Turbogenerators Rating Plate Data for Generator

General

PROJECT NAME: 660MW IB VALLEY, P.O-10825A13501 &10832A13501

BHARAT HEAVY ELECTRICALS LTD

KW 660,000 R.P.M 3000

P.F. 0.85 LAG Hz 50

KVA 777,000 Phase 3

Type: THDF 115/67 Connections : YY

Volts 21000 Coolant : Hydrogen & Water

Stator
Amps 21362 Gas Pressure : 5 Kg/cm2 (g)

Volts 470 Insulation : Class F

Rotor
Amps 5710 Specn.: IS:5422 IEC:34

MADE IN INDIA Division: Haridwar

BHEL,Haridwar 2.1-1002-0 6 6 0 /1
0316E
 Turbogenerators
General
1 General
The two- pole generator uses direct water cooling for
the stator winding, phase connectors and bushings
and direct hydrogen cooling for the rotor winding. The
losses in the other generator components, such as
core losses, friction and windage losses as well as
stray losses are dissipated to the hydrogen.
The generator frame is pressure-resistant and
gastight and equipped with end shields at the turbine
end as well as the exciter end. The hydrogen coolers
are arranged vertically inside of the cooler section at
the turbine end.The generator comprises the following
components:
ƒ Stator
Outer casing
Stator core and winding assembly
Cooler section
Hydrogen coolers
End shields
ƒ Rotor
Rotor shaft
Rotor winding
Rotor retaining rings
Field connections
ƒ Bearings
ƒ Shaft seals
The following auxiliary equipment is required for
operation.
ƒ Oil system
ƒ Gas system
ƒ Primary water system
ƒ Excitation system
2 Cooling system
The heat losses generated in the generator
interior are dissipated to the secondary coolant (such
as raw water or condensate) via the hydrogen and
primary water.
The generator is exclusively cooled by direct
cooling where the heat is dissipated directly to the
coolant. This means that hot spots and large
temperature differentials between adjacent
components which could lead to different thermal
expansion are largely eliminated thus minimizing
mechanical stresses particularly with regard to the
copper conductor, insulation, rotor and the stator core.
BHEL,Haridwar
General Design Features
Design and Cooling system
3 Hydrogen Cooling System
The hydrogen is circulated though the generator interior
in a closed system by means of a single multi-stage axial-
flow fan which is arranged at the TE rotor end. The fan
draws the hot gas from the air gap and the core and
delivers it to the coolers.Downstream of each cooler, the
gas is divided into several flow paths as follows:
Flow path I routes the cold gas through ducts in the
stator frame and the terminal box to the EE end-winding
space where the cold gas flows along the clamping fingers
before entering the axial bores in the core. For this purpose,
the clamping fingers and pressure plates are designed
as gas ducts to enable the cold gas to be routed between
clamping fingers and end lamination into the stator core.
Along its path through the stator core from the EE to the
TE, the gas absorbs the heat given off by the stator core
before exiting the core at the turbine end via the ducts
along the clamping fingers and entering the stator end-
winding space from where it is returned to the coolers by
the axial flow fans.
Flow path II routes the cold gas under the hub of the fan
into the rotor end-winding space for direct cooling of the
TE half of the rotor winding. The rotor winding is
symmetrical relative to the generator center and the rotor
axis.
Each winding is divided into eight cooling zone.
The first cooling zone includes the slot portion from the
end to the center of the rotor body, and the second cooling
zone extends across half of the end winding. These two
cooling zones are repeated four times in a symmetrical
arrangement around the rotor.
The cooling gas for the slot portion enters the
hollow conductors through openings in the end winding
and flows through these conductors to the center of the
rotor body. The hot gas is then discharged into the air
gap between the rotor body and stator through radial
openings in the conductors and the rotor slot wedges.
The cooling gas holes are arranged at different levels in
the conductor assembly to give each hollow conductor
its own cooling gas outlet. The cooling gas for the end
winding is admitted through the end face and flows through
the conductors up to approximately the pole center, where
it passes into a collection compartment and is then
discharged into the air gap via slots in the end of the rotor
body.
Flow path III routes the hydrogen to the EE rotor end-
winding space for direct cooling of the exciter-end half of
the rotor winding. Because of the symmetrical configuration
of the cooling gas flow, the cooling is performed in the
same manner as for the turbine-end half of the rotor
winding. The hot gas also flows to the center of the rotor
befor being discharged to the air gap.
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0316E
Flow path IV routes the cold gas through the flux
shield in the TE stator end-winding space.
Flow path V routes the cold gas through the flux
shield in the EE stator end-winding space.
Flow path VI routes the cold gas radially into the TE
core end. This flow is required since the gas for axial
core cooling flows from the exciter end to the turbine
end which means that it has already absorbed heat
when it exits the core at the turbine end.
Following heat absorption, the six flows are
mixed before being returned to the coolers by means
of the axial flow fan.
3.1 Coolant Temperature Control
The cooling water flow through the hydrogen
coolers is automatically controlled to maintain a
uniform temperature level for all loads and cold water
temperature. The cold gas temerature is used as
referance variable.
4 Primary Cooling Water System
The treated water used for cooling the stator
winding, phase connectors and bushings is referred
to as primary water in order to distinguish it from the
secondary coolant (raw water, or condensate). The
primary water is circulated in a closed system and
dissipates the absorbed heat to the secondary cooling
water. The pump is supplied with hot primary water
from the primary water tank, and delivers the water to
the generator via the coolers. Upstream of the
generator, the cooling water flow is divided into the
two following paths:
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0316E
Flow path 1 is used for cooling the stator winding.
This flow path routes the water to the manifold at the
exciter end and from there to the stator bars via
insulating hoses. Each stator bar is connected to
the manifold by a separate hose. The cooling water
flows through hollow conductors towards the turbine
end of the generator. After exiting the stator bars, the
water flows through insulating hoses to a water
manifold from where it is rerouted to the primary water
tank. Since the water flows through the stator bars in
one direction only, the temperature rise of the coolant
(and thus of the bars) is minimized which, in turn,
means that the relative movments between the top
and bottom bars due to different thermal expansions
are also minimized.
Flow path 2 is used for cooling the phase connectors
and bushing. The bushings and phase connectors
are made of thick-walled copper tubes carrying the
cooling water. The 6 bushings and the phase
connectors, which are arranged in circular fashion
around the stator-end winding, are interconnected in
such a manner that 3 parallel flow paths are
established. The cooling water is admitted from
ouside the generator through 3 bushings and exits
through the other 3 bushings.
The secondary water flow through the primary
water cooler is automatically controlled to ensure that
the generator temperature is maintained at a constant
level under different load conditions.
 Turbogenerators Generator Cooling Gas Circuit

General

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BHEL,Haridwar 0316E
 Turbogenerators
Operation
1 Stator
The Stator comprises a stator frame as well as the
stator core and winding assembly.
Manufacture of the stator frame is performed
independently of the stator core and winding assembly
production and prior to the installation of the winding ,
the core is linked to the stator frame by means of the
flat springs.
2 Stator Frame (Outer Frame)
The Stator frame is a gastight and pressure resistant
welded construction and houses the stator core , the
stator winding and the hydrogen coolers which are
arranged vertically in a seperate cooler housing at the
Turbine end.
A cage of circular and axial ribs on the inside of the
outer frame ensures the rigidity of the shell.End shields
containing the shaft seal and bearing components are
bolted to the stator frame .A high viscosity sealant is
injected in sealing grooves to ensure that the flanged
joints are sealed airtight.
The core portion of the stator frame is divided into
compartments which houses the springs for suspending
the stator core.The cold gas for cooling the stator core
and the exciter end rotor winding flows through gas
ducts welded to inside surface of the shell.
Feet are welded to the stator frame to support the
stator on steel plates embedde in the foundation.The
stator is firmly anchored to the plates with anchor bolts
through the feet.
BHEL, Haridwar
General Design Features
Stator
3 Stator Frame (Inner Frame)
The inner frame of the Stator comprises the core
and the winding .The spring baskets form part of the
inner cage which is suspended in the outer frame by a
large number of flat springs distributed over the entire
core length.The flat springs are tangentially arranged
over the circumference in sets of three springs each
on either side of the core and a single horizontal
stabilizing spring below the core.Its an alternative , the
springs below the core can be omitted.The springs are
so arranged and turned that forced vibration resulting
from the magnetic field will not be transmitted to the
frame and foundation.
3.1 Stator Core
The stator core is stacked from insulated electrical
sheet-steel laminations with a low loss coefficient and
mounted in spring baskets over insulated core bars.Axial
compression of the stator core is obtained by clamping
fingers, core press ring and non-magnetic through type
clamping bolts which are insulated from the core.
The core press ring and end zones of the stator
core are effectively shielded against stray magnetic
fields by means of cooled flux shields
3.2 Stator Winding
The stator winding is fractional pitch two layer type
winding which is made up of individual bars.The bars
are so located in rectangular slots uniformly distributed
over the entire circumference of the stator core.
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 Turbogenerators
Operation
To facilitate manufacture, erection and transport,
the stator consists of the following main components:
Stator frame
Cooler housing
End shields
Terminal box
The stator frame with spring mounted core support
,core and stator winding is the heaviest component of
the entire generator.A rigid frame is required due to the
forces and torques arising during operation.In,addition
the use of hydrogen for the generator cooling requires
the frame to be pressure resistant upto an internal
pressure of aprrox 10 bar (130 psig).
The welded stator frame consists of the cyllindrical
frame housing, two flanged rings and axial and radial
ribs.The cooler housing at the turbine end encloses
the entire end-winding portion of the stator up to the
end wall of the slot portion.The cooler housing is used
for routing the cold gas into the cooling gas ducts at the
exciter end.The header is made of magnetis steel.
The arrangement and dimensioning of the ribs are
determined by the cooling gas passages and the required
mechanical strength and stiffness.Dimensioning is also
dictated by vibrational considerations, resulting partly
in greater wall thickness than required from the point of
view of mechanical strength.
BHEL, Haridwar
Stator Frame
Two lateral supports for the spring mounted core
support in the frame are located directly adjacent to the
points where the frame is supported on the foundation.
Due to the rigid design of the supports and foot portion
the forces due to the weight and short-circuits will not
result in any over stressing of the frame.
Manifolds are arranged inside the stator frame at
the bottom and top for filling the generator with CO2
and H2.The connections of the manifolds are located
side by side in the lower part of the frame housing.
Additional openings in the casing which are sealed
gastight by pressure resistant covers allow access to
the core press rings of the spring mounted core support
and also permit the lower portion of the core to be
inspected . Access to the end winding compartments is
possible via manholes in the TE cooler housing and EE
end shield.
In the lower part of the frame at the exciter end an
opening is provided for bringing out the winding
ends.The terminal box is flanged to this opening .The
terminal box is made of non-magnetic steel
The cooler housing is located at the Turbine end of
the stator frame.It accomodates the baffle ring, the baffle
ring carrier and the hydrogen cooler sections.The cooler
sections are installed in vertical cooler wells.Ribs in the
cooler assembly interior serve for improved cooling gas
passage and contribute towards mechanical strength
and stiffness.
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 Turbogenerators
Operation
, Pressure-resistant end shields are provided to seal
the cooler housing at the turbine end and the stator
frame at the exciter end. The end shields contain the
generator bearings and shaft seal.
All bearings and seal oil inlet and outlet pipes are
permanently installed in the end shield .
The horizontally split end shields are of hollow box
type construction.Radial and axial ribs together with
the end walls provide for the necessary stiffness of
the end shields.
The lower half end shields accomodate the insulated
bearing shell supports.The insulation prevents any short
circuiting of shaft currents across the bearings .The
bearing shell supports accomodate the spherica bearing
shell and due to their shape ensure self-alignment of
the bearing with respect to the rotor axis.
.
BHEL, Haridwar
Stator End Shields
The bearing oil is supplied to the libricating gap via
ducts in the bearing shell support 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 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 is drained
towards the hydrogen side is first collected in a gas
and outlight prechamber below the bearing compartment
for defoaming and then passed to the seal oil supply
system.
The EE end shield is covered with a tapered copper
shield to prevent stray fields between stator winding
and frame.
.
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 Turbogenerators
Generator Terminal Box
Description

The phase and neutral leads of the three-phase
stator windings are brought out of the generator
through six bushings located in the generator
terminal box at the exciter end of the generator.
The terminal box is a welded construction of non-
magnetic steel plate. This material reduces stray
losses due to eddy currents.
Welded ribs are provided for the rigidity of the
terminal box. Six manholes in the terminal box provide
access to the bushings during assembly and
overhauling.

1 2 3

1 Generator terminal box

2 Manhole
3 Flange for bushing

Fig.2 Terminal Box

BHEL,Haridwar 2.1-2170-0600/1
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 Turbogenerators
Operation
1 Design
Stator bars,phase connectors and bushings are
designed for direct water cooling.In order to mininmize
the stray losses,the bars are composed of seperately
insulated strands which are transposed by 540 in the
slot portion and consolidated with epoxy resin in heated
molds.After bending , the end turns are consolidated
with baked synthetic resin fillers.
The bars comprise of hollow and solid strands
distributed over the entire bar cross section to ensure
good heat dissipation.At the bar ends , the solid strands
are brazed to a connecting sleeve and the hollow
strands to a water box which is linked to water manifold
by an insulating hose made of polytetrafluoroethylene
(PTFE). The electrical connection between the top and
bottom bars is made by bolted connections at the
connecting sleeve.
The water manifolds are insulated from the stator
frame so that the dielectric resistance of the winding
can be measured without having to remove the water.
During operation, the water manifolds are grounded.
2 Micalastic High-Voltage Insulation
The proven Micalastic system is used for the high
voltage insulation of the stator bars.With this system ,
several layers of half-overlapping mica tape are applied
to the bars.The mica tape is composed of a thin high-
strength backing material to which the mica is bonded
by a small amount of epoxy resin.The number of layers
and consequently the thickness of the insulation
depends on the generator voltage.Following application
of the mica tape, the bars are dried under vacuum and
impregnated with epoxy resin which exhibits very good
penetration properties due to its low viscosity.
During next stage of this impregnation process the
bars are pressurized with nitrogen to complete the
vacuum-pressure inpregnation (VPI) process.The
impregnated bars are then formed to a required shape
in molds and cured in an oven at high temperature.This
BHEL, Haridwar
General Design Features
Stator Winding
ensures a virtually void free high voltage insulation
which is characterized by excellent electrical ,
mechanical and thermal properties in addition to being
fully water proof and oil resistant. To minimize corona
discharges between the insulation and the slot walls ,
a final coat of semiconducting varnish is applied to the
surface of the slot portion of all the bars.In addition , all
bars are provided with end corona protection to control
the electric field at the transition point from the slot
portion of the bar to the end winding section and to
prevent arcing.
3 Bar support System
To protect the stator winding against the effects of
load induced magnetic forces and to ensure permanent
firm seating of the bars in the slots during operation ,
the bars are provided with side ripple spring , a slot
bottom equalizing strip and a top ripple spring located
under the slot wedge.The gaps between the bars in the
stator end windings are filled with insulating material
and cured following installation.The ends of the bars
thus form a cone-shaped end winding.For radial
support, the end windings are clamped to a rigid support
ring made of insulating material which is fully supported
by the stator frame.
Curable filler material is arranged between the stator
bars and the support ring to ensure firm support of
each individual bar by the support ring.The bars are
clamped to the support ring with pressure plates held
by bolts made from high strength insulating material.The
stator end winding and support ring thus form a rigid
short circuit proof structure which does not restrict
movements of the winding due to thermal expansion
because the support ring is allowed to move axially
within the stator frame.
The stator winding connection are routed to six
bushings located in a compartment of welded non
magnetic steel below the generator at the exciter end.
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 Turbogenerators
General
1. Rotor Shaft
The rotor shaft is a single-piece solid forging
manufactured from a vacuum casting. Slots for insertion
of the field winding are milled into the rotor body. The
longitudinal slots poles are obtained. The rotor poles are
designed with transverse slots to reduce twice system
frequency rotor vibrations caused by deflections in the
direction of the pole and neutral axis.
To ensure that only high-quality forging is used,
strength tests, material analysis and ultrasonic tests are
performed during manufacture of the rotor.
After completion, the rotor is balanced in various
planes at different speeds and then subjected to an
overspeed test at 120% of rated for two minutes.
2. Rotor Winding
The rotor winding consists of several coils which
are inserted into the slots and series connected such
that two coil groups form one pole. Each coil consists of
several series connected turns, each of which consists
of two half turns which are connected by brazing in the
end section.
The rotor winding consists of silver-bearing
deoxidized copper hollow conductors with two lateral
cooling ducts. L-shaped strips of laminated epoxy glass
fiber fabric with Nomex filler are used for slot insulation.
BHEL,Haridwar
General Design Features
Rotor
The slot wedges are made of high-conductivity material
and extend below the shrunk seat of the retaining ring.
The seat of the retaining ring is silver-plated to ensure a
good electrical contact between the slot wedges and
rotor retaining rings. This system has long proved to be
a good damper winding.
3. Retaining Rings
The centrifugal forces of the rotor end windings are
contained by single-piece rotor retaining rings. The
retaining rings are made of non-magnetic high-strength
steel in order to reduce stray losses. Each retaining ring
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.
4. Field Connections
The field current is supplied to the rotor winding
through radial terminal bolts and two semicircular
conductors located in the hollow bores of the exciter and
rotor shafts. The field current leads are connected to
the exciter leads at the exciter coupling with
multicontact plug-in contact which allow for
unobstructed thermal expansion of the field current
leads.
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SEAL OIL SYSTEM 
 Turbogenerators General Design Features
Shaft Seals
Operation

The points where the rotor shaft passes through

the stator casing are provided with a radial seal ring.The
seal ring is guided in the seal ring carrier whih is bolted
to the end shield flange and insulated to prevent the
flow of shaft currents.The seal ring is lined with babbitt
on the shaft journal side.The gap between the seal ring
and the shaft is sealed with seal oil.The seal oil is
supplied to the sealing gap from the seal ring chamber
of the seal ring carrier via radial bores and an annular
groove in the seal ring.To ensure effective sealing, the
seal oil pressure in the annular gap is maintained at a
higher level than the gas pressure in the generator
casing.The oil drained on the hydrogen and air sides of
the seal rings is returned to the seal oil system through
drains in the stator end shields.In the seal oil system,the
oil is regenerated by a vacuum treatment , cooled ,
filtered and then returned to the shaft seals.
On the air side, pressure oil is supplied laterally to
the seal ring via an annular groove.This ensures always
free movement of the seal ring in the radial direction.

BHEL, Haridwar 2.1-1460-0660/1

0316E
 Turbogenerators
Description
1 Construction of the Seal Oil System
The shaft seals are supplied with seal oil from the
seal oil system which consists of the following principal
components:
Seal oil storage tank (in bearing oil drain line)
Seal oil tank incl. vacuum pump
Intermediate oil tank
Seal oil pumps (2 x 100%)
Standby seal oil pump (1 x 100%)
Pressure controller downstream of each pump
Seal oil coolers (2 x 100%)
Seal oil filters (2 x 100 %)
Differential pressure control valves (2 x 100%)
Except for the seal oil storage tank, all the above
major components are combined in one unit.
2 Seal Oil Circuit
The seal oil is drawn from the seal oil tank by the
seal oil pump in service and passed to the shaft seals
via coolers, filters and differential pressure regulating
valve.
2.1 Seal Oil Storage Tank
The seal oil storage tank is a larger-diameter pipe
section in the bearing oil return line of the generator. After
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
system. The seal oil storage tank and the seal oil tank
are interconnected by piping.
The exhauster of the waste gas system maintains a
slight vacuum in the seal oil storage tank.
2.2 Seal Oil Tank
The seal oil tank is arranged below the seal oil
storage tank. The oil from the seal oil storage tank is
available at oil column pressure upstream of the float-
operated valve in the seal oil tank inlet.
The float-operated valve in the inlet pipe keeps the
oil level in the seal oil tank at a predetermined level and
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
remains continuously activated to admit the volume of
oil drawn by the seal oil pump in service.
BHEL, Haridwar
General Design Features
Seal Oil System for Shaft Seals
A vacuum pump keeps the seal oil in the seal oil
tank under vacuum and largely extracts the gas absorbed
by the oil while passing through the hydrogen and air
atmospheres. A deterioration of the hydrogen purity in
the generator is thus largely avoided.
2.3 Seal Oil Pumps
Two seal oil pumps are directly connected to the
seal oil tank on their suction sides.
One of the two seal oil pumps is always in operation
while the second one remains activated for starting. If
neither of the two pumps can establish the specified seal
oil pressure, the standby seal oil pump is automatically
started. It is directly connected to the seal oil storage
tank.
The seal oil pressure downstream of each full-capacity
seal oil pump is maintained constant by one pressure
controller each while the respective pump is in service.
2.4 Seal Oil Pressure Regulation
The seal oil pressure required upstream of the shaft
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
pressure.
For reasons of availability, two differential pressure
control valves with graded settings are provided.
3. Seal Oil Drain
3.1 Hydrogen Side Seal Oil Drain
The seal oil drained from the hydrogen side is passed
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
oil level in the Intermediate oil tank at a predetermined
level, thus preventing gas from entering the oil drain
system. During normal operation, the float-operated valve
remains continuously activated to return the hydrogen
side seal oil to the seal oil circuit. The seal oil leaving the
intermediate oil tank is admitted into the seal oil tank by
the action of the vacuum maintained in the seal oil tank.
3.2 Air Side Seal Oil Drain
The seal oil drained from the air side of the shaft
seals flows directly into the bearing oil return line for being
returned to the seal oil storage tank.
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0316E
 Turbogenerators General Design Features
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

BHEL, Haridwar 2.1-1511-0660/1

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GAS SYSTEM 
 Turbogenerators General Design Features

Operation Gas System

1 General

The gas system contains all equipment necessary
for filling the generator with CO 2 , hydrogen or air and
removal of these media, and for operation of the
generator filled with hydrogen. In addition, the gas
system includes a nitrogen (N 2) supply. The gas system
consists of :
• H 2 supply
• CO2 supply
2 Carbon Dioxide (CO2 ) Supply
As a precaution against explosive hydrogen air
mixtures, the generator must be filled with an inert gas
(CO 2) prior to H 2 filling and H2 removal.
The generator must be filled with CO 2 until it is
positively ensured that no explosive mixture will form
during the subsequent filling or emptying procedures.

• N 2 supply 4 Compressed Air Supply

• Pressure reducers

• Pressure gauges To remove CO2 from the generator, compressed air

• Miscellaneous shutoff valves is to be admitted into the generator.
• Gas analyzer The compressed air must be clean and dry. For
• Gas dryer this reason, a compressed air filter is installed in the
• CO 2 flash evaporator filter line.
• Flowmeters
5 Nitrogen (N 2 ) Supply
2 Hydrogen (H 2 ) Supply
Nitrogen is required for removing the hydrogen or
2.1 Generator Casing air during primary water filling and emptying procedures
The heat losses arising in the generator are A nitrogen environment is maintained above the primary
dissipated through hydrogen. The heat dissipating water in the primary water tank for the following
capacity of hydrogen is eight times higher than that of reasons.
air. For more effective cooling, the hydrogen in the
generator is pressurized.
• To prevent the formation of a vacuum due to
different thermal expansions of the primary water
& tank.

• To ensure that the primary water in the pump

suction line is at a pressure above atmospheric
pressure so as to avoid pump cavitation.

• To ensure that the primary water circuit is at a

pressure above atmospheric pressure so as to
avoid the ingress of air on occurrence of a leak.

BHEL, Haridwar 2.1-1520-0660/1

0316E
 Turbogenerators Gas System

General Simplified Diagram

1 H2 bottle 10 Gas drier fan

2 H2 pressure reducer 11 Gas drier chamber
3 N2 bottle 12 CO2/H2 purity transmitter
4 N2 pressure reducer 13 Dehydrating filter for measuring gas
5 Primary water tank 14 Pressure reducer for measuring gas
6 Pressure controller 15 Compressed air hose
7 Upper generator gas header 16 Compressed air filter
8 Lower generator gas header 17 CO2 flash evaporator
9 Gas drier heater 18 CO2 bottle

BHEL,Haridwar 2.1-1521-0660/1
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PRIMARY WATER SYSTEM 
 Turbogenerators General Design Features

Operation Primary Water Supply

1 General
failure of one pump, the standby pump is immediately
Th e p r i m a r y w a t e r r e q u i r e d f o r c o o l i n g t h e l i v e
ready for service and cuts in automatically.
components is circulated in a closed system.
In order to prevent corrosion, only copper,
4 Coolers
stainless steels or simillar corrosion-resistant materials
The function of the primary water cooler is to
are used throughout the entire cooling system.
dissipate the heat absorbed from the water-cooled
The primary water system comprises of the
components to the secondary coolant (water).
following principal components:

5 Filters
„ Primary water tank
In order to prevent the narrow cooling ducts in the
„ Primary water pumps
stator winding from becoming blocked by foreign matter
„ Coolers
a filter is installed in the main primary water system and
„ Fiters
a fine filter is provided downstream from the primary
„ Primary water treatment system
water treatment system.
„ Alkalization unit

6 Primary W ater Treatment System

The primary water admitted to the pump from
Because the primary water makes direct
the primary water tank is first passed to the EE
contact with the high-voltage stator winding, the
cooling water manifold in the generator interior and
conductivity of primary water must be very low. During
then to the neutral point of the terminal bushings via
operation, the electrical conductivity is maintained below
the cooler and fine filter. After having absorbed the
a value of 2μS/cm. In order to maintain such a low
heat losses in the stator winding, phase connectors
conductivity, it is necessary to provide for continuous
and main bushings, the water is returned to the
treatment of the primary water. For this purpose, a small
primary water tank from the TE cooling water manifold
quantity of the water flow is continuously passed
or the phase connectors. The gas pressure above the
through an ion exchanger arranged in a bypass to the
water level in the primary water tank is maintained
primary water main cooling system. The ion-exchanger
constant by a pressure controller.
resin material requires replacement at certain intervals.
The resins can be replaced during operation of the
turbine generator, since even with the water treatment
2 Primary Water Tank
system is out of service, the conductivity will deteriorate
The primary water tank is arranged in an easily
only very slowly.
accessible location on the stator frame on an elastic
The primary water system can be filed during
support, thus forming the highest point of the entire
commissioning and topped up from the condensate
primary water system in terms of static head.
system.

3 Primary Water Pumps

7 Alkalization Unit
The primary water is permanently circulated in a
The low-oxygen primary water is alkalized to prevent
closed system. To ensure uninterrupted generator
flow blockage due to copper corrosion in the water-
operation, two full-capacity pumps are provided. Each
cooled winding. The pH of the primary water is kept
pump is driven by a separate motor. In the event of
constant at 8.5 to 9 by continuous dosing of diluted
sodium hydroxide solution.

BHEL, Haridwar 2.1-1530-0660/1

0316E
 Turbogenerators Primary Water System

General (Simplified Diagram)

Primary water circuit, general

Coolant flow : stator winding
Coolant flow : main bushings and phase connectors
Water treatment
Waste gas
Hydrogen

1 Primary water tank 7 Bypass line

2 Pressure regulator 8 Cooling water for stator winding
3 Waste gas to atmosphere 9 Ion exchanger
4 Pump 10 Cooling water for main bushings and phase connectors
5 Cooler 11 Teflon hose
6 Filter 12 Cooling water manifold
13 Alkaliser unit

BHEL,Haridwar 2.1-1531-0660/1
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 Turbogenerators
General and Electrical Data
Technical Data

General
Job name 660MW IB VALLEY, BANHARPALLI
Generator type THDF 115/67
Year of manufacture 2016
Stator serial no.
12438
Rotor serial no.
Shaft identification no. 9U1024

Rated Data and Outputs

Apparent power 777 MVA
Active power 660 MW
Current 21.362 KA
Voltage 21 kV r 5%
Speed 50 s-1
Frequency 50 Hz
-- All Rights Reserved

Power factor 0.85

Inner connection of stator winding / slots YY
H2 pressure 5 bar
Cont. perm. unbalanced load 8%
e Siemens AG 2011

Rated field current for rated output 5710 A

Rated field voltage 470 V
The machines are designed in conformity with IEC 34 and should be operated according to these specifications.
The field current is no criterion of the load carrying capacity of the turbogenerator.
Copyright
Distribution: UNRESTRICTED

BHEL,Haridwar MK &MDA 2.1-1810-0660/1

Siemens AG 2.1-- 1810-0660/1
Energy Sector 0316E 0316E
 Turbogenerators
Cooler Data
Technical Data

Design Data for the H2 Cooler

Data for
2 x Type: 3895 / 612 / 18 / 2 − NSv − S201 −34N300 Units Materials and Pressures
100%
(2 identity elements 50% each)
Hydrogen pressure 5 bar Materials
Fins Cu
Gas flow 24 m3/s
Tubes CuNi10Fe
Heat dissipating capacity 6366 kW Tubesheets CuZn38SnAl
Cold gas temperature 44 _C Water channels Tar epoxy

Hot gas temperature 84.8 _C

Cooling Water Side Pressures
Gas pressure drop 945 Pa Design pressure: 12 bar
Cooling water flow 700 m3/h Test pressure: 18 bar

Maximum water inlet t emperature 39 _C

Water outlet temperature 46.9 _C
Terminal temperature difference at rated operation 5 K
Siemens AG 2013 − All Rights Reserved
e
Copyright
Distribution: UNRESTRICTED

BHEL,Haridwar 2.1-1820-0660/1
Siemens AG MK &MDA 2.1−1620−13031
Energy Sector 0316E
0913E
 Turbogenerators

Description
Gas Specification

1. Compressed Air Q If obtained from a central bulk supply, the gas shall be
made available at the following conditions:
Q The compressed air shall be free of-
Gauge pressure : 1 to 2.5 bar
corrosive contaminants and
Temperature : 20 to 30 0C
hazardous gases, flammable or toxic.
Volumetric flow rate : 144 to 216 m3/h.
Q The maximum total oil or hydrocarbon content,
exclusive of non-condensables, shall be as close 3 Hydrogen (H2)
to zero (0) w/w or v/v as possible, and under no
circumstances shall it exceed one (1) ppm w/w or Q The hydrogen gas shall be made available with a purity
v/v under normal operating conditions. 99.9% v/v. The remaining 0.1 % v/v shall be free of
Q The compressed air shall be practically free of dust. corrosive contaminants: traces of ammonia (NH3) and
The maximum particle size in the air stream shall be sulphur dioxide (SO 2) shall not be detectable by
five (5) micrometers. analysis.
Q The oxygen content of the expanded air shall be Q If obtained from a central bulk supply, the hydrogen
between 20 and 21% v/v. gas shall be made available at the following conditions:
Q The dew point at line pressure shall be at least 15 K
below the minimum possible generator temperature. Gauge pressure : 8 to 9 bar
In no case should the dew point at line pressure Volumetric flow rate : 144 to 216 m3/h.
exceed 10 °C.
Q The compressed air shall be available at a gauge 4 Nitrogen (N2)
pressure between 6 and 9 bar.
Q Volumetric flow rate: 144 to 216 m3/h. Q The nitrogen gas shall be made available with a purity
of 99.99 % v/v.
2. Carbon Dioxide (CO2)
Contaminants (O2, H2O): not applicable
Q Carbon dioxide shall be made available with a purity ≥
99.9 % v/v. The remaining 0.1 % v/v shall be free of The remaining 0.01% v/v shall be free of corrosive
corrosive contaminants: traces of ammonia (NH3) and contaminants; traces of ammonia (NH3) and sulphur
sulphur dioxide (SO2) shall not be detectable by dioxide (SO2) shall not be detectable by analysis.
analysis.

1) s.t.p. = 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.

BHEL,Haridwar 2.1-1883-0 6 6 0 /1
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 Turbogenerators

Description Primary Water Specification

The water used must not contain any contaminants Cu, dissolved/
that might have a harmful effect on the materials used in undissolved : Less than 20 ppb
the primary water circuit. For this reason, the water must
have the following quality criteria : Fe, dissolved/
Undissolved : Less than 20 ppb
Conductivity : < 10 μ mho/cm. preferably
0.5 μ mho/cm Dissolved solids : The water shall not contain chemicals
pH : 6-8 from treatment processes, such as
Dissolved O2 : Minimum, preferably less than 100 ppb hydrazine, morpholine, levoxine, phos-
Dissolved CO2 : Minimum, permissible conductivity phate, etc.
Chlorides and after a strongly acidic cation
other anions exchanger < 0.2 μ mho/cm If the water to be used does not meet these quality
Ammonia : Minimum, test with Nessler’s solution criteria, BHEL Haridwar must be informed for their evalua-
as a reagent shall not cause a change tion and approval.
in color.

BHEL,Haridwar 2.1-1885-0 6 0 0 /1
0115E
 Turbogenerators

Description Specification for

Ion Exchange Resins

1. General

The primary water must have a low condictivity since it
comes into direct contact with the high-voltage winding.
To maintain a low conductivity the primary water requires
continuous treatment. This is achieved by continuously
passing a small primary water volume flow through a mixed
bed ion exchanger arranged in the bypass of the main
cooling circuit. The ion exchange resins must be replaced
at certain intervals. The resins may be replaced while the
generator is in operation, since with the water treatment
system out of service the conductivity will continue to rise
only very slowly.
2. Resin Specification
The resins should contain no impurities or soluble
substances having a detrimental effect on the materials
used in the primary water circuit and thus on the availability
of the generator.
Our recommendation to use Lewatit ion exchange
resins is based on many years of service experience and
the close cooperation between the resin supplier and many
power plant operators as well as the high quality standard
of the resins.
The initial charge of the mixed-bed ion exchanger
consists of the following types of resins.
Q Lewatit S 100 KR/H/chloride-free
Q Lewatit M 500 KR/OH/chloride-free
When replacing the resins, use either the above types
or resins available from other manufacturers which must
comply with the specification below.

Cation exchanger Anion exchanger

(Lewatit S100KR/H/chloride-free) (Lewatit M500 KR/OH/chloride-free)

Functional group Strongly acidic Very strongly basic

Grain shape Beads Beads

Particle size (0.3 - 1.25) mm (0.3 - 1.25) mm

Bulk density of swollen resin (800 - 900) g/dm3 (670 - 750) g/dm3

Resin form H-ions OH-ions

Specific load up to 40 dm3/h × dm3 40 dm3/h × dm3

Total capacity of swollen resin (1.9 - 2.2) mol/dm3 (1.1 - 1.6) mol/dm3

Useful capacity min. 50 gCaO/dm3 16 gCaO/dm3

Chloride content up to 50 mg/dm3 50 mg/dm3

Thermal stability up to 1200C 700C

Stability in pH range Unlimited Unlimited

Shelf life min.

(in original packing 5 years 3 years
at temperatures of +1oC to +40oC

BHEL,Haridwar 2.1-1887-0 6 0 0 /1
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 Turbogenerators

Description Additive Specificaiton

for Alkalizer Unit

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

Also refer to the following information

[1] 2.1-7341 Alkalizer Unit for Primary Water Circuit
[2] 2.1-1885 Primary Water Specification

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