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SEAL OIL SYSTEM

IN ORDER TO PREVENT ESCAPE OF HYDROGEN


FROM THE GENERATOR IT IS ESSENTIAL TO PROVIDE SHAFT
SEALS AT BOTH ENDS WHERE THE SHAFT EXTENDS
THROUGH THE CASING.
THIS IS ACHIEVED BY PROVIDING RADIAL OIL
FILMS IN THE SYSTEM, THIS OIL BEING KEPT AT A HIGHER
PRESSURE THAN THAT OF THE HYDROGEN INSIDE THE
GENERATOR.
THE LOCATION WHERE THE ROTOR SHAFT PASSES
THROUGH THE STATOR CASING ARE PROVIDED WITH
RADIAL OR RING TYPE SEAL RINGS.THE SEAL EING IS
FORMED BY JOINING TWO SEMICIRCULAR RINGS.

BABBIT METAL
BABBIT METAL IS A COMPOSITION OF TIN, ANTIMONY AND
COPPER .THE SEAL RING IS LINED WITH BABBIT METAL ON THE
SHAFT JOURNAL SIDE.

BABBIT METAL HAS A LOW MELTING TEMPERATURE TO
SAFEGUARD THE SHAFT IN CASE OF OIL STARVATION.

THE SEAL OIL IS SUPPLIED TO THE SEALING GAP FROM THE
SEAL BODY VIA RADIAL HOLES AND ANNULAR GROOVE IN
THE SEAL RING.

THE TWO HALF OF THE SEAL RING ARE GUIDED IN THE SEAL
BODY, WHICH IS BOLTED ON THE END SHIELD
SEALING PHENOMENON
TO ENSURE EFFECTIVE SEALING THE SEAL OIL PRESSURE IN
THE ANNULAR GAP IS MAINTAINED AT 1.5 KSC ABOVE THE GAS
PRESSURE WITHIN THE GENERATOR CASING.

THE OIL DRAINED ON THE HYDROGEN SIDE AND AIR SIDE OF
THE SEALRINGS IS THROUGH DRAINS IN THE SEAL BODY AND
SEALING COVER RESPECTIVELY.

ON THE AIR SIDE RING RELIEF OIL IS SUPPLIED AT 0.5KSC
ABOVE THE SEAL OIL PRESSURE LATERALLY TO THE SEAL
RING VIA AN ANNULAR GROOVE.
Seal oil system scheme

EQUIPMENTS IN SEAL OIL SYSTEM
SEAL OIL PUMP ( 3 X 100%) DUTY
VACUUM PUMP (1)
SEAL OIL COOLER ( 2 X 100%) DUTY
DIFFERENTIAL PRESSURE REGULATOR
SEAL OIL FILTERS (DUPLEX & SIMPLEX)
SEAL OIL PUMP
SEAL OIL PUMP IS A THREE SCREW DESIGN POSITIVE
DISPLACEMENT PUMP
ONE DOUBLE THREADED DRIVING ROTOR AND TWO DRIVEN IDLER
SCREWS ARE CLOSED MESHED AND RUN WITH A CLOSE
CLEARANCE IN THE CASING INSERT.
BY INTERMESHING, THE HELICAL PASSAGES IN THE ROTORS ARE
DIVIDED INTO COMPLETELY SEALED COMPARTMENTS, WHILE
ROTATING, TRAVEL UNIFORMLY AND WITH OUT UNDUE STRESSES
FROM SUCTION TO DISCHARGE END.
THIS ACTS LIKE A PISTON
DUE TO LOW COMPRESSIBILITY OF OIL VERY HIGH PRESSURE MAY
ARISE ON THE DELIVERY SIDE
HENCE RELIEF VALVE IS PROVIDED ON THE PUMP CASING TO
PROTECT THE SEAL OIL SYSTEM
VACUUM PUMP
THE VACUUM PUMP IS A SINGLE STAGE ROTARY VANE TYPE
ROTARY SLIDING VANE PUMP CONSISTS OF A CYLINDRICAL CASING
WHICH IS ECCENTRICALLY SUPPORTED
THE ROTOR HAS VANES WHICH ARE FORCED APART BY SPRINGS
THE VANES SLIDE ALONG THE CASING WALL.
IT PUSHING FORWARD THE AIR DRAWN IN AT THE SUCTION
CHANNEL AND FINALLY DISCHARGING IT AT THE PUMP THROUGH
THE OIL IMMERSED DISCHARGE VALVE
THE OIL ALSO SERVES AS THE PUMP LUBRICATION
OIL LEVEL IN THE PUMP HAS TO ENSURED AS OIL VAPOUR GETS
EXTRACTED WHEN EXPELLING THE GAS.
SEAL OIL COOLER
THIS COOLER IS DESIGNED FOR SERVICE WITH RAW WATER.
COOLER CONSISTS OF
I. UPPER WATER BOX
II. SHELL
III. TUBE SYSTEM
IV. LOWER WATER BOX
THE LOWER TUBE PLATE IS FIXED AND THE UPPER TUBE
PLATE IS MADE FLOATING TO CATER FOR THE THERMAL
DIFFERENTIAL EXPANSION BY USING A RUBBER RING.
OIL INLET AND OUTLET ARE PROVIDED IN THE SHELL.
THE CIRCULATING WATER SIDE OF THE TUBE PLATE AND THE
INNER SURFACE OF THE WATER BOX ARE PAINTED WITH EPOXY
COAL TAR
SEAL OIL COOLER MAINTENANCE
THE EFFICIENCY OF THE COOLER DEPENDS VERY MUCH ON THE
CLEANLINESS OF THE COOLING SURFACE
CLEANING OF THE INSIDE OF THE TUBES CAN BE CARRIED OUT BY MEANS
OF SOFT BRASS WIRE BRUSH MECHANICALLY.
IF THERE ARE HARD SCALES CHEMICAL TREATMENT HAS TO BE RESORTED
LIKE WISE SHELL SIDE CAN BE CLEANED.
SHELL CAN BE CLEANED IN A HOT BATH OF 10% CAUSTIC SODA SOLUTION
IN CASE OF LEAKAGE OF COOLER TUBE IS SUSPECTED THE SHELL SIDE
SHOULD BE SUBJECTED TO A PRESSURE OF 16 KSC USING LUBE OIL.
KEEPING THE COOLER IN THE HORIZONTAL POSITION AND THE FAULTY
TUBE SHOULD BE PLUGGED WITH TAPER PLUGS. 5 % OF THE TUBES CAN
BE PLUGGED WITH OUT SACRIFICING THE DUTY.
DIFFERENTIAL PRESSURE REGULATING VALVE
DIFFERENTIAL PRESSURE REGULATING VALVE IS INTENDED TO
REGULATE THE SEAL OIL PRESSURE BEING SUPPLIED TO SHAFT SEALS
IN RELATION TO GAS PRESSURE IN THE GENERATOR CASING.

DIFFERENTIAL PRESSURE REGULATOR HAS
1. VALVE HEAD
2. MAIN BELLOWS
3. UPPER STUFFING BELLOWS
4. VALVE STEM
5. COMPRESSION SPRING
6. ADJUSTING NUT
7. CHECK NUT
8. YOKE
9. LOWER STUFFING BELLOWS
10. VALVE HOUSING
11. VALVE CONE

SEAL OIL TANK
GAS
IMPULSE
OIL
IMPULSE
O
I
L
S
E
A
L
S
SEAL OIL
PUMP
DIFFERENTIAL PRESSURE REGULATOR A
FUNCTION
DIFFERENTIAL PRESSURE REGULATOR
FUNCTION

THE DIFFERENCE BETWEEN OIL AND GAS IS SET BY COMPRESSION OF THE
SPRING WITH HELP OF THE ADJUSTING NUT.
COMPRESSION OF THE SPRING LEADS TO DOWN MOVEMENT OF THE
VALVE STEM AND VALVE CONE.
THIS MOVEMENT REDUCES THE PRESSURE THROUGH THE VALVE AS THE
VALVE CLOSES AND INCREASES THE PRESSURE THROUGH THE LINE.
INCREASE IN H
2
PRESSURE WILL LEAD TO COMPRESSION OF THE MAIN
OPERATING BELLOW WHICH IN TURN WILL MOVE THE VALVE HEAD IN TURN
VALVE AND VALVE CONE TO CLOSE THE VALVE
CLOSING OF THE VALVE WILL REDUCE THE PRESSURE OF THE OIL AT THE
OUT LET OF THE VALVE WHILE OIL PRESSURE GOING TO THE SEALS WILL
INCREASE.
DIFFERENTIAL PRESSURE REGULATOR B
FUNCTION

GAS
IMPULSE
OIL
IMPULSE
OIL SEALS
FROM
GOVERNING
OIL
SEAL OIL FILTER
THE DUPLEX AND SIMPLEX FILTERS ARE USED IN SINGLE FLOW RING TYPE
SEAL OIL SYSTEM
THE FILTER IS INSERTED INTO THE PIPE CIRCUIT BY MEANS OF FLANGES
A CHECK IS KEPT ON THE STRAINER SCREEN BY MEANS OF THE
RECOMMENDED DIFFERENTIAL PRESSURE INDICATOR .
WHEN PRESSURE REACHES 0.6 KSC THE STRAINER SHOULD BE CLEANED.
THE COMMON PROBLEM IS THE O RING FAILURE IN THE STOP COCK.
SEAL OIL FILTER -I
IF THERE IS LEAK FROM THE STOP COCK
REMOVE THE PINS
PULL OUT THE STOP COCK
REMOVE THE O RING
WASH OUT THE STOP COCK AND HOUSING
INTRODUCE THE STOP COCK AFTER GOOD OILING BUT WITHOUT O RINGS INTO
THE OPENING IN THE HOUSING
PUSH THE STOP COCK UNTIL THE GROOVE FOR THE O RING IS FREE
FIT THE O RING AND CAREFULLY PULL BACK THE STOP COCK UNTIL THE
GROOVE AT THE OPPOSITE END IS FREE.
CLEANING OF FILTER CHAMBER IS NECESSARY ONLY AFTER EVERY THIRD
FILTER ELEMENT CLEANING

STATOR WATER SYSTEM
ONE OF THE EFFICIENT WAYS OF TAKING AWAY THE LOSSES
FROM THE WINDINGS OF ANY ELECTRICAL MACHINE IS BY
DIRECT COOLING USING WATER.

EQUIPMENTS INVOLVED IN THE STATOR WATER SYSTEM
EXPANSION TANK
STATOR WATER PUMP
STATOR WATER COOLERS
STATOR WATER MECHANICAL FILTERS
STATOR WATER MAGNETIC FILTERS
POLISHING UNIT
GAS TRAP
STATOR WATER SYSTEM HEADERS
INLET
HEADER
OUTLET
HEADER
STATOR WATER TO BUSHING LEADS

QUALITY OF THE DISTILLATE
CONDUCTIVITY < 5 MICRO MHO, PREFERABLY
< 1 MICRO MHO
PH 6.5 TO 8.5
DISSOLVED OXYGEN MINIMUM, PREFERABLY LESS THAN 100 PPB
DISSOLVED CO
2
NIL
AMMONIA MINIMUM, PREFERABLY ZERO
CHLORIDE MINIMUM, PREFERABLY ZERO
DISSOLVED/UNDISSOLVED CU < 20 PPB
DISSOLVED/UNDISSOLVED FU < 20 PPB
DISSOLVED SOLIDS THE WATER SHOULD BE FREE OF
ANY CHEMICALS FROM TREATMENT
PROCESS,SUCH AS HYDRAZINE,
MORPHOLINE,LEVOXINE,PHOSPHATES


THE EXPANSION TANK
THE EXPANSION TANK IS A HERMETICALLY SEALED CONTAINER MADE
OF STAINLESS STEEL.
THE DM WATER FROM THE STATOR WINDING OUTLET HEADER
DISCHARGES IN TO A SECTION OF THE TANK THROUGH PERFORATED
PIPE.
THE TANK IS UNDER A VACUUM OF 250-300MM OF MERCURY.
THE TANK IS CLEANED DURING ANNUAL MAINTENANCE.
THE FLOAT VALVE OPERATION IS CHECKED BY HAND FOR SMOOTH
AND EASY OPERATION FROM ONE EXTREME LOWER POSITION TO
EXTREME TOP POSITION.
THE FLOAT IS CHECKED BY DIPPING IN WATER FOR 1 HOUR AT A
TEMPERATURE OF 60 DEGREE CENTIGRADE
THE HEALTHINESS OF THE TRANSDUCERS ARE CHECKED.
ALL THE JOINTS ARE CHECKED FOR ANY LEAK.

EXPANSION TANK
GAS OUT LET
WATER
INLET
FROM
WINDING
TANK
COVER
TRANSDUCER
RIB
LEVEL
GAUGE
D
R
A
I
N
WATER
OUTLET TO
PUMPS
LINE
REGULATOR
STATOR WATER PUMP
STATOR WATER PUMPS ARE SINGLE STAGE CENTRIFUGAL
TYPE SPIRAL CASING AND OVERHANG IMPELLER .

THE PUMP SUCTION IS ARRANGED IN THE AXIAL DIRECTION
WHILE THE DISCHARGE IS DIRECTLY RADIALLY UPWARD.

THE PUMP IMPELLER AND THE SPIRAL CASING IS OF
STAINLESS STEEL CONSTRUCTION.

NORMALLY THE PUMP IS OVERHAULED ONCE IN 5000 HOURS.
STATOR WATER COOLER

STATOR WATER COOLER
UPPER
WATER BOX
TUBE
PLATE
SEALING
CORD
VENT PLUG
PARTITION
TUBE
OUTER SHELL
SEALING RUBBER
DRAIN PLUG
THERMOMETER
STATOR WATER INLET
STATOR
WATER
OUTLET
VENT
DRAIN
PLUG
LOWER
WATER BOX
RUBBER
CORD
STATOR WATER COOLER-I
THE STATOR WATER COOLER IS SHELL AND TUBE TYPE HEAT
EXCHANGER SUITABLE FOR VERTICAL MOUNTING
THE SHELL IS MADE OF NONMAGNETIC STAINLESS STEEL AND THE DM
WATER FLOWS THROUGH THE SHELL.
TUBES ARE MADE OF STAINLESS STEEL AND THE COOLING WATER
FLOWS THROUGH THE TUBES.
TO HAVE EFFECTIVE HEAT TRANSFER BAFFLES ARE MADE OF BRASS
ARE PROVIDED ACROSS THE TUBE NEST.
THIS GUIDE THE WATER IN ZIG ZAG FASHION.
THE TUBES ARE CLEANED BY NYLON BRUSH.


STATOR WATER COOLER -II
WHEN PUSHING THE BRUSH THROUGH THE TUBES IT SHOULD ALSO BE
TURNED AROUND SIMULTANEOUSLY
IF THE DIRT DEPOSITS DO NOT COME WITH MECHANICAL TREATMENT
CHEMICAL CLEANING IS NECESSARY.
THE MOST CAUSE OF LEAKAGE IS TUBE PERFORATION OR LEAKAGE.
THE ROLLED ENDS OF THE TUBE ARE LIKELY TO BECOME DEFECTIVE FIRST.
REROLL THE AFFECTED TUBE WITH TUBE EXPANDER.
IF NOT PLUG THE TUBE IF IT IS URGENT .
UPTO 5% OF THE COOLING TUBE CAN BE PLUGGED WITH OUT AFFECTING
THE DUTY

POLISHING UNIT-I
POLISHING UNIT SERVES TO MAINTAIN LOW ELECTRICAL CONDUCTIVITY
OF THE CONDUCTIVITY OF THE PRIMARY WATER.
POLISHING UNIT IS CONNECTED IN PARALLEL TO THE MAIN CIRCUIT
POLISHING UNIT CONTAINS
1. MIXED BED ION EXCHANGER
2. FILTER
3. FLOW METER
4. CONDUCTIVITY METER
THE BASE SUBSTANCES OF THE EXCHANGER ARE POLYMERS.
THE POLYMERS IN THE CATION EXCHANGER ARE HIGHLY ACIDIC GROUPS
THE POLYMERS IN THE ANION EXCHANGER ARE HIGHLYBASIC GROUP.
WHEN RESINS ARE EXHAUSTED THEY THEY MUST BE REPLACED.

POLISHING UNIT TECHNICAL DATA
CAPACITY 2 M
3
DESIGN CONDUCTIVITY AT THE IN LET 1 MICRO MHO/CM
CONDUCTIVITY OF THE WATER AT OUT LET 0.44 MICRO MHO/CM
PH VALUE OF THE WATER AT THE INLET 6 TO 7 MICRO MHO/CM
PH VALUE OF THE WATER AT THE OUTLET 70.2
OPERATING RESIN BED 6 MONTHS
FINAL FILTER SIZE 5 MICRONS
RESIN TULSION T 42
TULSION A-27 MP
REAGENT HCL 30% 20.3KG
NAOH 100% 11.5 KG

MAGNETIC FILTER-PRINCIPLE
THE MAGNETIC FILTER IS OF PERMANENT MAGNET TYPE
DESIGNED TO TRAP FERRO MAGNETIC PARTICLES

THE FILTER MAINLY CONSISTS OF AN UPPER AND A LOWER
BODY HOUSING THE PERMANENT MAGNET SYSTEM,
COMPRISING OF THE MAGNETS POLE SHOES AND POLE RINGS

THE DM WATER PASSES THROUGH TWO ANNULAR AIR GAPS IN
WHICH THE FERRO MAGNETIC PARTICLES ARE FILTERED OUT.
MAGNETIC FILTER MAINTENACE
THE UPPER BODY IS REMOVED

WITH HELP OF THE REMOVABLE BOLTS THE POLE RING IS
DISMANTLED .

THE POLE RING AND THE POLE SHOES ARE CLEANED AND THE
ENTRAPPED FERRO MAGNETIC PARTICLES ARE THOROUGHLY WIPED

THE FILTER IS ASSEMBLED AND INSTALLED BACK IN POSITION AND O
RING IS REPLACED , IF IT IS IN DAMAGED CONDITION

MAGNETIC FILTER

MAGNETIC FILTER TECHNICAL DATA
MAGNET TYPE PERMANENT MAGNET
THE CAPACITY OF THE MAGNETIC FILTER 36M
3
MAXIMUM INDUCTION DENSITY 4000GAUSS
PRESSURE RATING NOT MORE THAN 10 KSC
TYPE OF PARTICLES FILTERED HIGHLY AND
MEDIUM MAGNETIC
HYDRAULIC TEST PRESSURE 16KSC FOR 10 MINUTE
PRESSURE DROP NEGLIGIBLE


STATOR WATER MECHANICAL FILTER
THE FILTER BODY CONSISTS OF CYLINDRICAL BODY HAVING
SEPARATE INLET AND OUT LET CHAMBERS.
A PERFORATED CYLINDRICAL BODY HAVING HOLES ALL ALONG ITS
LENGTH AND PERIPHERY IS SURROUNDED BY THE ASSEMBLY OF 30 TO
34 FILTER ELEMENTS.
THE FILTER ELEMENTS ARE KEPT IN POSITION BY A HELICAL SPRING
WHICH IS KEPT PRESSED BY A COVER.
THE FILTER ELEMENTS CONSISTS OF CORRUGATED BRASS SHEET
WITH A CENTRE HOLE AND TWO SIZES OF WIRE MESH APERTURES
0.224 MM AND 0.5 MM HELD IN ONE ASSEMBLY BY INNER AND OUTER
BRASS RING.
THE WATER AFTER PASSING THROUGH THE FILTERING ELEMENTS
ENTERS THE PERFORATED CYLINDER FROM WHERE IT FLOWS TO THE
OUTLET CHAMBER.
IMPURITIES GET COLLECTED IN THE WIRE MESH.
THE FILTER IS PROVIDED WITH DRAIN AND VENT PLUGS.


STATOR WATER MECHANICAL FILTER
TECHNICAL DATA
TYPE WIRE MESH TYPE
RATED DISCHARGE 30 M
3

MAXIMUM PRESSURE RATING 12 KSC
MINIMUM SIZE OF THE PARTICLES 0.224
THAT CAN BE FILTERED
PRESSURE DROP 0.1 KSC TO 0.2 KSC
PRESSURE DROP WHEN CLEANING IS
RECOMMENDED 0.4 KSC
MATERIAL OF THE BODY AND
PERFORATED CYLINDER Stainless steel
MATERIAL OF THE FILTER ELEMENT BRASS
SIZE OF THE WIRE MESH 0.224 MM AND 0.5 MM
HYDRAULIC TEST PRESSURE 38 KSC FOR 15 MINUTES
GAS TRAP
GAS TRAP IS USED FOR DETECTING THE PRESENCE OF HYDROGEN
GAS IN THE STATOR WATER SYSTEM.
PRESENCE OF THE GAS IN THE WATER SYSTEM IS POSSIBLE DUE TO
LOOSE AND LEAK AS JOINTS AS THE WATER PRESSURE IS KEPT LOWER
THAN THE HYDROGEN PRESSURE IN THE GENERATOR CASING.
THE GAS ENTRAPPED IN THE WATER GOES TO THE UPPER CHAMBER
FROM WHERE THE GAS IS SAMPLED FOR ANY MIXING.
TOP POINTS OF THE SUPPLY AND DRAINAGE ARE CONNECTED TO ANY
INLET POINTS OF THE DEVICE.
THE THIRD POINT IS CONNECTED TO PIPE LINE AT THE OUTLET OF THE
GENERATOR.

GAS TRAP -I
DRAIN PIPE IS CONNECTED TO THE DRAINAGE SYSTEM.
THREE POINTS OF THE INLET ARE CRACK OPENED AND THE WATER IS
ALLOWED TO ENTER CONTINUOUSLY.
THE WATER SO ENTERED WILL BE CONFINED TO LOWER CHAMBER OF
THE DEVICE AND THE EXCESS WATER IS DRAINED TO THE DRAIN PIPE .
IN CASE OF WATER CARRYING HYDROGEN,THE SAME IS LIBERATED AT
THE TOP CHAMBER
THE GAS ENTERS THE SPACE THROUGH THE CENTRE HOLE IN THE
PLUG AND IS DIRECTED TO THE UPPER CHAMBER THROUGH THE
SLOT IN THE PLUG.
GAS SYSTEM-I
GAS REQUIREMENT 56M
3
AMOUNT OF HYDROGEN REQUIRED TO FILL THE GENERATOR 300M
3
CASING TO RATED PRESSURE AT NTP-M/C STATIONARY
AMOUNT OF HYDROGEN REQUIRED TO FILL THE GENERATOR
CASING TO RATED PRESSURE AT NTP-M/C STATIONARY 340M
3
MAKE UP OF HYDROGEN REQUIRED /DAY 15M
3
AMOUNT OF CO
2
REQUIRED TO REMOVE HYDROGEN AT NTP 120M
3
WHEN MACHINE IS RUNNING 168M
3
AMOUNT OF CO
2
REQUIRED TO REMOVE AIR AT NTP 90M
3
WHEN MACHINE IS RUNNING 112M
3


EACH H
2
CYLINDER IS OF CAPACITY 46.7 LITRES AND CONTAINING
APPROXIMATELY 7 M
3
AT 150 ATM
NO. OF H
2
CYLINDERS REQUIRED TO FILL THE MACHINE
WHEN STATIONARY 50
WHEN RUNNING 56
NO. OF CYLINDERS REQUIRED/DAY 2 TO 3


EACH CO
2
CYLINDER IS 30 KGS WEIGHT OF CO
2
WITH GAS
EQUIVALENT TO 15M
3
OF GAS VOLUME.
NO. OF CYLINDERS REQUIRED FOR PURGING HYDROGEN
WHEN STATIONARY 11
RUNNING 14
NO. OF CO
2
REQUIRED FOR PURGING AIR WHEN STATIONARY 8
NO. OF CO
2
REQUIRED FOR PURGING AIR WHEN RUNNING 10
GAS SYSTEM-II
GAS DRIER



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