A

Presentation
on

Presentation on Generator Cooling System

Siddhartha panda
 CONTENT
1. Generator cooling system
A. Generator Hydrogen system
a) Why hydrogen cooling
b) Components
c) Precautions for hazard
B. Stator water system
a) Purpose
b) Components
c) Problems in Stator water
 GENERATOR COOLING SYSTEM

Stator
water
Stator
Hydrogen
Generator

Rotor Hydrogen
GENERATOR COOLING SYSTEM

Minimize drag
- “windage
loss”

Maintain low Keep

Generator
dew point for generator
component internals
durability clean

Cooling
Goals
Minimize
electrical, Maximize
mechanical generator
and corrosion output
problems
 GENERATOR HYDROGEN COOLING
Why Hydrogen Cooling ?
Lowest density gas yields lowest drag (14 times lighter
than air)

Highest thermal conductivity of any gas (7 times

better than Air)

High heat transfer Co-efficient (Pick-up heat from

surface)

Controlled atmosphere to maintain Clean & Dry

 GENERATOR HYDROGEN COOLING
System Specification
• Rated Pressure: 0.3 Mpa
• Purity: More then 96%
• Humidity of hydrogen: <4 g/m3
• Cold H2 Temperature: 35 C Min, 50 C max
• Hot H2 Temperature: 65 C Min, 80 C max
• Hydrogen Consumption < 5% of Gas volume (83
m3)
 GENERATOR HYDROGEN COOLING
Components
Filling station

Gas control station( H2 & CO2 filling / purging system)

Dryer system

Blower system

Hydrogen purity analyzer

Hydrogen humidity analyzer

LLD

Generator fan blade

Hydrogen coolers
 GENERATOR HYDROGEN COOLING
Fan Assembly
Fan hub Fan blade
 GENERATOR HYDROGEN COOLING
Gas Flow Path
 GENERATOR HYDROGEN COOLING
Hydrogen Cooler
• Purpose to pick up the heat carried by hydrogen
inside generator.
• 4 Nos cooler provided
• ACW water used for cooling purpose
 GENERATOR HYDROGEN COOLING

Hydrogen Flammability Range

 GENERATOR HYDROGEN COOLING
Precautions for Hazard
• Prior to hydrogen charging, CO2 gas is used to drive out
air from the generator, after CO2 gas content in the
generator is over 85%, and then CO2 gas shall be driven
out by hydrogen, finally, then the generator is charged with
hydrogen.
• During hydrogen discharging, CO2 gas is carried to the
generator to drive out hydrogen, after CO2 gas content is
over 95%, compressed air can be fed into the generator to
drive out CO2 gas, after CO2 gas content is lower than
15%, the compressed air introduced to the generator will
be stop.
 GENERATOR HYDROGEN COOLING
Precautions for Hazard
• Hydrogen is a flammable gas.
• It is very buoyant, escapes readily and does not pool. Hydrogen has
no natural odor, no color, so leaks require detection equipment.
• Hydrogen has no health effects other than potential flammability, and
the ability to displace oxygen.
• Hydrogen burns with a pale blue flame that is nearly invisible in
daylight. The flame may appear yellow if there are impurities in the air
like dust or sodium.
• A pure hydrogen flame will not produce smoke.
• Do not extinguish the fire until the hydrogen supply has been shut off,
as unburned gaseous hydrogen can result in an explosion. Spray
water on adjacent equipment to cool it.
• Non sparking tool
GENERATOR HYDROGEN COOLING
 GENERATOR HYDROGEN COOLING
Hydrogen Drier

The hydrogen drier works

on principle of refrigeration
of hydrogen to cause its
temperature drop to dew
point below and separate
the water, thus received
goal of hydrogen humidity.
GENERATOR HYDROGEN COOLING
 GENERATOR HYDROGEN COOLING
Hydrogen Drier cycle
 GENERATOR HYDROGEN COOLING
Hydrogen Drier Abnormal conditions

Operation • hydrogen pipeline issue

• Valve opening quantity is oversized or
excessively small. Entering hydrogen
light solenoid valve is damaged

twinkle

Unusual • Electric heating system issue

• Heater electric circuit is break down.
Fuse is fused. The refrigeration frost
light is temp. controller is bad. The power
source lacks phase or pressure is too low,

twinkle The heater or limiting temp. controller is

bad.
 GENERATOR HYDROGEN COOLING
Hydrogen Drier Abnormal conditions

• refrigeration system issue

Unusual • The expansion valve is ice
block or dirty. The cooling
light is water does not pass or
the cooling water temp. is
bright too high. Compressor
damage. The power

frequentl
source lacks phase or
pressure is too low or too
high. The refrigerant is too
y much.
GENERATOR HYDROGEN COOLING
 GENERATOR HYDROGEN COOLING
Constraints
• Hydrogen
– Dew point
– Purity
– Leakage
• CO2 filling during purging process
– Hose availability
– Hot water/ electric heater availability
 STATOR WATER SYSTEM
• Kinetic energy (rotational) from a Turbine is converted to
electrical energy by a Generator.
•  When mechanical energy do the work against
electromagnetic force and produce Electricity, during this
process high current flow through Stator coils heat is
generated in the Generator stator coils.
•  The stator cooling water system is used to remove heat
from generator armature bars.
•  To maintain efficient operation and energy conversion,
the coils must be cooled to keep the stator within
specified operating limits
•  The cooling medium is demineralized water - typically
with a conductivity of 0.5µS/cm.
 STATOR WATER SYSTEM
Five points of stator water cooling system

• To provide deionize water for cooling to the Generator stator hollow

windings at a rated pressure and rated flow.
• To detect and alarm if the conductivity of DM water goes up to unsafe
level.
• To provide filtration to remove any particulates which could plug the
very small bores of the stator tubes.
• To provide venting to atmosphere for any H2 gas that becomes
entrained in the stator coolant.
• To provide for addition of DM coolant to make-up for any loss due to
leaks or evaporation from the stator cooling system.
 STATOR WATER SYSTEM
Equipment
Water Tank

Water pump

Water cooler

Water filter

De-mineralizer

Conductivity meter

Temp. regulating device

 STATOR WATER SYSTEM

• Volume: 1.78 m3
Water Tank • Filling water volume 1.6 m3

• 2 Nos (One running another S/B)

Water Pump • Auto start ( Disch. Pressure low < 0.4 Mpa/ Flow
low 45 TPH)

Water • 2 Nos (One operation another S/B)

Cooler

Water Filter • 2 Nos (One operation another S/B)

 STATOR WATER SYSTEM

• Mix bed type (Anion/Cation 2:1)

De-mineralizer • Water flow 5 TPH (8% of total flow)

• Generator stator winding inlet (Inlet water

Conductivity condition)
meter • Demineralizer outlet (Resin condition)

Temp. regulating
device

Flow Low Switch • 3 Nos (35-37 TPH TD:30s trip)

 STATOR WATER SYSTEM
System Description
• Total water flow: 55t/h
• Water pressure at inlet: 0.1-0.2 Mpa
• Water temperature at the inlet: 45+3°C
• Return water temperature: ≤80°C
• Circulating water flow required: ~160t/h
• Circulating water pressure required: 0.15-0.3MPa 
•  Water quality requirements:
– Conductivity: 0.5-1.5 s/cm
– PH value: 7-9
– DO> 2 PPM
 STATOR WATER SYSTEM

Problem
• Copper Corrosion & Plugging in
s on copper hallow conductors
Stator • Water leakage of stator windings
• Clip-to-strand leak due to crevice
water corrosion.
coils and • End-winding vibration
• Increase in conductivity of
solution water. 
s
 STATOR WATER SYSTEM
• Copper Corrosion:
• As the Stator water chemistry copper corrosion is not a normally
problem firstly, but if the poor chemistry can lead to another problems if
it excess or less.
• The copper does not react with pure water (DO - less than 5ppb, pH=
7). As the water enters in the winding, the hollow conductor Copper
comes in contact with the water and form cuprous oxide Cu2O (Red
Colour) /cupric oxide CuO (Black colour).
• In generators, a mix of these oxides is always found, predominantly
Cu2O with low concentrations of dissolved oxygen, and predominantly
CuO with higher levels of oxygen
• The copper oxide forms a stable passive layer on the hollow copper
conductor inner surface. This stability of passive layer increases with
the increase of stator water pH. As shown in the figure, the corrosion
rate of copper in contact with the cooling water mainly depends upon
the pH and Dissolved Oxygen (DO).
Stator water system
 STATOR WATER SYSTEM
Water leakage of stator windings:

• Leaks in stator winding cooling system mainly caused by

problems with brazed connections
• Water penetrates the bar insulation and increases the risk of
electrical failure
• Small leaks in these locations will not result in winding
damage during normal operation as H2 gas Pressure is
maintained well above stator cooling water pressure.
• But small leaks pose problem during outage when generator is
de-gassed and stator water system is left in operation. Under
those circumstance the Press. Diff. force the leaking water into
insulation.
 STATOR WATER SYSTEM
Monitoring Chemistry Parameters
• Our system is neutral pH & high DO system. So
accordingly these below chemistry parameters
to be monitored.
– Monitoring of Online Dissolve Oxygen
– Measurement of pH (Should be 6.0-7.0 neutral pH)
– Online conductivity Monitoring (should be less than 1
µS/cm.)
– Copper content of stator water (Should be less than
40 ppb)
 STATOR WATER SYSTEM
Operational Parameter
In addition to the chemistry parameters, some operational
parameters to be monitored periodically.
• Stator water flow
• Stator water inlet and outlet temperature, together with
stator water flow and generator load
• Individual bar temperatures (outlet water hoses),
together with generator load
• Gas-to-water pressure
• Hydrogen leakage rate
• Make-up water consumption
 STATOR WATER SYSTEM
Maintenance of Stator cooling water system
• Apart from mechanical & electrical maintenance of stator
cooling system, some chemical maintenance to be taken
care.
• Replacement of ion exchange resins when exhausted
• Cleaning/Replacing filters
• Maintenance & Calibration of online sensors
• Inspection of the stator coolant bars for corrosion
products
• Mechanical and/or chemical cleaning
STATOR WATER SYSTEM
STATOR WATER SYSTEM
 STATOR WATER SYSTEM
Constraint
• PH & Conductivity of stator water
– Increase due to condensate passing to makeup
header – MIV isolated
Thank You