REV. 01 DATE: 03.10.

2020

WRITE UP OF GENERATOR PRIMARY WATER

(PW) SYSTEM
BHEL DOC. NO. TGE-3668

1.0 INTRODUCTION:
INTRODUCTION:
The trend towards higher and
higher generator ratings
necessitates intensive cooling of
the conducting components. This is
achieved by the use of water as the
cooling medium, because water has
a particularly high heat removal
capacity and easy availability. The
water used for direct cooling of the
current carrying parts of the
generator is referred to as
It must not be used directly or indirectly in any way detrimental to the interest of the company
chemical and mechanical treatment
is also required while the generator
is in service.
2.0 DESIGN CRITERIA:
2.1 PRESSURE
The primary water system for the
generator is designed for a gauge
2
pressure of 10 kg/cm . In some
regions, however special pressure
conditions apply. In the stator

winding, for example, the primary

The information on this document is the property of Bharat Heavy Electricals Limited.

generator primary water. water pressure must be less than

the pressure of the hydrogen in the
REFERENCE generator casing, i.e. less than 5
Process and instrumentation 2
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kg/cm gauge. In the primary water

diagram for PW System-
cooler, the primary water pressure
01530001137
must be greater than the pressure
of the secondary cooling water.
1.1 REQUIREMENTS AND
FUNCTIONS
2.2 TEMPERATURE
The generator primary water
The service temperature of the
system is required to cool the
overall primary water supply circuit
following generator components:
lies between 48 and 80 °C. The
(i) Stator winding
primary water circuit is cooled to
(ii) Phase connectors, including the
49°C with the aid of the primary
bushings.
water coolers. The cold end
Since primary water is in contact
primary water temperature is
with high voltage carrying parts
monitored and the mechanical
and in some regions is required to
generator protection circuitry trips
flow through extremely narrow
the turbine generator set if
hollow conductors, it requires
generator inlet temperature of
extremely intensive chemical and
primary water exceeds 59 °C.
mechanical treatment. The primary
water is ultra-high purity water
with very low conductivity approx.
1.8 micro siemens/cm. Continuous
Page 1 of 10
PROJECT NAME: 1X660 MW BHUSAWAL THERMAL POWER STATION, MAHARASHTRA
 REV. 01 DATE: 03.10.2020

WRITE UP OF GENERATOR PRIMARY WATER

(PW) SYSTEM
BHEL DOC. NO. TGE-3668

2.3 FLOW RATE primary water conductivity remain

The flow rate is a decisive factor in between 1.0 to 2.5 micro
designing to ensure adequate siemens/cm in continuous service.
supply of primary water to the
stator winding, phase connectors 3.0 DESCRIPTION:
DESCRIPTION:
and bushings. These regions are
monitored section by section to 3.1 OVERALL SYSTEM
ensure that the required primary CONFIGURATION
water flow is present at all times. If The primary water required for
the primary water flow rate falls cooling is continuously circulated in
below a certain level (about 80 %), a closed loop by a separately
the mechanical generator installed pump. Two full load
protection circuitry trips the pumping units are provided to
It must not be used directly or indirectly in any way detrimental to the interest of the company
The information on this document is the property of Bharat Heavy Electricals Limited.

turbine generator set with a delay
of 60sec. Operating value of
3
Primary water flow is 125m /hr.
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ensure trouble free operation of the
generator. An automatic control
circuit ensures that if one of the
two pumps becomes unavailable,

There will be pre trip alarm if flow

3 the second standby pump is ready
goes less than 112.5 m /hr and
to take over at any time. Each
trips the turbine generator set if
pump is driven by a dedicated
flow decreases to less than 100
3 electric motor. Only copper,
m /hr. Design is based on a stainless steels and similar
maximum primary water flow rate corrosion resistant materials are
3
of 150 m /hr. used throughout the system to rule
Operating value of flow for each out any possibility of corrosion.
3
bushing is 2.7 m /hr. There will be
pre trip alarm if flow goes less than The generator primary water
3 system essentially comprises the
2.26 m /hr and trips the turbine
following components:
generator set if flow decreases to
3 * Primary water tank (MKF01
less than 2.11 m /hr. BB001)
* Primary water pumps (MKF11
2.4 ANALYSIS AP001 & MKF12 AP001)
The primary water has to be * Primary water coolers (MKF21
treated since it comes into contact AC001 & MKF22 AC001)
with the high voltage carrying * Primary water filters (MKF27
stator winding conductor. AT001 & MKF28 AT001)
Continuous treatment ensures a * Fine mesh filter (MKF35 AT011)
Page 2 of 10
PROJECT NAME: 1X660 MW BHUSAWAL THERMAL POWER STATION, MAHARASHTRA

WRITE UP OF GENERATOR PRIMARY WATER
(PW) SYSTEM
* Ion Exchanger (MKF35 AT001)
* NaOH dosing pump (MKF36
AP001)
∗ NaOH Dosing tank (MKF36
BB001)
∗ CO2 Absorber (MKF36 AT001)
∗ Motorized control valve (PGB33
AA151)
∗ Pipe and its fitting to connect the
system in closed loop
The primary water flowing to the
pump from the primary water tank
It must not be used directly or indirectly in any way detrimental to the interest of the company
The information on this document is the property of Bharat Heavy Electricals Limited.
is passed via coolers and filters to
the water ring manifold inside the
generator and to the bushings.
When the water has fulfilled its
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cooling function, it is returned from
the other end of the generator to
the primary water tank and from
the bushings to the suction line of
the pumps. Any hydrogen present
in P.W. Water is released into P.W.
Tank. The primary water tank is to
be flushed with nitrogen before
startup and after shutdown of the
primary water loop. The nitrogen is
supplied from a nitrogen cylinder.
The Hydrogen gas in the P.W. Tank
is vented to atmosphere via a
safety relief valve in the waste gas
system. If gas pressure in the tank
2
increases from 0.3 kg/cm gauge
pressure then safety valve releases
the gas to waste gas system.
PROJECT NAME: 1X660 MW BHUSAWAL THERMAL POWER STATION, MAHARASHTRA
REV. 01 DATE: 03.10.2020
BHEL DOC. NO. TGE-3668
3.2 INDIVIDUAL SYSTEM
SYSTEM
CONFIGURATION
3.2.1 EXTERNAL COOLING
CIRCUIT
The two primary water pumps
(MKF11 AP001 and MKF12
AP001), only one of which is in
service at any time, the second
remaining on standby ready to take
over in the event of mechanical or
electrical failure of pump and motor
set which is running, pump draw
water from the primary water tank
(MKF01 BB001) and deliver the
water to (2 x 100 % duty) primary
water cooler units (MKF21 AC001
& MKF22 AC001). In these Primary
water coolers, the heat absorbed
by the primary water during
passage through the generator is
transferred to the secondary
coolant. As a rule, only one PW
cooler is in service at a time, while
the other cooler remains standby.
After passing through the PW
coolers, the primary water flows
through the main primary water
filter (MKF27 AT001 & MKF28
AT001).
The quality of the primary water
downstream of the main filter
(MKF27/MKF28 AT001) is
monitored by a conductivity meter
(MKF29 CQ011). An alarm is given
if the conductivity reaches greater
than 3 micro siemens/cm and if
conductivity value increase to
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WRITE UP OF GENERATOR PRIMARY WATER
(PW) SYSTEM
greater than 4 micro siemens/cm
then flushing with DM water
recommended.
Downstream of this conductivity
meter a small fraction of the total
primary coolant flow is
continuously branched off and
passed through ion Exchanger
(MKF35 AT001). The ion
exchanger vessel is filled with
anion and cation exchanger resins
to form a mixed bed. The water
It must not be used directly or indirectly in any way detrimental to the interest of the company
The information on this document is the property of Bharat Heavy Electricals Limited.
thus treated is then passed through
a fine filter (MKF35 AT011), which
retains any abraded resin particles.
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Downstream of this fine-mesh
filter, the quality coolant is
monitored by conductivity meter,
and an alarm is given if the
conductivity reaches below 1 micro
siemens/cm and above 3 micro
siemens/cm. Dosing pump will On
or OFF to maintain the conductivity
between 1-2.5 micro siemens/cm
The treated primary water is then
returned to the main primary water
flow at the suction of the primary
water pumps. A dilute 1-2% NaOH
is fed into the bypass circuit after
ion exchanger with the help of a
short stroke diaphragm dosing
pump. By this a pH level of approx.
8.5 is maintained in the main circuit
so as to minimize corrosion effects
on copper.
PROJECT NAME: 1X660 MW BHUSAWAL THERMAL POWER STATION, MAHARASHTRA
REV. 01 DATE: 03.10.2020
BHEL DOC. NO. TGE-3668
3.2.2 INTERNAL COOLING
CIRCUIT
Upstream of the generator, the
cooling water flow is divided into
two part flows. Part flow (1) cools
the stator winding. This part flow is
first routed to a ring manifold at the
terminal end of the generator and
from there via insulating teflon
hoses to the bars of the stator
winding. The cooling water flows
through the hollow conductors of
the winding bar to the other end of
the generator, where it is again
passed via teflon hoses to a ring
manifold and from there back to the
P.W. tank. Since flow is in the same
direction through all bars, the heat
up of the coolant, and therefore of
the bars, is low. This prevents
relative movement between the top
and bottom bars as a result of
different degrees of thermal
expansion.
Part flow (2) cools the phase
connectors and the bushings. The
six bushings and the phase
connectors arrange so as to form a
ring around the stator end winding
are hydraulically connected in such
a way that three parallel flow paths
are formed. The cooling water is
delivered outside the generator
through three bushings and
removed via the other three
bushings. From there it is returned
to the suction line of the pumps. In
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WRITE UP OF GENERATOR PRIMARY WATER
(PW) SYSTEM
order to keep the temperature of
the primary water as steady as
possible regardless of generator
output and cold water temperature,
the primary water temperature is
automatically controlled by
variation of the secondary coolant
flow rate via motorized control
valve (PGB33 AA151).
3.2.3 GAS CIRCUIT
The primary water leaving the
generator is returned to the
It must not be used directly or indirectly in any way detrimental to the interest of the company
The information on this document is the property of Bharat Heavy Electricals Limited.
primary water tank (MKF01 BB001)
where it is able to release any gas.
The hydrogen released in this
degasification process is passed to
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the exhaust via a pressure relief
valve. During the filling and
draining of the primary water tank,
nitrogen as an inert gas is used to
displace the hydrogen or air
present. During normal operation
also the primary water tank will be
partially filled with nitrogen at 0.3
2
Kg/cm .
3.3 DESCRIPTION OF THE
SYSTEM COMPONENTS
3.3.1 PRIMARY WATER PUMPS
AND FILTER UNIT
The primary water pump and filter
unit comprises the following main
components of the primary water
system:
* Water treatment plant
* Primary water pumps
* Primary water filter
PROJECT NAME: 1X660 MW BHUSAWAL THERMAL POWER STATION, MAHARASHTRA
REV. 01 DATE: 03.10.2020
BHEL DOC. NO. TGE-3668
3.3.1.1 WATER TREATMENT
PLANT
The water treatment plant consists
of the ion exchanger vessel
(MKF35 AT001), which is filled
with anion and cation exchanger
resins to form a mixed bed. A
perforated plate in the lower part
of the exchanger vessel prevents
the resins from escaping from the
vessel into the piping system. A
fine mesh filter (MKF35 AT011) is
provided downstream of the ion
exchanger vessel with the function
of trapping abraded resin particles
entrapped in the primary water. A
differential pressure switch
visualizes the degree of plugging of
the filter and generates an alarm if
the differential pressure across the
filter becomes greater than 0.9
2
kg/cm . The flow of the water
through the mixed bed is limited in
both the upward and the downward
directions by the specific density of
the resins on one hand and the flow
velocity of the primary water
through the resin bed on the other.
A flow meter measures the flow of
water through the mixed bed.
Downstream of the filter, an orifice
plate deflects a part flow of the
water through a conductivity meter,
which monitors the effect of the
resins. If the conductivity of the
primary water exceeds a preset
limit (greater than 3.0 micro S/Cm),
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WRITE UP OF GENERATOR PRIMARY WATER

(PW) SYSTEM
BHEL DOC. NO. TGE-3668

this conductivity meter generates 3.3.1.3 PRIMARY WATER FILTERS

an alarm. The mixed bed ion
exchanger has a specific capacity
i.e. its capacity for absorbing the
ions to be exchanged is limited.
When the resins are used up i.e.
when their absorption capacity has
been exhausted, the resin filling
must be replaced by new
regenerated resins. The resins can
be replaced while the generator
remains in service since the
conductivity of the primary water
It must not be used directly or indirectly in any way detrimental to the interest of the company
(MKF27 AT001 & MKF28
AT001)
Primary water filter of nominal
bore NB150 and nominal pressure
2
10kg/cm is used for filtering the
demineralised water. The mesh
material and mesh size of the filter
are SS316 and 150μm respectively.
A differential pressure switch is
also provided across the filter to
measure the DP and give alarm

when differential pressure greater

The information on this document is the property of Bharat Heavy Electricals Limited.

rises only very slowly even when 2

than 0.9 kg/cm .
the water treatment plant is out of
service.
COPYRIGHT AND CONFIDENTIAL

3.3.2 PRIMARY WATER COOLERS

3.3.1.2 PRIMARY WATER PUMPS
(MKF21 AC001 & MKF22
(MKF11 AP001 & MKF12
AC001)
AP001)
The heat absorbed by the primary
Two full load-pumping units are
water in the generator is
provided to ensure uninterrupted
transferred to the secondary
operation of the generator. Both
coolant in the primary water heat
pumps are of equal operating
exchangers. The primary water
priority and they are operated
heat exchanger consists of two
alternately. Changeover from one
units (2 x 100 % duty). When the
pump to the other is possible at any
plant is in normal full load
time without interrupting primary
operation, one unit is in service at
water circulation. The pump not in
a time while the other unit remains
service at any given time remains
as standby. The primary water heat
as standby, ready to start
exchanger is a counter flow plate
automatically if the pump in service
type heat exchanger.
fails. Manual selection of pumps
will be provided on HMI by BHEL
3.3.3 PRIMARY WATER TANK
EDN Bangalore.
(MKF01 BB001)
The primary water tank is mounted
on rubber metal vibration dampers

Page 6 of 10
PROJECT NAME: 1X660 MW BHUSAWAL THERMAL POWER STATION, MAHARASHTRA

WRITE UP OF GENERATOR PRIMARY WATER
(PW) SYSTEM
on the stator frame. It forms the
point of highest elevation of the
entire primary water circuit. In this
tank, the primary water leaving the
stator winding is able to release
any gas. The water level in the
primary water tank is indicated by
a magnetic type level gauge.
Capacitance type water level
sensors are provided for
annunciation purposes, should the
water level rise or drop to its
allowable maximum or minimum
It must not be used directly or indirectly in any way detrimental to the interest of the company
The information on this document is the property of Bharat Heavy Electricals Limited.
level. Operating value of level in
PW tank is between 240-300mm
and alarm will be generated when
tank level reaches less than 240mm
COPYRIGHT AND CONFIDENTIAL
or greater than 300mm.
3.3.4 ALKALYSER UNIT
The dependence of corrosion
mechanism on oxygen decreases
with increasing alkalinity of water
and becomes insignificant at pH
values of 8.5 to 9.0. Dilute alkali
(NaOH) is therefore introduced into
the bypass circuit after the Ion
exchanger. The Alkalyser Unit
contains mainly electronic
diaphragm dosing pump, NaOH
tank, CO2 absorber and junction
box. All status & control will be
provided on HMI (Human Machine
Interface).
3.3.4.1 ALKALISATION PROCESS
Dilute (1-2 %) NaOH solution is
injected into the low conductivity
PROJECT NAME: 1X660 MW BHUSAWAL THERMAL POWER STATION, MAHARASHTRA
REV. 01 DATE: 03.10.2020
BHEL DOC. NO. TGE-3668
primary water circuit, where it
remains as dissolved, dissociated
sodium hydroxide solution. OH ion
concentration determines the pH
value. The ion exchanger remains
in service continuously. This
removes all unwanted ions, e.g. CL
(-) and HCO3 (-) from the water as
well as Na (+) ions from the
sodium hydroxide solution. This
elimination of sodium that is
proportional to the volumetric flow
rate of water through the Ion
exchanger is compensated by
continuous feeding of dilute sodium
hydroxide solution. The
conductivity of the water after
injection provides a reference for
pH value as the pH and
conductivity are related to each
other by a curve.
Direct pH measurements using pH
electrodes cannot be used since the
instruments available have not
proven for continuous service in
low conductivity primary water
system. As such occasional checks
are recommended.
A pH value of 8.5 to 9.0 is optimum
to ensure minimum corrosion.
3.3.4.2
3.3.4.2 MODE OF OPERATION
The dosing pump draws dilute
sodium hydroxide solution from the
tank and delivers it to the primary
water system after Ion exchanger
via a spring loaded feed valve. Low
NaOH tank level is sensed with a
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WRITE UP OF GENERATOR PRIMARY WATER
(PW) SYSTEM
level detector. A CO2 absorber in
the air supply line removes carbon
dioxide in the inlet air and prevents
the formation of carbonates in the
NaOH solution. The tank has a
capacity to store sodium hydroxide
solution required for a service
period of a few months.
3.3.4.3 CONTROL AND
MONITORING
The feed rate is controlled by
It must not be used directly or indirectly in any way detrimental to the interest of the company
changing stroking rate dependent
The information on this document is the property of Bharat Heavy Electricals Limited.
on conductivity in the treatment
circuit. For this purpose, a
controller and an analog to digital
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convertor is provided in the control
system. Interlocks using the
volumetric flow rate in the
treatment circuit as a criterion
prevent starting of the
Alkalyser Unit and NaOH feeding
into the circuit under no flow
condition. To avoid overfeeding
due to fault or incorrect operation
of the Alkalyser Unit, the dosing
pump is stopped as soon as:
* Conductivity in treatment circuit
is > 3.0 micro S/Cm.
OR
* Conductivity in the main circuit is
> 2.5 micro S/Cm.
OR
* Volumetric flow rate in treatment
circuit is low.
PROJECT NAME: 1X660 MW BHUSAWAL THERMAL POWER STATION, MAHARASHTRA
REV. 01 DATE: 03.10.2020
BHEL DOC. NO. TGE-3668
After the pump has been stopped
on account of one of these
conditions, the conductivity of the
water promptly decreases by action
of the Ion exchanger. The
Alkalyser Unit provides warning
alarms in the following events by
displaying them on HMI:
* Low conductivity in the main
circuit < 1.0 micro S/Cm.
* Low conductivity in treatment
circuit < 1.0 micro S/Cm
* Low level in NaOH tank (Until
probe immersed in liquid, No
alarm).
In these generator modes, the
primary water supply system
remains in operation to preserve
the purity of the primary water.
3.4 OPERATING MODES
3.4.1 STANDSTILL AND TURNING
GEAR OPERATION
This continued operation of the
primary water system is kept even
during prolonged periods of
generator standstill, because
draining and refilling of the primary
water system is very time
consuming and elaborate.
3.4.2 GENERATOR START-
START-UP
Before the generator can be started
up, the following conditions must
have been established as regards
the Primary Water System.
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 REV. 01 DATE: 03.10.2020

WRITE UP OF GENERATOR PRIMARY WATER

(PW) SYSTEM
BHEL DOC. NO. TGE-3668

(i) Entire primary water circuit
filled.
(ii) All instrumentation, including
protection and alarm circuits,
operative.
(iii) Generator filled with hydrogen
to nominal pressure.
(iv) Primary water heat exchangers
filled and vented.
(v) Primary water cold end
temperature at least 5 K higher
than the temperature of the cold
gas.
It must not be used directly or indirectly in any way detrimental to the interest of the company
in such a way that the flow in the
3
circuit doesn't fall below 100m /hr
(trip set point) from the time of
sensing set pressure till the pump
accelerates to deliver flow above
3
100m /hr. The conductivity of the
primary water rises when the
resins of the ion exchanger are
used up. To rectify this condition,
the water treatment plant is to be
taken out of operation and the
resins replaced. The generator may

continue in operation while the

The information on this document is the property of Bharat Heavy Electricals Limited.

resins are being replaced, because

3.4.3 NORMAL OPERATION
OPERATION
the conductivity of the water rises
Low oxygen and chemically pure
only very slowly even when the
distilled water or condensate can
COPYRIGHT AND CONFIDENTIAL

water treatment plant is not in

be used to fill the cooling circuit.
service. Any blockage in the
Demineralized water and
primary water system is detected
condensate may be used only if
by means of flow rate
they satisfy the specified quality
measurements performed in the
requirements. In no case the
individual section. The individual
generator is operated without
sections are the following:
primary water.
* Stator winding
3.4.4 FAULTS
* Bushings, three flow meter per
If the primary water pump, which is
phase
running, becomes unavailable,
whether due to a mechanical fault
If the flow rate measured at these
or loss of the supply voltage,
flow meters drops to about 80 %,
automatic changeover to the
the mechanical generator
standby pump is affected. The
protection circuitry trips the
criterion which causes changeover
turbine generator set with a delay
to be initiated is the reduction in
of 60sec.
water pressure on the discharge
side of the pump. The set point of
Leakage in the primary water
the discharge pressure when
system should be located as
changeover is initiated is selected
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PROJECT NAME: 1X660 MW BHUSAWAL THERMAL POWER STATION, MAHARASHTRA
 REV. 01 DATE: 03.10.2020

WRITE UP OF GENERATOR PRIMARY WATER

(PW) SYSTEM
BHEL DOC. NO. TGE-3668

quickly as possible. Further loss of

primary water can then be
prevented by isolation of the
section in which the leak is located.
If this cannot be done without
interrupting cooling water
circulation, the turbine set is to be
shut down. The mechanical
generator protection circuitry,
likewise, trips the turbine
generator set if the primary water
temperature downstream of the
heat exchangers rises too high.
It must not be used directly or indirectly in any way detrimental to the interest of the company
The information on this document is the property of Bharat Heavy Electricals Limited.

This can occur if the heat

exchangers are not in good
condition. Overheating of the
primary water may in turn lead to
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overheating of the generator

winding.

3.4.5 TRIPS

A-Turbine generator set will trip

when primary water flow at the
outlet of stator winding reaches
3
less than 100 m /hr.

B- Turbine generator set will trip

when primary water flow bushing
3
reaches less than 2.11m /hr.
C- Turbine generator set will trip
when inlet temperature of primary
o
water reached greater than 59 C.

**********************************
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PROJECT NAME: 1X660 MW BHUSAWAL THERMAL POWER STATION, MAHARASHTRA