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POWER PLANT OPERATION GENERATOR & AUXILIARIES

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Presentation outline
Seal Oil System line up

Hydrogen filling
Stator Water System line up

Generator Synchronization
LP heater charging

Load Raising
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SEAL OIL SYSTEM


EE BEARING TE BEARING

FLOW M.
FROM GAS SYSTEM GAS EXHAUST

PS PG
TS ES

TG
SOST
BEARG DRAINS

FR

DPRV

IOT

DP SW
VACCUM PUMP

VACUUM TANK SOP 1

FILTERS
2

SOP-3 DC OIL COOLER

CONSTANT PRESS. REGULATORS WITH ORFICE PLATES


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SEAL OIL SYSTEM CHARGING


Commissioning of seal oil system will be required when the 1) generator to be filled with hydrogen or air. 2) machine to be put on barring gear Prior to commissioning make sure that all instruments and devices are ready for operation after calibration, overhauling and trial.

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SEAL OIL SYSTEM CHARGING


Seal oil system has to be filled with oil Prerequisite for oil filling 1) set all level switches 2) close all stop and non-return shut off valves 3) open all pressure gauge and pressure switches isolating valves 4) open pressure transducer isolating valves 5) open isolating valves of impulse lines of differential pressure regulator 6) bearing lube oil system is in service

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SEAL OIL SYSTEM CHARGING


Open isolating valve of seal oil storage tank to seal oil system. Oil will start filling the seal oil system Open valves in oil flow path Take coolers and filters into service After oil is filled up into the system level will be visible in the gauge glass of the SOT Take governing oil system into service Start AC seal oil pump To clear air locking seal oil pump should be switched on and off till its discharge pressure gauges shows a constant pressure Vent DPRV-A and DPRV-B
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SEAL OIL SYSTEM CHARGING


Vent both the coolers one by one Vent filters Vent pressure gauges, pressure switches and transmitters Set seal oil pressure by DPRV-A Stop AC seal oil pump and set DPRV-B (<0.3Kg/cm2 from DPRV-A) Set thrust oil pressure (0.5 Kg/cm2 more than seal oil pressure) Take vacuum pump into service and adjust SOT vacuum as recommended
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SEAL OIL SYSTEM CHARGING


Check all the meter readings are within limit Check seal oil flow is as per system requirement. Check automatic starting of stand by DC seal oil pump by different interlocks including alarm Check function of level switch of SOT, seal oil storage tank and pre-chambers After seal oil temperature reaches 300C start cooling water flow to seal oil cooler and adjust the flow in such a way so that the seal oil temperature is maintained at 400C
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HYDROGEN COOLING SYSTEM


ANALYZER
H2 DISTRIB CO2

TO SEALOIL DPT
H2 DRIER

FILTER

DPI
OP

VAPOURIZER HYDROGEN

CO2

AIR

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DRAIN

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PRE CHECHS

HYDROGEN COOLING SYSTEM

Overhauling of gas drier has been carried and the drier is boxed up Check all instruments are in position after calibration Functionally check the gas drier system Check the availability of adequate no of CO2 filling point and adequate no of co2 cylinders. Check availability of adequate no of Hydrogen filling points and cylinders. Check whether the relief valves in the high pressure valves are alright. Check the generator is completely boxed up & its air tightness test is successfully completed. Check the seal oil system is in service.
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Purging of Air By CO2


CO2 is admitted from CO2 manifold to generator casing at bottom by opening the valves on cylinder and regulator. Rate of admission is being controlled normally by regulating the valves on the manifold. To avoid excessive frosting, the CO2 flow rate should be carefully regulated. When CO2 percentage reaches 98%, the filling of CO2 can be stopped and preparation for filling hydrogen can be made. After achieving 98% CO2 concentration and a pressure of 0.15 to 0.2 Kg/cm2 inside the machine, filling of hydrogen in machine can be started.
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H2 FILLING
Hydrogen is admitted into the generator through hydrogen feed pipe which is connected to perforated pipe header inside the generator extending along the length of the cooling at the top. During process of filling with H2 the CO 2 air mixture is discharged through CO2 feed pipe from bottom. During H2 filling, continuously analyze the concentration of H2 in gas mixture inside the machine. Continue purging till hydrogen purity reaches above 98% and H2 pressure attains rated value. Take drier into service. Take gas coolers into service. Vent the coolers and establish flow.
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STATOR WATER SYSTEM


EXPANSION TANK GAS TRAP FLOW METERS DIFF PRESS SWITCH

MAGNET FILTER
FSI I

FILTERS

DIFF PRESS. CONDUCTIVITY MAKE UP

POLISH UNIT

COOLERS PUMPS VACUUM PUMPS


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Stator Water System


For commissioning the system the system has to be filled up first Prerequisites for filling the cooling circuits a. Circuit should be flushed b. Installation of pump and motors after O/H c. Filters cleaned and boxed up d. Coolers and all other components are boxed up e. Ion exchanger is ready and is in service f. All instruments and measuring devices are in position after their calibration
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Stator Water System


System should be lined up for filling. Complete stator water system should be filled with DM water having required quality. All air should be vented from the system before starting of the pump. Take trial of the water pumps. Check the stand by pump for automatic starting Adjust level regulator in the expansion tank. Check all the instruments and meters for their proper functioning.
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Stator Water System


Adjust make up water pressure around 2.0Kg/cm2 Adjust small water flow through the gas trap Check there is no leakage of water in the system Take ejector into service Take one cooler into service Check emergency switching in circuit of the stand by water pump Check high and low alarm of the expansion tank Check high conductivity alarm and tripping Check pump discharge pr., filter diff. pr., conductivity, flow, inlet winding pr., winding diff. pr., vacuum in expansion tank, motors current
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GENERATOR SYNCHRONISATION

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Check before synchronisation


CHECK all the generator Parameters are healthy Stator cooling water flow more than 21 T/Hr. Stator cooling water temp less than 40 oC. Cold end hydrogen temp less than 40 oC Seal oil pressure at turbine and 5.0 KSC Seal oil pressure at exciter end 5.0 KSC Seals oil D.P. between1.2 -1.5 KSC Generator stator water specific conductivity is less than 5 m mho/cm Gen. hydrogen and stator water coolers are charged and ''Clarified water pressure to hydrogen & stator water coolers low' alarm is not on.
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Check before synchronisation


CHECK before closing the field breaker before synchronization Turbine RPM is more than 2980 rpm. Generator isolators are closed from switchyard. Generator excitation control is on REMOTE. Generator excitation control is on MANUAL OR AUTO. AUTO/MANUAL excitation controllers are on HOME position. CLOSE the generator field breaker. Generator field breaker gets closed & Generator voltage increases to 10 KV, 15.75 KV approx. on manual / auto excitation control, respectively. RAISE generator excitation manually, to raise gen. voltage. CHECK all the generator voltages (phase to phase). All the three phases should read equal voltages
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SWITCH-ON the synchroscope to CHECK mode. IN-COMING/RUNNING voltages and frequencies start showing on their Corresponding meters. Alternatively synchroscope is put on Check mode and auto synchroniser can be switched on. Synchroscope needle starts rotating at a rate proportional to difference between the generator and grid frequencies. ADJUST turbine speed reference to match generator freq with the grid (running). ADJUST generator excitation to match the gen. voltage with that of grid. As synchroscope needle comes to 11'O clock position (clockwise), the green CHECK lamp comes on & the red lamp goes off. At 12' O clock position the check lamp goes off and red lamp comes on again.
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Synchronisation

Synchronisation
When the voltage and frequency match, the synchroscope will move very slowly in the clockwise direction. This position shows that: i) Phase sequence of generated voltage and system voltage is same. ii) Effective values of both the voltage are same. iii) Frequency of both the system and the incoming m/c is same.
CLOSE the generator breaker when the check lamp is green. ''Generator motoring'' alarm comes on. INCREASE Starting Device to 100%. RAISE speed reference slightly to increase Gen load, immediately after closing the generator breaker. Turbine load increases to 20 MW approximately. ''Speed controller'' transfers to 'Load controller'' after some time delay.
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Synchronisation
Gen. voltage and P.F., will be maintained by AVR if the excitation mode is on "Auto", otherwise, maintain Gen. voltage and PF by varying the field rheostat from the Gen. control desk. If excitation mode is on manual, then change over to "Auto" mode after matching the parameters. Slowly raise the load on Generator upto 80 MW (Follow the guide lines given for loading the machine). Now the voltage and power factor will be maintained by the automatic voltage regulator (AVR).

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Check that the unit auxiliary supply incoming breakers are racked in service position, springs are charged and "Local/Remote" switches are on "Remote" position. SWITCH-ON synchroscope to CHECK mode. Synchroscope green lamp comes on after the two voltages are matching CLOSE UAT (A/B) incomer to Unit bus. ''Unit/Station transformers paralleled'' annunciation comes on. Immediately OPEN the station breaker.

Unit Supply Changeover From Station To UAT

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LP HEATERS CHARGING
CHECK these conditions are satisfied before charging the LP heaters. Generator load is at least 40 MW. All LP heaters are CHARGED from waterside and their bypass valves are closed. All LP heaters airline to condenser, are OPEN. All pneumatic drip valves are OPERATIONAL & on REMOTE. OPEN LPH-1 Extraction steam block valve ES-1. Condensate temperature across LPH starts rising. OPEN LPH-2 extraction block valve ES-2. Associated line drain valve starts closing after the extraction block valve opens 100%. LPH-2 alternate drain to condenser starts closing. LPH-2 normal drain valve starts modulating to maintain the level. OPEN LPH-3 extraction block valve ES-3.
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HP HEATERS CHARGING
CHECK before charging the HP Heaters: Unit load is more than 120 MW. HPHs water side inlet/outlet valves OPEN and individual bypass valve are CLOSED. HPHs group bypass valves are IN-SERVICE position and "HPHs bypassed" alarm is NOT On. All HPHs shell drains are OPEN. All HPHs airlines to condenser isolating valves are open. OPEN HPH-5 extr. steam block vlv ES-5. After ES-5 is open, extr. line drain DW-73 closes. HPH-5 alternate drain to condenser HD-31 closes HPH-5 normal drain to D/A starts modulating to maintain the level. Feed water temp after HPH-5 starts increasing. Similarly charge HPH-6 and maintain the drip level. Put drip level control on Auto.

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Capability Curve

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LOAD RAISING
Increase the firing rate in the boiler as per the TSE margin and load schedule.

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THANK YOU

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