INDONESIA

SURALAYA POWER PLANT

STEAM TURBINE GENERATOR

OPERATION & MAINTENANCE

FOR
GENERATOR

March 2011

MITSUBISHI ELECTRIC CORPORATION

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 BASIC OF GEN. & ITS AUX.
- CONTENTS -

1. SEAL OIL SYSTEM

2. GENERATOR HYDROGEN GAS

2.1 H2 & CO2 GAS ＳYSTEM
2.2 GAS DRYER

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 3
MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 PENGOPERASIAN SEAL OIL SYSTEM
A. Persiapan start seal oil
1.Start vapour MOT
2.Start oil bearing pump , pilih salah satu sesuai kebutuhan , sesuai
kondisi
a) AOP MOT
b) TOP MOT
c) EOP MOT
3.Posisi seletor swicth di lokal panel seal oil lock off semua system seal
oil
4.On remote Air side seal oil di MCC 380 v Relay Room
5.On remote Air side seal oil DC 220 di Relay Room
6.On H2 side seal oil system di MCC 380 V turbine
7. On remote Float pump di MCC 380V turbine
8. On remote Vapour lube seal tank ( vapour generator ) di MCC 380V
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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 PENGOPERASIAN SEAL OIL SYSTEM

B. Start Seal Oil System

1. Start Vapour Generator
2. Start Air side seal oil pump
3. Start H2 side seal oil pump
4. Start Float pump seal oil
5.Posisikan auto , selector switch Air side DC , seal oil local panel .
Apabila bearing oil yang operasi AOP open valve Back – up oil
bearing. lokasi valve diatas motor DC seal oil .
a.Open back – up oil inlet valve( from bearing oil system no286)
b.Openback – up oil inlet valve ( from GOV oil system no 287 )

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 PENGOPERASIAN SEAL OIL SYSTEM

C. Apabila oil bearing yang operasi AOP, point 5a & 5b , prosedur

pembukaan valve di ikuti dan DC air side posisi remote ,
serta selector switch DC local seal oil posisi Auto
Pengaman oil pressur seal oil ada 2 (dua) :
(1)DC seal oil
(2)Bearing oil Back – up

D. Untuk start turning gear Generator silahkan penuhi persyaratan lainnya

.
Sesuai kebutuhan untuk turning gear generator operasi .

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 PENGOPERASIAN SEAL OIL SYSTEM

STOP SEAL OIL SYSTEM

A. Stop turning gear Generator
B. Stop seal oil system
1.Close valve oil bearing untuk back – up
a.Close back – up oil inlet valve
( from bearing oil system no 286 )
b.Close back – up oil inlet valve
( from GOV oil system no 287 )
2.Lock off selector switch Air side DC seal oil local panel
3.Stop Float pump seal oil
4.Stop H2 side seal oil pump
5.Stop Air side seal oil pump
6.Stop Vapour Generator

E. Stop vapour MOT sesui kebutuhan

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 PENGOPERASIAN SEAL OIL SYSTEM
C. Untuk keamanan sebaiknya seal oil stand by posisi power :

1. Off MCC Air side seal oil pump 380 v lokasi di Relay Room
2. Off MCC Air side seal oil pump 220 v DC lokasi di Relay Room
3. Off MCC H2 side seal oil pump 380 v lokasi di MCC 380 v turbin
4. Off MCC Float pump seal oil 380 v lokasi di MCC 380 v turbin
5. Off MCC Vapour Generator 380v lokasi di MCC 380 v turbin

D. Stop bearing oil pump , sesuai kebutuhan

a. AOP MOT
b. TOP MOT
c. EOP MOT

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 SEAL OIL SUPPLY SYSTEM EQUIPMENT

AIR SIDE SEAL OIL PUMP & MOTOR

H2 SIDE SEAL OIL PUMP & MOTOR

GLAND SEAL OIL PUMP & MOTOR

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 SEAL OIL SUPPLY SYSTEM EQUIPMENT

DIFF.PRESS.REGULATOR SEAL OIL COOLER

Air side seal oil cooler

H2 side seal oil cooler

( SAMPLE PICTURES) 10
MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
SEAL OIL SUPPLY UNIT COMPONENTS

VAPOR EXTRACTOR

( SAMPLE PICTURES) 11
MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 SEAL OIL FILTER
FUNCTION
To remove the foreign substances in seal oil
MESH
300 MESH

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 SEAL OIL FILTER

BY PASS VALVE

LOCK MANUVER

PIN LOCK

HAND MANUVER

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
SEAL OIL FILTER

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
SEAL OIL FILTER

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
TCV SEAL OIL SYSTEM

VALVE BY PASS TCV

COOLER SEAL OIL
SYSTEM

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TCV H2 COOLER

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
BY PASS TCV H2 COOLER

VALVE BY PASS TCV

H2 COOLER

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
FANEL INDIKSTOR SEAL OIL SYSTEM

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SEAL OIL SUPPLY UNIT COMPONENTS (2)

DRAIN REGULATOR TANK

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 GLAND SEAL CONSTRUCTION
Air Side Hydrogen Side
Seal Oil Supply Seal Oil Supply
Float Oil Supply
Seal Ring
Generator Shaft
Gas Pressure
Outboard Inboard
(Air Side) (Hydrogen Side)

Generator
Gland Seal
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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 SEAL OIL BACKUP SYSTEM

SEAL OIL PRESSURE (kg/cm2)

Pg+0.85 kg/cm2 Pg+0.85 kg/cm2

NORMAL EMERGENCY
OPERATION SEAL OIL PUMP
Pg+0.60 kg/cm2 (DC) OPERATION
BACKUP
SEAL OIL OPERATION
PRESSURE
DROP Pg+0.35 kg/cm2
AIR SIDE
SEAL OIL PRESSURE
PUMP (AC) BACKUP
REGULATOR FROM MAIN
OPERATION OIL PUMP •DIFFERENTIAL
WORKS PRESSURE-LOW ALARM
SYSTEM
•EMERGENCY SEAL OIL
PUMP (DC) WORKS

Pg: GENERATOR INTERNAL GAS PRESSURE (NORMAL 5.0 barg)

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 SEAL OIL BACKUP SYSTEM
SEAL OIL PRESSURE (kg/cm2)

Pg+0.85 kg/cm2 Pg+0.85 kg/cm2

NORMAL
OPERATION EMERGENCY SEAL
OIL PUMP (DC)
OPERATION

SEAL OIL
PRESSURE
DROP

AIR SIDE Pg+0.35 kg/cm2

SEAL OIL
PUMP (AC) •DIFFERENTIAL
OPERATION PRESSURE-LOW ALARM
•EMERGENCY SEAL OIL PUMP
(DC) WORKS

Pg: GENERATOR INTERNAL GAS PRESSURE (NORMAL 4.00 kg/cm2)

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 SEAL OIL BACKUP SYSTEM
POWER AC TRIF / KEHILANGAN AC POWER

Pg+0,85 Kg/Cm2 Pg + 0,85 Kg/Cm2

DC AIR SIDE OPERASI

AIR SIDE OPERASI

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 SEAL OIL SYSTEM UNIT
ALARM SET POINT
① SEAL OIL DIFF. PRESS. LOW : 0.35 kg/cm2
② AIR SIDE SEAL OIL PUMP STOP : 0.35 kg/cm2
③ H2 SIDE SEAL OIL PUMP STOP : 0.35 kg/cm2
④ GRAND SEAL SIDE SEAL OIL PUMP STOP : 0.35 kg/cm2
⑤ AIR SIDE SEAL OIL FILTER DIFF. PRESS. HIGH : 0.5 kg/cm2
⑥ H2 SIDE SEAL OIL FILTER DIFF. PRESS. HIGH : 0.5 kg/cm2
⑦ HYDROGEN SIDE OIL LEVEL LOW : -100mm
⑧ HYDROGEN SIDE OIL LEVEL HIGH : +100mm
⑨ SEAL OIL TEMP. HIGH (AIR SIDE) : 46℃
⑩ SEAL OIL TEPM. HIGH (H2 SIDE) : 46℃

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 SEAL OIL SYSTEM UNIT
ALARM SET POINT
⑪ EMERGENCY SEAL OIL PUMP AUTO START
⑫ EMERGENCY SEAL OIL PUMP TROUBLE
⑬ DEFOAMING TANK OIL LEVEL HIGH (TURBINE SIDE) : NL+30mm
⑭ DEFOAMING TANK OIL LEVEL HIGH (EXCITER SIDE) : NL+30mm
⑮ DEFOAMING TANK OIL LEVEL LOW (TURBINE SIDE) : NL-30mm
⑯ DEFOAMING TANK OIL LEVEL LOW (EXCITER SIDE) : NL-30mm

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 SEAL OIL OPERATION

①CHECK THE LUB OIL SYSTEM OPERATION

②SEAL OIL SYSTEM MAKE UP VALVE
(THE NEXT VALVE TO BE CLOSED:#286 #287)
(THE NEXT VALVE TO BE OPEN:#216 #223)
③AIR SIDE SEAL OIL PUMP START
(PRESSURE CHECK:0.85 kg/cm2 ±0.2 kg/cm2)
④H2 SIDE SEAL OIL PUMPSTART
(PRESSURE CHECK:PA2+1.5～2.0 kg/cm2)
⑤GRAND SEAL SIDE SIDE SEAL OIL PUMPSTART
(PRESSURE CHECK:PA2×1.5～2.0 kg/cm2)

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 SEAL OIL OPERATION

⑥ SEAL OIL SYSTEM MAKE UP VALVE

(THE NEXT VALVE TO BE OPEN:#286 #287)
(THE NEXT VALVE TO BE CLOSED :#216 #223)

⑦ LEAKAGE CHECK THE SEAL OIL SYSTEM

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 VENTILATION OF GENERATOR

STATOR CORE GAS COOLER

EXCITER SIDE TURBINE SIDE

ROTOR

BLOWER

STATOR CORE

BLOWER GAS COOLER

ROTOR (E-SIDE) ROTOR (T-SIDE)

COOLING GAS FLOW

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
Inspection Items (Generator, HYDROGEN GAS COOLER)

Outlet Water Chamber

Water Tube
Inlet Water Chamber

Water Air Cooler

Flow Construction (Sample)

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 HYDROGEN GAS COOLER

GAS COOLER TWO SECTIONS

(SEPARATE
WATER CIRCUIT)

COOLING TUBE
WITH SPIRAL FIN

■ VERTICALLY MOUNTED SPIRAL FIN-TUBE TYPE GAS COOLER

■ TWO COOLERS - FOUR SECTIONS CONFIGURATION
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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 HYDROGEN GAS COOLER

GENERATOR GAS
COOLER
OUT OUT OUT OUT

#1 #2 #3 #4
IN IN IN IN

VALVE

COOLING
WATER
SYSTEM

EACH GAS COOLER SECTION CAN BE OPERATED INDEPENDENTLY.

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
Inspection Items (Generator, HYDROGEN GAS COOLER)

As for Expected Incidents;

1. Reduction of the water tube occur.

Leakage of Cooling Water inside Generator

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
Inspection Items (Generator, HYDROGEN GAS COOLER)

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
GENERATOR AUXILIARIES
H2 & CO2 GAS ＳYSTEM

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 H2 & CO2 GAS SYSTEM EQUIPMENT
EQUIPMENT FUNCTION
H2 SUPPLY UNIT SUPPLY HYDROGEN &
REGULATE GAS PRESSURE
H2 GAS DRYER REMOVE HUMIDITY IN
HYDROGEN
H2 GAS PRESSURE MONITOR GAS PRESSURE
/PURITY MONITORING AND PURITY
UNIT

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 H2 GAS SUPPLY UNIT
TO OUTSIDE TO GENERATOR

H2 GAS FEED VALVE OUTLET PRESSURE

INDICATOR
INLET PRESSURE
INDICATOR

H2 GAS PRESSURE
REGULATOR FROM H2 GAS
(SET VALUE : 0 – 3.1kg/cm2) REDUCING UNIT

(TYPICAL FIGURE) 37
MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 H2 GAS DRYER
TO OUTSIDE

H2 GAS DRYER BLOWER

TO IN AIR

H2 GAS DRYER HEATER H2 GAS DRYER HEATER & BLOWER SWITCH

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
H2 GAS PURITY METER BLOWER

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
H2 GAS PRESS./PURITY MONITORING UNIT

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
H2 GAS PRESS./PURITY MONITORING UNIT

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 PERSYARATAN SEBELUM H2 DI BUANG
1.Seal oil system tetap Operasi
2.Buka Valve Ex H2, Buang H2 / Turunkan Pressure sampai 0.1 – 0.2 Kg/Cm2
3.Buka Valve Co2 In pertahankan Pressure 0,1 – 0,2 Prosess pembilasan H2
ke Co2 degan mengatur pembukaan valve
4.Setelah Furity 75% – 100 % Co2 , tutup valve Co2 in bilas dengan udara
instrumen
5.Proses pembilasan Co2 dengan Udara instrumen tetap pertahankan pressure
0.1 kg/cm2 – 0,2 kg/cm2
6.Setelah Furity 100% udara generator sudah aman
1. Kenapa Pressur harus rendah maksimal di atas tekanan udara luar
atmosfir 0,1 Kg/cm2– 0,2 kg/Cm2
❑ Pressur yang di bilas membutuhkan pressur yang lebih besar untuk
mendorong
❑ Membutuhkan gas pendorong sangat banyak dan rata rata
pressurenya tinggi ( Co2 dan udara instrumen )
❑ Resiko ledakan lebih tinggi

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 REPLACEMENT (AIR→CO2)

H2 MANIFOLD

CO2 MANIFOLD

MAIN
LEAD

FROM
INSTRUMENT
AIR SYSTEM VALVE
STATION

TO OUTSIDE
H2 GAS
SUPPLY
FROM CO2 GAS FROM H2 GAS
UNIT REDUCING UNIT 43
SUPPLY UNIT
MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 REPLACEMENT (CO2→H2)

H2 MANIFOLD

CO2 MANIFOLD

MAIN
LEAD

FROM
INSTRUMENT
AIR SYSTEM VALVE
STATION

TO OUTSIDE
H2 GAS
SUPPLY
FROM CO2 GAS FROM H2 GAS
UNIT REDUCING UNIT 44
SUPPLY UNIT
MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 REPLACEMENT (H2→CO2)

H2 MANIFOLD

CO2 MANIFOLD

MAIN
LEAD

FROM
INSTRUMENT
AIR SYSTEM VALVE
STATION

TO OUTSIDE
H2 GAS
SUPPLY
FROM CO2 GAS FROM H2 GAS
UNIT REDUCING UNIT 45
SUPPLY UNIT
MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 REPLACEMENT (CO2→AIR)

H2 MANIFOLD

CO2 MANIFOLD

MAIN
LEAD

FROM
INSTRUMENT
AIR SYSTEM TEMPORARY VALVE
PIPING STATION

TO OUTSIDE
H2 GAS
SUPPLY
FROM CO2 GAS FROM H2 GAS
UNIT REDUCING UNIT 46
SUPPLY UNIT
MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 H2 GAS SYSTEM./PURITY MONITORING UNIT

ALARM SET POINT

① HYDROGEN PURITY LOW: 90 % ( normal 97-100 % )
② HYDROGEN PRESSURE HIGH: 4.35 kg/cm2
③ HYDROGEN PRESSURE LOW: 3.80 kg/cm2
④ HYDROGEN PURITY MONITOR: TROUBLE
⑤ H2 DEW POINT HIGH: 5.0℃
⑥ H2 DEW POINT MONITOR: TROUBLE
⑦ H2 MANIFFOLD PRESSURE LOW: 6.4 kg/cm2
⑧ H2 BOTTLET PRESSURE LOW: 15 kg/cm2 ( 250 kg/cm2
⑨ WATER LEVEL HIGH ( water detector ): 200cc

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 Daily Inspection
• 1) Local operation
a) Physical damage
b) Loose parts
c) Gas, oil, or water leaks
d) Electrical arcing
e) Unusual noise
f) Unusual local heating

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 Daily Inspection

• 2) Performance checks
a) Rotor vibration
b) Bearing metal temperature
c) Bearing oil drain temperature
d) Seal oil pressure
e) Seal oil temperature
f) Hydrogen gas pressure
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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 Daily Inspection
• 2) Performance checks(continue)
g) Hydrogen purity
h) Cold gas temperature
i) Warm gas temperature
j) Stator winding temperature

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 Operating Condition

Checking location Normal condition

a) Rotor Vibration ＜50μmp-p
b) Bearing metal temperature ＜77℃
c) Bearing oil drain temperature ＜107℃
d) Seal oil pressure P3=Pg + 0.85 kg/cm 2
e) Seal oil temperature(Air’s H2’s) 36～40 ℃
f) Hydrogen gas pressure 3.80～4.35 kg/cm2
g) Hydrogen purity ＞ 90 %
h) Cold gas temperature ＜50℃
i) Warm gas temperature ＜100℃
j) Stator winding temperature ＜120℃

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
Allowable load when water flow into
cooler is reduced

: In service : Out of service

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
Trouble shouting
(alarm operation)

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 Trouble shouting
3. HYDROGEN GAS PURITY – Low
Check generator load and gas temperature
Check pressure indicator (confirm with local
indicator)
Check H2 supply system (include supply valve condition)
Check H2 gas cooler
system
4. Water detector –
High
Drain from water detector
(Should be close all inlet valves before drain)
If it is necessary, analyze the water

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 Trouble shouting
5. Drain regulator level – Low
Check the oil level at drain regulator
Close the outlet valve of drain regulator tank (if necessary)

6. Drain regulator level –

High
Check the oil level at drain regulator
Open the outlet by-pass valve of drain regulator tank

(Note)

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 Trouble shouting

7. Differential pressure – Low

Check the seal ring inlet pressure.
Check the relief valve operating condition
Check the seal oil temperature
Re-adjust the differential pressure regulator

8. Seal oil temperature –

High
Check the seal oil temperature at local indicator
Open and re-adjust the seal oil cooling water outlet valve

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MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
 Trouble shouting

9. Seal oil filter differential pressure –

High
Check the seal filter differential pressure at local indicator
Change the filter circuit to other
side
Cleaning the strainer and normalize
10. Seal oil pump stop
Check the seal oil pump outlet pressure at local
indicator
Check the electric
circuit
11. H2 gas purity calculator –
Fault
Check the electrical circuit for purity monitoring
system
power supply – off, cable – loose,
( etc.) 57
MITSUBISHI CONFIDENTIAL AND PROPRIETARY INFORMATION
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PENGENALAN BAGIAN
GENERATOR

TIDAK KENAL
MAKA TIDAK
SAYANG 59
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 Terima kasih / thank you

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