips must therefore
be sharpened by means of a special sharpening tool prior
7. Turning Inside Diameter of labyrinth Ring to assembly. After completion of this work, the half
After color print control. the half labyrinth rings labyrinth rings should be bolted together again.
should be assembled according to the marks and then
turned on a lathe to suit the shaft dimensions and
Caution: Wear leather gloves while sharpening the
clearances specified on the drawing Erection and
Setting Clearances. strip to prevent injuries.

Turbogenerators Insulation Resistance Measurements
Inspection on Stator Winding
During manufacture and transport, the insulation of correction to an agreed reference temperature (formerly
the stator winding may have been exposed to moisture 75 °C) must be made.
which would reduce the insulation resistance of the An insulation resistance of 1 megohm per each
windings. The insulation resistance should therefore be kilovolt of rated voltage at 75 °C is normally attainable
measured prior to initial start-up. after prolonged without any difficulties.
shutdowns and after work on the windings. If required, New international standards specify an insulation
the generator should be dried until a sufficient insulation resistance of not less than 1 megohm per each kilovolt
resistance is obtained. of rated generator voltage at 40 0C.
A correction of the insulation resistance measured
1. Required Insulation Resistance of Stator at the winding temperature prevailing during the
Winding measurement to the above reference temperature can
be made using the diagram in Fig. 1.
If the insulation resistance measured is lower than
the specified minimum value, the neutral connections
must be separated and the insulation resistances of the
individual winding phases measured. During the test, the
other two phases which are not involved should be
grounded. If the insulation resistances of the individual
phases are likewise lower than the required limit value,
drying of the windings will be indispensable. Great
differences in the insulation resistance values are
indicative of local contaminations, e.g. insulators in bus
duct or terminal bushings. If practicable additional
connections should be separated.
If this measure does not result in an improvement, it
is recommended to obtain the services of a specialist
from the manufacturer’s works.
2. Measurement of Insulation Resistance

Prior to each measurement, the generator must be
de-excited and any static charges removed by grounding
the winding. The windings should also be grounded after
each measurement for the duration of the recharging
period.
The insulation resistance of the stator is measured
between the winding copper and the stator core.
Note: When the generator is filled with hydrogen,
make sure that the rotor shaft ends are properly
grounded during measurement and discharging.
The measurement should be made with a megger
giving a scale reading of not less than 1000 megohm.
The megger voltage should be not less than 1000 V, but
Fig.1 Diagram for Correction of Insulation Resistance may amount to up to 5000 V. The insu1ation resistance
measured to a Temperature of 400 C should be read after one minute.
The insulation resistance measured is dependent
on the temperature. To permit a proper assessment, a

Turbogenerators Drying the Windings
Inspection
The epoxy resin insulation used for the stator wind- Should this not be the case, the generator will have to be
ing absorbs practically no moisture. Any reduction of the de-excited and the cause of the non-uniformity (e.g. poor
insulation resistance during transport, erection or a pro- contact of buses) removed.
longed shutdown is mostly caused by a moisture film on
the surface of the insulation. To prevent damage to the The stator winding temperature and the hot and cold
insulation, it will be necessary to check the insulation gas temperatures should be brought to the maximum
resistance of the stator and rotor windings prior to run- operating values by slowly raising the field current.
ning up the unit to full voltage. In case of an insufficient
insulation resistance being detected, a drying procedure During drying, the absorbent materia! in the gas
should be performed first. dryer should be carefully observed. When the gas dryer
Drying should preferably be carried out with the gen- filling is no lorger active, reactivation should be carried
erator filled with hydrogen, making sure that the gas dryer out.
is in operation and that the absorbent material is suffi- During drying, the generator should be occasionally
ciently active. de-excited and run down for measurement of the
The stator winding should be short-circuited at the insulation resistances. In the event of sufficient insulation
bushings by means of buses. The buses should be fitted resistances being obtained, short-circuit drying may be
so as to permit a measurement of the short-circuit cur- stopped.
rent by means of current transformers. Remove the short-circuit at the bushings. Following
Run up the turbine-generator to rated speed and this, the generator may be run up to full voltage.
excite generator. As a result of this, a current in accor- In the event of a prolonged shutdown of the
dance with the short-circuit characteristic will flow in the generator, it is preferred that the hydrogen filling be
stator winding. The currents in the three phases should retained in the generator, thereby eliminating surface
be of identical magnitude. moisture on the windings.

Turbogenerators Treatment of Bolted Contact Surfaces
Inspection
1. General of a cloth wetted with solvent. In the case of the terminal

The silver-plated contact surfaces and the bright bushings make sure that the insulators never come into
copper surfaces of the contact faces should be treated contact with the solvent.
with contact grease primarily to fill up the gaps remain- Copper surfaces without silver coating should be
ing after bolting. cleaned and degreased by means of solvent after emery-
In addition, the contact grease improves the electri- polishing.
cal conductivity of the contact surfaces, it is chemically After this preparatory treatment, apply the contact
inert and water-repellent, it does not dry up, it cleans grease to the contact surfaces with clean fingers in such
oxidized contact surfaces and protects them against cor- a quantity that a little excess grease is pressed out all
rosion. around on bolting of the contact faces.
Contact grease has a grease-like, pasty consistency. If greased surfaces are soiled prior to making the
bolted connection, these should be cleaned and greased
anew.
2. Application
Excess contact grease should be wiped off with a
Degrease silver-plated contact surfaces by means
clean rag.

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

[1] 2.5-3300 Insulation Resistance Measurements on Rotor
and Exciter Windings
[2] 2.5-2310 Drying the Windings

Turbogenerators Insulation Resistance Measurements
Inspection on Rotor Winding
During manufacture and transport, the insulation of Note: When the generator Is filled with hydrogen,
the rotor winding may have been exposed to moisture make sure that the rotor shaft ends are properly
which would reduce the insulation resistance of the grounded during measurement and discharging.
winding. The insulation resistance should therefore be
measured prior to initial startup, after prolonged
shutdowns and after work on the winding. If required.
the generator should be dried until a sufficient insulation
resistance is obtained.
1. Required Insulation Resistance of Rotor

Winding
The insulation resistance should amount to > 1
megohm at 40°C (104°F).
At winding temperatures other than 40 °C, a
correction can be made using the curve shown in Fig. 1.
2. Measurement of Insulation Resistance

Prior to each measurement, the generator must be
de-excited and any static charges removed by grounding
the winding.
The insulation resistance should be measured
between one slipring and the generator shaft, using a
megger with a voltage < 500 V. This voltage will present
no danger to any of the devices in the excitation circuit.
The duration of the test should be approximately two
minutes. After each measurement, the winding
capacitance should be discharged for not less than two
minutes.
The insulation resistance of the entire excitation
circuit should be measured with the brushes applied. If
an insufficient insulation resistance value is obtained, all
slipring carbon brushes should be lifted off and separate
measurements conducted on the rotor winding and
excitation circuit.
Fig.1 Correction Curve for Insulation Resistance
Measured (Rmeas) to a Temperature of 400C

Turbogenerators Ultrasonic Examination of
Inspection Rotor Retaining Rings at Power Plants
Austenitic retaining rings manufactured from 3 Execution of Ultrasonic Examination

X55MnCr(N)18k steel are sensitive to stress To perform the examination, the rotor must be
corrosion. If these retaining rings are kept for removed and supported so that an inspection is
persisting sufficiently long in an unfavorable practicable on the entire circumference of the retaining
environment during storage, operation or outages, ring. The coating of the retaining ring should be
stress corrosion may lead to crack initiation and stripped with a paint remover. Care should be taken
crack growth. In addition to preventive measures to to ensure that the winding and insulating parts do not
avoid stress corrosion, it is advisable to arrange for come into contact with the paint remover. Openings in
examination of the retaining rings at the power plant. the pole areas and the gaps between the retaining
ring and rotor body should be sealed.
Such an examination is urgently required after
disturbances during which the retaining rings are
After completion of the examination, the oil-wetted
exposed to moisture. In the following the use of the
portions of the retaining ring should be decreased
ultrasonic inspection method for nondestructive with a solvent. When performing cleaning work care
examination is outlined and recommendations are should be taken to ensure that the winding and
given on the test procedure. insulating parts do not come into contact with the
solvent. The retaining ring should then be repainted
1. Purpose and Scope of Ultrasonic and the rotor reinserted.
Examination
Ultrasonic examination of the shrink fitted retaining Approximately three days are required for
rings serves to detect incipient cracks and particularly preparations and execution of the examination,
those which have already grown to a dangerous size. including repainting of the retaining rings.
The examination can only be performed with the rotor
withdrawn. It is therefore recommended to subject the
retaining rings to such an examination during a major
overhaul involving the withdrawal of the rotor.
In addition, it is recommended to repeat this
examination at regular intervals. Any changes detected
when comparing the test results with the previous
results provide useful information for assessing the
integrity of the retaining rings. 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.
2. Flaw Detection
Ultrasonic examination of the shrink-fitted retaining
rings inevitably also involves the generation of spurious
echoes, resulting in 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. Based on previous
experience and using special probe heads and.
reference blocks, the BHEL specialists are in a position fig. I Ultrasonic Examination of Rotor Retaining Ring
to determine with a high degree of probability the flaw
size from the indications obtained. According to
experience so far available, the detectable flaw size is
far below the critical flaw size that may result in a sudden
forced rupture. If the echoes reflected by a flaw are
markedly above the spurious echo level of the inner
periphery and can be interpreted as incipient cracks
with a high degree of probability, it is recommended to
pull off the respective retaining ring for further
examination.

Turbogenerators Hydrogen Cooler
Inspection
1. General Gas Side:

Depending on the extent of the inspection, the P3 Grato 90 Henkel KGaA. Dusseldorf
hydrogen cooler sections should be cleaned thoroughly Ameroid ACC9 Drew Ameroid GmbH, Hamburg
both on the gas and water sides. During a less extensive Vecom B-85 Vecom GmbH, Hamburg
inspection, when the hydrogen is left in the generator, Equipment Required:
the tubes should be cleaned on the water side only. For Pump
this purpose, no withdrawal of the cooler sections will be
Vessel
necessary.
Piping
The cooler cleaning interval depends on the cooling
Shutoff fittings
water condition and is indicated when a substantial
reduction of the heat removal capacity is observed at Cleaning agents
the cooler sections. A repetition of the tube cleaning every Close water inlet valves and then open vent and
two months may be necessary when the cooling water is drain valves. Drain water from cooler sections. Close
heavily contaminated. It may be possible, however, that drain valves and water outlet valves. Connect circulating
the interval between one cleaning and the next may pump to cleaning circuit via water inlet and outlet pipes.
amount to several years. It is recommended to perform Fill system. Close vent valves and circulate cleaning
the first cleaning operation two months after initial agent through the circuit. After cleaning, thoroughly flush
commissioning. The date at which the next cleaning will circuit with water.
be required can be determined at that time. The intervals Remove cleaning equipment and place water circuit
for cleaning can, however, be definitely fixed only after in service again. It is advisabie, in the event of sufficient
several years of operation. experience not being available, to have such chemical
The coolers should be withdrawn from their wells cleaning work performed by specialist firms.
when more extensive inspection work is required. After Caution: When performing chemical cleaning work
withdrawal, the coolers should be thoroughly inspected be sure to observe the applicable instructions for the
on the gas side. On detection of any contamination, the handling of chemicals.
gas side should be cleaned by means of dry and clean
compressed air. The coolers should then be installed in 4. Hydraulic CleanIng
the generator housing, using new gaskets for reassembly. Close water inlet valves at the individual cooler
section and then open vent and drain valves. Detach
2. Mechanical Cleaning on Water Side retum water channel after the water has been drained
For this purpose, no withdrawal of the cooler sections from the cooler.
will be necessary.
Close water inlet valves at the individual cooler High-Pressure Water Spray Cleaning
sections and then open vent and drain valves for a short Connect high-pressure water spray cleaning unit and
period. push spray nozzle into each individual tube.
Detach return water channels after the water level
in the cooler tubes has been lowered. Steam Cleaning
The tubes are cleaned by special brushes, which Connect steam lance to a steam generator or
are moved up and down in the individual tubes of the operating steam supply. Insert steam lance into each
tube bundle. After all tubes are brushed, a new flat gasket individual tube.
should be fitted and the return water channel bolted tightly After cleaning remove cleaning equipment. Refit
to the tube sheet of the cooler section. This should be return water channels, using only new gaskets and place
followed by reopening the inlet and outlet valves, whereby water circuit in service again.
the tube bundle is flushed with cooling water.
Cleaning Cooler on Gas Side
3. Chemical Cleaning To do this, the cooler sections must be removed
Brushing of the tubes normally suffices for cleaning. according to the respective instruction and set down on
Any scale deposits which cannot be removed by brushing a support. To remove minor contaminations, clean the
should be dissolved with a chemical solution. fins and tubes with dry compressed air. In case of more
The following commercially available cleaning agents are severe fouling, high-pressure water spray cleaning may
recommended: be used. Recommended pressure 120 bar with 3 mm
Water Side: dia, spray nozzle. Distance between spray nozzle and
Cleaning agent Manufacturer tube bundle should be approximately 2 meters.
P3-288 Henkel KGaA, Dusseldorf
SAF-ACID Drew Ameroid GmbH, Hamburg
Vecom BA-S Vecom GmbH, Hamburg Also refer to the following information
[1] 2.3-5003 Hints for cooler operation

Turbogenerators Bearings
Inspection
The insulation resistance of insulated bearings resistance has been previously measured, the respective
should be measured prior to each inspection. The bearing should be inspected thoroughly for any damage
bearings should then be dismantled and cleaned by cathodic action. Clean the insulation at the bearing
thoroughly. Bearing sleeves and shaft journals should saddle, as otherwise the insulation properties are
be checked for proper condition. If grooves are detected affected. The inspection procedure described above
the manufacturer should be asked for advice whether should be performed at all sleeve bearings of the turbine
the bearings may be used further. If a low insulation generator.

Inspection
The inspection of shaft seal rings and seal ring displaying signs of wear shall be replaced or
carriers is performed as follows: reworked.
If the components are not dismantled for the In addition, the contact surfaces shall be examined
inspection, the insulating effect of the shaft seal with for fractures and scoring marks. This is particularly
regard to the generator casing can only be measured required if parameters such as seal oil pressure, seal
via the shaft current. oil volume, H 2 side seal oil temperature, etc.
If the seal ring is removed, the clearances between displayed fluctuations in the operating period prior
seal strips of the labyrinth rings and the shaft must to the inspection. Liquid penetrant testing may be
be recorded prior to removing the seal ring. During performed to obtain more accurate results.
the removal, the condition of all shaft seal
components and particularly that of insulating Reassembly of the shaft seals should be performed
elements such as flange insulation and insulation with utmost care.
barriers shall be checked. During each inspection. a check should be made to
Following removal of the shaft seal, all components ensure that the seal rings are still sufficiently insulated
shall be cleaned thoroughly. Any components from the stator frame.

Inspection
The work to be performed at an inspection is very 3. Safety Valves

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

Turbogenerators Seal Oil Pumps and
Inspection Bearing Vapor Exhausters
1. Electrical Motors of Seal Oil Pumps 2. Seal Oil Pumps

At the manufacturer’s works, the antifriction bearings Disassemble the seal oil pumps. Check whether the
of the seal oil pump motors are packed with grease dummy pistons, the screws or the deep-groove ball
sufficient to give troublefree service for a period of two to bearing are worn. The passage in the casing insert and
three years. For this purpose, a grease on lithium-soap the sliding rings should also be checked. The seal rings
base with a drop point above 160 0C is used. The period and gaskets should be examined for tight sealing and
will be shorter under onerous service conditions or at replaced, if required.
high ambient temperatures. On expiry of this period, a Prior to recommissioning the seal oil system, add a
thorough cleaning of the bearing interior and an inspection small quantity of turbine oil via the oil filling plugs on the
for wear will be required. This work necessitates a seal oil pumps to ensure proper lubrication of the shaft
withdrawal of the armature, followed by washing the seal and the necessary sealing of the screws for suction.
bearing shield bore, the bearings and the bearing covers
with light petroleum to which a small quantity of oil was
added, until the grease is completely removed. The 3. Bearing Vapor Exhausters
bearings should then be packed with grease of the same The antifriction bearings of the exhauster motors
grade, taking care that both sides of the cages are normally require no maintenance.
covered with grease so that an effective seal is obtained After approximately 8000 operating hours, the
against the ingress of foreign matter. The unit can then bearing vapor exhausters should be thoroughly examined.
be reassembled. After reassembly, a check should be The motor should be disassembled and the bearings
made whether the shaft turns properly in the bearings. cleaned and packed with new high melting point grease
Measure the carbon brush wear on dc motors. If the or replaced by new bearings. Remove the old grease
brushes are heavily worn, new carbon brushes should from the regreasing device and check the packing washer
be installed. and seals for wear. If necessary, replace the packing
Measure the insulation resistance between the washer and seals. Be sure to observe the specified order
windings and ground with a 500 V megger. If the of the spring washers and spacers when reassembling
insulation resistances does not comply with the related the unit. On recommissioning of the unit, measure the
equipment manuals, the motors should be dried in an vacuum in the bearing compartments.
oven at approximately 700C for several hours.

Turbogenerators Vaccum Pump
Inspection Type S4B
1. Draining 011 From Vacuum Pump Open exhaust filter and clean or replace the filter
Remove the oil drain plug to drain the oil from the element. Clean interior of filter housing and inspect float
pump. When the oil flow decreases, start and immediately valve for free movement. Clean oil filter in vacuum pump
stop the pump to drain the residual oil. after removal of the oil reservoir.
Push the two spring clips in outward direction each
and lift off the holding frame. Then carefully lift off the
2. Draining Oil from Drain Trap and Exhaust Filter filter. Clean filter or replace it with a new filter. Reassemble
Open drain cock at drain trap to drain the liquid from pump.
the trap [1]. Remove the oil drain plug from the exhaust
filter to drain the oil. 4. Filling Vacuum Pump With Oil
After the pump has been completely reassembled,
fill pump with oil via the intake port. Keep the pump
3 Cleaning Pump Components and Replacing Filters
running for not less than 10 minutes and then drain the
A wire mesh strainer placed In the intake port of the
oil. If the oil drained is clean, fill the vacuum pump and
vacuum pump serves to arrest coarse matter. This wire
the exhaust filter with grade N62 special oil or an
mesh strainer should be removed and cleaned.
equivalent mineral oil up to the maximum oil level marks.

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


Inspection
1. General 2. Work to be Performed

2.1 Dust Filters before the Pressure Reducers
The work to be perfomed at an inspection is very Cleaning the dust filters before the pressure reducers.
difficult to determine in advance. The scope of this work Replace, if required.
depends on what defects were detected from the date of
the last inspection. The operating log should be checked 2.2 Pressure Reducer
to determine which deficiences should be corrected at Check and, if required, replace the pressure reducer
the inspection. diaphragms.
The main purpose of an inspection of the gas
2.3 Valves
system is to restore a satisfactory gastightness. All pipe
Check all valves of the gas system for leaks. If
connections of the gas system should be checked for
required, replace the diaphragms and valve inserts.
leaks [1] before the unit is shut down. All leaks should
be marked and corrected during the inspection.
After completion of all inspection work on the gas
In addition, the scope of inspection work depends system, the gas system and generator should be leak
on the intervals between Inspections. the scope of the tested.
work performed during the preceding inspection and on
the time available. During a full-scale inspection the parts The electrical purity meter system should be
listed under items a, band c should always be replaced. calibrated with pure CO2 and H2.
Depending on the inspection conditions, the following
work should normally be perfomed:


Turbogenerators Excitation System
Inspection Exciter
1. General 8. Make-Up Air Filters

The scope of work to be performed during an The filter mats of the make-up air filters should be
inspection depends mainly on the equipment on which cleaned or replaced. Slightly, contaminated filter mats
defect have been detected since the last inspection. It should be beaten out or washed in a cold to lukewarm
will therefore be necessary to extract from the operating water bath (300C maximum), adding a detergent (e.g.
log all deficiencies to be corrected during the inspection. Pril). When placing the filter mats in the water bath, make
In accordance with the Inspection Schedule [1] the sure that the air inlet side points downward. After washing
following inspection work should be performed. the filter mats should be rinsed with clean water.
2. Hydrogen Leakage Test With Coupled Exciter

Rotor 9. Bearing and Labyrinth Rings
Prior to removing the hydrogen gas from the Check the insulation of the bearing pipe connection
generator casing, the dc field connections should be leak and labyrinth rings. For details see the respective
tested. instruction [6].
If the bearing babbit is found scored our erection
3. Hydrogen Leakage Test With Uncoupled Exciter engineer should be consulted regarding the further use
Rotor of the bearing.
With the rotor uncoupled the same leakage tests The seal strips of the labyrinth rings should be
using helium gas should be performed as on the checked for proper condition and replaced if required.
generator rotor [2].
4. Dismantling and Cleaning the Exciter 10. Checking the Contact Pins and Plug in Socket
Remove exciter rotor. The coupling flange at the rotor Strips
should be checked both at the guide flange and at the The contact pins and plug-in socket strips should
coupling bolt holes. Check coupling bolts for proper be checked for proper mechanical condition. If the silver
condition and take dimensions. plating of the contact pins shows signs of are erosion,
Any accumulations of dirt in the ventilating air ducts the contact pins require reconditioning and replating. A
of the rotor, at the diodes, fuses and heat sinks must be check should be made to ensure that the projecting
removed. Cleaning should be done very carefully to avoid contacts of the plug in socket strips are spuatly distributed
damage to the numerous insulated parts. If is therefore on the entire circumference of the contact sleeve.
recommended to remove these contaminations with a 1 2
brush cloth (non-lining) and a vacuum cleaner. Particular
care should be exercised when cleaning the porcelain
bodies of the diodes.
5. Measuring the Insulation Resistances of the

Windings
Disconnect cables at stator terminal boards of the
pilot and main exciters.
Remove measuring brushes of ground fault detection
system from sliprings.
The insulation resistances to ground of the individual
windings should be measured with a megger. For details
see the repective instruction [3].
6. Drying the Windings

If the exciter dryer is not in operation due to special
circumstances during a prolonged outage of the exciter
the resulting formation of a moisture film on the surface
of the winding may lead to a reduced insulation
resistance. If the dryer cannot be placed in operation hot
air should be admitted into the exciter by means of a
fan-forced heater with a rating of approximately 2 KW.
1. Coupling flange 2. Multikontakt plug
7. Checking the Diodes, Fuses and Rectifier Wheels
For details see the respective instructions [4], [5]. Fig.1 Multikontakt Connector

11. 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.
Ensure to insert the carbon brushes of the specified grade
which match the slipring contour. After complete
assembly of the exciter, the complete ground fault
detection system should be subjected to a functional test.
12. Cleaning the Exciter Coolers

Depending on the degree of fouling on the water
and air sides, the coolers should be removed and cleaned
[7].
1. Insulation
2. Contact sleeve
3. Plug-in contact strip
Fig.2 Section Through Contact Sleeve

[1] 2.5-1090 Inspection Schedue-Excitation System
[2] 2.5-3000 Rotor
[3] 2.5-3300 Insulation Resistance Measurements on Rotor
and Exciter Windings
[4] 2.5-9010 Checking the Insulation Resistance of the
Heat Sink Insulation
[5] 2.3-9901 Fuses on Rectifier Wheels
[6] 2.5-0300 Checking the Bearing and Seal Insulation
[7] 2.4-9440 Exciter Coolers

Inspection Checking the Insulation Resistance
of the Heat Sink Insulation
Regular inspection work should include checking the would then no longer the ensured, resulting in a phase-
insulating sections between the diode heat sinks and to-phase fault in the main exciter circuit.
rectifier wheels [1]. Leakage paths may be formed at After removal of the fuses, the insulation resistance
these points as a result of dirt deposits, rendering the between points a and b or a1 and b1 respectively, can be
fuses connected after the diodes ineffective in the event measured by means of a megger, applying a voltage of
of a failure. 500 to 1000 V. The insulation resistance between the
In the event of a diode losing its blocking capability, heat sink and rectifier wheel should not be less than 10
an interruption of the respective bridge arm by the fuse MΩ.

[1] 2.5-9011 Checking the Insulation at Rectifier Wheels

Inspection Checking the Insulation
at Rectifier Wheels
1. Fuse
2. Heat sink
3. Diode
4. Rectifier wheel (negative polarity) Current path
5. Tension bolt
6. Terminal bolt
3 1 4
7. Hot air outlet
8. Rectifier wheel (positive polarity)
9. Insulation
10. AC lead
11. DC lead
Detail X

Turbogenerators Exciter Cooler
Inspection
1. Generator This should be followed by reopening the inlet and outlet

Depending on the extent of the inspection. The valves, where by the tube bundle is flushed with cooling
exciter cooler sections should be cleaned thoroughly both water.
on the gas and water sides. During a less extensive
inspection, the Tubes should be cleaned on the water 3. Chemical Cleaning
side only. For this purpose, no withdrawal of the cooler Brushing of the tubes normally suffices for cleaning.
sections will be necessary. Any scale deposits which cannot be removed by brushing
The cooler cleaning interval depends on the cooling should be dissolved with a chemical solution.
water condition [1] and is indicated when a substantial Close Water Inlet valve and then open vent and drain
redution of the heat removal capacity is observed at the valves. Drain water from cooler sections. Close drain
cooler section. A repetition of the tube cleaning every valves and water outlet valves. Connect circulating pump
two months may be necessary when the cooling water to cleaning circuit via water Inlet and outlet pipes. Fit
Ia heavily contaminated. It may be possible, however system. Close vent valves and circulate cleaning agent
that the interval between one cleaning and the next may through the circuit. After cleaning thoroughly flush circuit
amount to several years. It is recommended to perform with water.
the first cleaning operation two months after initial Remove cleaning equipment. Refit return water
commissioning. The date at which the next cleaning will channel using only a new gasket and place water circuit
be required can be determined at that time. The intervals again. It is advisable, in the event of sufficient experience
for cleaning can however, be definitely fixed only after not being available, to have such chemical cleaning work
several years of operation. performed by specialist firms.
The coolers should be withdrawn from their wells Caution: When performing chemical cleaning work, be
when more extensive inspection work is required. After sure to observe the applicable Instructions for the handling
withdrawal, the coolers should be thoroughly inspected of chemicals.
on the air side. On detection of any contamination, the
air side should be cleaned by means of dry and clean
4. Hydraulic Cleaning
compressed air. The coolers should then be installed, Close water inlet valves at the individual cooler
using new gaskets for reassembly. section and then open vent and drain valves. Remove
cooler after the water has been completely drained from
the cooler.
2. Mechanical Cleaning on Water Side
For this purpose, no withdrawal of the cooler sections High-pressure Water Spray Cleaning
will be necessary. Connect high -pressure water spray cleaning unit
Close water inlet valve at the individual cooler and push spray nozzle into each individual tube.
sections and then open vent and drain valves. Steam Cleaning
The tubes are cleaned by special brushes, which Connect steam lance to a steam generator or
are moved up and down in the individual tubes of the operating steam supply. Insert steam lance into each
tube bundle. After all tubes are well brushed, a new flat individual tube. After cleaning, remove cleaning
gasket should be fitted and the return water channel equipment. Refit return water channel, using only a
bofted tightly to the tubes sheet of the cooler section. new gasket and place water circuit in service again.


Turbogenerators Introduction
Appendix
The Appendix contains the following information:

z General Information
z Bibliography
General Information
This includes information required in all parts
of the Manual,
Symbols
Abbreviations
Units
Bibliography
This includes the most important papers in
the field of turbogenerators.

Turbogenerators Symbols for Supply Circuits and
Appendix Supervisory Equipment
Piping
Liquid Control valve, motor operated
Air
Shutoff valve, solenoid operation
Combustible gas
Control valve, piston operated
Non – combustible gas
Control valve, hydraulically or pneumatically operated
Waste gas (combustible/non-combustible gas)

Pressure relief valve, spring loaded
Process flow line, signal line

Pressure relief valve, spring loaded, safety function
Lines, crossing
Level control valve
Lines, joining
Restricting orifice
Tee branch
Sight glass
Loop, siphon Mixing section
Flexible line Orifice plate
Drain funnel
Heat Exchager and Tanks
Drain trough
Generator cooler (hydrogen / air)
Exhaust to atmosphere above roof
Electric heater, CO2 – flash evaporator
Valves and Fittings Shell and tube heat exchanger
Shutoff valve
Liquid tank
Control valve
Gas bottle
Multi-way valve
Machines
Check valve Electric motor
Check valve, lockable Centrifugal pump
Pressure reducing valve, safety function Diaphragm pump
Gate valve Screw pump
Three-way cock Exhauster and vacuum pump
Coupling, general

Turbogenerators Symbols for Supply Circuits and
Appendix Supervisory Equipment

Treatment Systems Meanings of Identification Letters and Symbols to DIN 19 227. Part 1
Electrical
Separator, general
Flow rate
Filter, general
Level
Air or gas filter, general
Moisture
Liquid filter, general
Pressure
Tubular element filter
Quality variables (e.g. O2 or conductivity)
Mixed – bed filter
Temperature
Ion exchange filter
Vibration
Gas dryer
Framing for valve and fitting identification
Measurement and Control
Framing for measuring point identification

Flow measurement
Terminal Points in Supply Circuits
Controller, general
System limit
Limit of Supply
Component Limit
2.9-0210-0004/2
2.9-0210-0004/2
Turbogenerators Electrical Test on Stator Winding
With Vacuum Impregnated Micalastic
High-Voltage Insulation
1. The Insulation System of the Stator There are several methods of electrical testing. All of
Winding these are indicated below for the sake of completeness.
The Insulation system serves to insulate the However, for reasons to be explained in the following
generator stator bars, whcih are subjected to a high- sections, not all of these tests are suitable for checking
voltage potential of upto 30 KV, from each other and the insulation of large turbogenerators, especially those
from the grounded stator iron parts for reliable with water-cooled windings.
protection against the additional thermal and z Insulation resistance measurement (meggar)
mechanical stresses arising during operation.
For decades, Insulation system with a high mica z Recharging and leakage current measurment for
content of up to 65% have been and are still being exact determination of insulation resistance
used most successfully. Up to the mid-fifties. mica z Dissipation factor measurement
was predominantly bonded with shellac or asphalt. z Partial discharge measurements
Insulation systems of this type are greatly affected by
moisture and develop low Insulation resistances z High-potential proof tests
especially after a prolonged outage of the generator AC voltage
in a humid atmosphere. DC voltage
The present day system uses epoxy resin 0.1-Hz voltage
featuring a high resistance to mechanical, thermal
and electric stresses. 3. Insulation Resistance Measurement
The MIcalastic insulation consists of mica tapes Insulation resistance measurement is by far the
applied continuously from end to end on the bars, simplest and easiest of the available tests to perform to
including the end winding portions. Vacuum determine the integrity of the insulation. It is made with an
impregnation with epoxy resin provides an insulation instrument commonly known as meggar and supplying
system which is highly resistant to mechanical, a variable DC voltage between 100 V and 5000 V. The
thermal and electric stresses and also impervious to instrument is cailbrated for direct reading of the insulation
moisture. Drying the insulation prior to startup of the resistance in mega-ohms. The DC voltage for
generator will thus only be required to remove any measurement is generated by a hand-operated or motor-
moisture film on the surface. operated generator or by electronic means. This voltage
should be applied for not less than one minute prior to
2. Purpose and Kind of Electrical Tests reading the insulation resistance value to allow for the
The mechanical, thermal and electric strength of decay of the absorption current component with time
the insulation system is assured by numerous due to a polarization of the dielectric in the electric field.
laboratory tests performed prior to using the insulation This process, which follows an exponential function, is
in actual service on the generators and by the results
reflected at the instrument by a pointer deflection which
of service on the generators and by the results of
is initially fast and then gradually slows down. The
service experince.
results of this reading indicate only the presence or
During the manufacturing process until delivery
absence of a winding short to ground and that insulation
of the generator, a comprehensive quality verification
resistance is at a level above the accepted minimum
program is performed by subjecting the insulation to
limit. This test is performed prior to each startup of the
electrical tests. Unless the insulated parts in the
generator are stressed due to abnormal conditions unit and prior the each high-potential test on a winding.
during transport or during the installation and assembly On water-cooled generators with water filled winding
at the power plant, no electrical testing would be the relatively low resistance of the water in the hoses
required prior to placing a new generator into between the winding and ground potential is connected
operation. For safety considerations, the insulation in parallel to the true insulation resistance. A megger
resistance should, however, be checked by means reading would indicacate the resistance value of the water
of a meggar prior to each startup. in the hoses. Depending on the conductivity of the water and
It is a known fact that even the best insulaion the number of parallel connected hoses, this value may be
system is subject to aging during service, especially far below 1 mega-ohm and does not provide any
as a result of operational disturbances, such as voltage information of the magnitude of insulation resistance of
surges due to sudden short-circuits, etc. the winding. It merely serves to determine that there exists
During overhauls, the degradation of the insulation no direct short to ground.
and any damage due to accidental disturbances To determine the insulation resistance of water-filled
should therefore be asceratained by a visual windings by means of megger reading in the usual way,
inspection and by means of suitable electrical tests to
give assurance of trouble free operation for further
years.
the water must be drained from the windings, and the factor measurement, partial discharges will occur
surface of the supply hoses requires thorough drying. which increase with rising voltage and result in a
4. Recharging and Leakage Current dissipation factor tip–up.
Measurement Mlcalastlc insultion is impregnated with epoxy
To determine the true insulation resistance of an resin under vacuum to be essentially void-free. In
insulation, some what larger and more complicated new condition, this insulation thus exhibits a
equipment is required, permitting also a determination dissipation factor tip-up of less than 0.001 for each
of the polarization index. For this test, a stabilized DC measuring interval of 20% of rated voltage.
power source and a micro ammeter are required, Prolonged exposure to thermal and mechanical
stresses and last but not least, the effect of partial
enabling the current to be measured as a function of
discharges may result in new separations and thus in
the test period under otherwise constant conditions
additional discharges. Measurement of the dissipation
and allowing the influence of temperature, moisture
factor as a function of the test voltage can therefore
and dirt to be determined and considered.
provide information on the aging of an insulation by a
In hydrogen-cooled generators, the ambient is quite
relatively simple method.
clean, and the winding is protected against moisture
Measuring the dissipation factor on individual
absorption, because, in contrast to air-cooled units,
winding components, such as bars, is mostly performed
these machines have a closed cooling circuit.
by means of a guarded electrode to eliminate the effect
In addition the insulation of Mlcalastlc -insulated
of leakage currents across the coil end. Such a guarded
generators is not subject to moisture absorption.
electrode system cannot be provided for complete
Recharging and leakage current behavior and the
winding which are mostly equipped with an end corona
insulation resistance, repectively, may merely be affected
protection. This effect must therefore be taken into
by dirt or moisture on the surface of the end winding.
consideration when evaluating the variation of the
On winding without water conductor cooling, this
dissipation factor with voltage.
test is just easy to perform as the megger reading.
The dielectric constant and the dissipation factor
However, to permit the use of this test also on water-
are measured with a Schering bridge.
cooled windings with water circulating in the windings
without affecting the recharging current or the
insulation resistance through the water in the multiple
parallel hoses from the winding to the ground, 500
MW generators are equipped with special device in
the water circuit, enabling the water manifolde to be
disconnected from the ground in a simple way. The
bushing hoses are equipped with contact sleeves to
compensate for the leakage current through the water
in the hoses.
Since, in addition to the leakage current, the
stabilized DC power source is also required to supply
the partial currents via the water in the hoses, i. e. up
to 40 mA dependent on the conductivity of the water,
the micro ammeter is inserted in the circuit through
which only this recharging current and the leakage
current of the winding insulation are flowing.
Fig. Schering Bridge
5. Dissipation Factor Measurement At balance, zero current flows through the bridge
The winding insulation system is primarily a
branch. The capacitance of the winding is then:
capacitive setup, with the winding copper costituting
one electrod, and the grounded frame the other
electrode. Such circuit is accessible for bridge method
of resistance measurement to determine the dielectric Cx = R4 . CN / R3
loss factor. Dielectric loss is defined as the ratio of
active power to reactive power. Inconnection with
insulation testing the dielectric loss indicate the
amount of electrical energy converted into heat in the and the dissipation factor:
insulation. tan delta = R4 . w. C4
The dissipation factor and capacitance of a solid To perform dissipation factor measurement on
insulating material are not dependent on the test voltage generator winding, disturbing error capacitances can
applied as long as there is no change in the conduction be eliminated with a universal capacitance/dissipation
mechanism. A change in the conduction mechanism of factor bridge using ancillary equipment for the initial
insulation materials occurs due to loss of bond between balancing adjustment. This scheme offers an effective
layers of insulation, with voids being formed in minute method for measurements on winding in a directly
cracks. As the voltage is increased above a certain level grounded stator.
(partial discharge start voltage) during the dissipation
2.9-2300-0001/2
6. Partial Discharge Measurements also on the aging of the insulation . They are indicative
The dissipation factor measurement described of the dielectric strength of the insulation with certain
in the preceding section covers the sum of the losses probability only.
occurring in the insulation voids due to partial A high-voltage test is an indispensible last
dichrages. Since partial discharge is a radio-frequency criterion for determining with assurance whether or not
phenomenon, this open up the possibility of using the insulation on a winding is suitable for continued
operation with sufficient reliability. The application of a
radio-frequency methods for detection.
high test voltage is especially recommended in all
Partial discharge measurements provide useful
cases where it is to be expected that the insulation
information for the detection of localized defects in may have suffered localized damages as a result of
winding components, such as the phase connector extremely high mechanical stresses due to a sudden
insulation system. This method is also used for short circuit or extremely high electric stresses due to
quality assurance during manufacturing. transients. A high-pontential proof test is also applied
in the case of serious aging as identified by a
dissipation factor measurement and if localized weak
points in the insulation cannot be ruled out.
Any breakdown occurring during a proof test indicate
that the winding is approaching the end of its service
ability. After removal of bars on which a breakdown has
occurred, the areas of the insulation most severely
affected by degradation can be assessed, permitting
scheduling of a suitable date for rewinding. If no breakdown
occurs during the proof test or following the removal of
already failed bars, this means that after completion of
the test even the weakest area of the insulation still has
a certain life expectancy which will be longer at the field
intensity arising during normal operation troublefree
operation at least for a certain service period following
the test and avoids the risk of a breakdown occurring
during operation together with the consequential damage
resulting from the high currents arising.
7.1 AC Voltage Test

This test is normally performed with a power-
frequency AC voltage of 1.5 time rated votage. The use
In the case of generator windings, the partial
of a 50-Hz or 60 Hz AC voltage offers the advatage that
discharge method has so far been applied only in special the field distributin will be the same as during normal
cases to detect high-energy discharges, as caused, for operation, especially at the transition between the straight
instance, by a break in the internal corona shielding slot section and the end winding, resulting in a
system. The measurement is performed in a manner proportional stressing of the winding components. As
similar to the disspation factor measurement by generator sizes increase, the capacitance of the winding
recording the maximum apparent discharge magnitude to ground increases accordingly and thus also the
as a function of the voltage for each phase up to 120% of transformer rating required for the test . To test one phase
rated voltage. To do this, a coupling capacitor CK is of a large turbogenerator, a test set of 400 kVA of more will
connected in parallel to the phase capacitance Cx. The fairly often be required. For this reason, resonance circuits
partial discharge is then detected in the ground connection are frequently used, permitting a compensation of the
of the coupling capacitor with a suitable partial discharge high leading reactive power. An exact control of the preset
detector via a four-terminal coupling network AKV. test voltage is accomplished through a high-voltage
As with the dissipation factor measurment, the instrument transformer.
test voltage is applied via a regulating transformer, a
high-voltage transformer and a reactor to compensate 7.2 DC Voltage Test
When utilizing a high DC voltage for proof testing,
for the winding and coupling capacitances.
the field distribution will differ from that described in
Such a test setup is sensitive to external noise
the prededing section especially at the end windings.
which cannot be avoided at the power station or in the As a result of this, DC testing subjects the end turn
test field. If no additional measures for rejection of insulation to considerably higher sresses than AC
the external noise are taken, background noise levels testing. This drawback arises especially on so-called
from 100 pC to more than 1000 pC are to be expected. discontinuous insulation systems where different
insulation are used for the end windings and the
straight slot portions, resulting in a joint at the transition
7. High-Potential Proof Tests from the slot to the end winding. The continuous
All test described in the proceeding sections are Mlcalastlc insulation does not involve the drawback.
performed with relatively low voltage. Using suitable The equipment involved in performing a DC high-
standards for comparison, they provide information potential test is considerably smaller and easier to
on the contamination, surface moisture condition and transport than the AC test equipment. If DC testing
2.9-2300-0001/3
For this reason, it is necessary to use a multiplication has been specified.
factor to obtain nearly, equivalent searching ability as
an AC test. It is recommended that 1.7 times the AC Laboratory tests on new and aged insulation
RMS test voltage be used. systems have rendered greatly differing values of the
multiplication factor to be used both for DC testing
7. 30.1-Hz Voltage Test and 0.1 Hz testing to obtain equivalent results as a
test at power frequency alternating voltage. These
An AC high-potential test requires a large and multiplication factors are mostly considerably higher
heavy testing transformer which is capable of for new insulation system than for aged insulation.
providing also the reative power of the winding
capacitance, whereas for DC over-voltage testing From this, it may be concluded that the stress
smaller and lighter test equipment is mostly sufficient. mechanism during both DC testing and 0.1 Hz testing
To make use of the lower weight, while retaining the differs from that obtained by the use of an alternating
advantage of a field distribution corresponding to that voltage. Accordingly, the multiplication factor should
obtained with a power frequency test equipment, tests be selected under due consideration of ageing of
are also performed at a reduced frequency of 0.1 Hz. the winding insulation. However since the high-
Tests conducted at Swedish and American potential test serves to establish the life of the
laboratories have shown that the 0.1 Hz test voltage insultion, it appears more appropriate to use a power-
to be applied must be higher than the 50 Hz or 60 Hz frequency alternating voltage for the high-potential
test voltage to obtain equivalent test conditions as an test, if it is practicable to obtain and transport the heavy
AC test. For such tests, a multiplication factor of 1.25 test equipment.
Note : While carrying out tests like DLA, PD, Tan delta, HV on Stator winding, it is to be ensured that the external
vibration leads are isolated from the vibration lead-in plate provided in the stator casing.
2.9-2300-0001/4

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OPERATION & MAINTENANCE

BHARAT HEAVY ELECTRICALS LIMITED

210 MW TOTALLY IMPREGNATED

INDIRECT GAS COOLED STATOR WINDING

BHARAT HEAVY ELECTRICALS LIMITED

This manual contains

BHEL, Haridwar 2.0-0005-0012/1

Title-Page 2.0-0001 Coil and End Winding Support System....... 2.1-2340

BHEL, Haridwar 2.0-0010-7500/1

This manual contains information on the operation and

BHEL, Haridwar 2.0-0030-0001/1

The turbogenerator instruction manual consists of

BHEL, Haridwar 2.0-0040-0009/1

The Turbogenerator is designed to operate within the temperature rises in

Continued operation of unit without recommended scheduled maintenance will

BHEL, Haridwar 2.0-0050-0002/1

1. General This sign is followed by information and

This category is used to warn against potential injury

BHEL, Haridwar 2.0-0100-0001/1

5. Personnel Support and lift generator parts only at

Do not carry out any modifications to the generator Notice:

BHEL, Haridwar 2.0-0100-0001/2

Fire and explosion hazard due to H2 Danger:

Persons with pacemakers must not

Danger: 8.5 Maintenance and Inspection

“ Involve engineers from BHEL.

BHEL, Haridwar 2.0-0100-0001/3

Danger: 9. Waste Disposal

BHEL, Haridwar 2.0-0100-0001/4

In line with ISO 14001 requirements HEEP-BHEL, a) Rubber:

2. Non Metals: Send the discarded oil to registered refiners who

May be disposed as scrap metal for recycling and b) Grease:

BHEL, Haridwar 2.0-0200-0001/1

Job Name : RAYALSEEMA TP, STAGE - 3

Bharat Heavy Electricals Limited

TTTt TYPE: THRI 108/39GTHTTTTTTTTTHJH P.O. NO. : 10251A12701

3 Phase 50 Hz YY PF=0.85 Lag

247 MVA 210 MW

15750 V 9056 A 3000 RPM

Coolant : Hydrogen Spec: IS 5422, IEC-34

Gas Pressure : 3 kg/cm2 (G) Insulation Class-F

Excitation: Voltage=251 V, Current=2260 A

Division : Haridwar YEAR : 2009

BHEL, Haridwar 2.1-1001-7515/1

1. General in a closed circuit by two axial-flow fans arranged on the

BHEL, Haridwar 2.1-1100-0030/1

1. Stator core and winding assembly during operation are

BHEL, Haridwar 2.1-1210-7500/1

1. Conductor Construction are inserted or used in all locations where a large-area

Fig.1 Prepared Stator in Global-VPI Plant

BHEL, Haridwar 2.1-1230-7500/1

2. Rotor Winding 4. Field Connections

Flg.1 Rotor Shaft

BHEL, Haridwar 2.1-1300-7500/1

Flg.1 Cooling Water Connections in a Double Section Cooler

BHEL, Haridwar 2.1-01440-7500/1

The sleeve bearings are provided with hydraulic shaft

2. Bearing 011 System

Both bearings of the generator and the bearing of

1. Connection for shaft lift oil

Fig. 2 Solid Model of Bearing

BHEL, Haridwar 2.1-1450-0001/1

Fig. 1 Shaft Seal

1. Oil wiper ring (air side) 9. Oil wiper ring H2side

1. Compressed Air The compressed air shall be available at a gauge

The oxygen content of the expanded air shall be 3. Hydrogen (H2)