STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO: SIM/1/TS/

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SHEET 1 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

1. PLANT DETAILS :
The 500 MW generator is coupled to the 500 MW KWU turbine.
The rated parameters of the generator are listed in plant
details (Section-1) of Testing schedule for generator
protection and generator bay. The design and constructional
features are outlined briefly below.
Generator manual
supplied by the manufacturer may be referred for details of
above.
STATOR BODY :
The stator body is a totally enclosed gas tight fabricated
structure suitably ribbed internally to ensure high
rigidity.
Hydrogen coolers are housed longitudinally
inside the stator body. Rigid end shields close the casing
and support the fan shields.
STATOR CORE :
The stator core is made up of segmental varnish insulated
punchings of cold rolled grain oriented silicon gel and is
assembled in an interleaved manner on core bars.
Steel
spacers for ventilating ducts are provided for radial
cooling of core by hydrogen.
The core is held pressed by
means of heavy non-magnetic steel press rings which are
bolted to the ends of the core bars. Additional support is
provided to the teeth portion.
In order to isolate the
stator body and thus the foundations from magnetic
vibrations, the core bars are designed to provide elastic
suspension of the core in the stator frame.
STATOR WINDING AND INSULATION:
The stator has a three phase, double layer short corded bar
type windings having two parallel paths. Each coil side
consists of glass insulated solid and hollow conductors with
cooling water passing through the latter. The elementary
conductors are Rosbel transposed in the slot portion to
minimize eddy current losses. The coil sides are firmly held

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SHEET 2 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

in position by fibrous slot wedges. The overhang portion of

the coil is securely lashed with glass chord to bondage
rings and special brackets of non-magnetic steel, which are
in turn fixed to the core press rings.
DISTILLATE HEADERS:
Ring type water headers, made of copper are provided
separately for distillate inlet and outlet in the stator on
turbine side. The headers are supported on insulators and
isolated from stator body. The winding ends are solidly
soldered into the coil legs which are then ultrasonically
tested. Individual bars are provided with water inlet/outlet
connections made of P.T.F.E Hoses, The bar heads are
insulated by fiber molded covers.
TERMINAL BUSHINGS:
Water cooled terminal bushings are housed in the lower part
of the stator on the slip ring side, Porcelain insulators
are provided to insulate the terminal bars from the stator
body. Effective sealing is provided between the terminal
bushings and the stator body to avoid any possible leakage
of hydrogen. Terminal bushings are housed inside a chamber
made of non-magnetic steel plates. Three phase terminals and
three neutral terminals are brought out. The terminal plate
of the end terminals, where bus bar connections are made is
silver plated.
ROTOR
The rotor is of cylindrical type; the shaft and body being
forged in one piece from chromium nickel molybdenum and
vanadium steel. The rotor with all the details assembled is
dynamically balanced to a high degree of accuracy subjected
to 20% over speed for 2 minutes.
FIELD WINDING:
The field winding is made from hard drawn silver bearing
copper. The winding is held in position and by non-magnetic

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SHEET 3 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

rotating ring in the overhang portion. Gap pickup method is

used for direct hydrogen cooling of rotor.
The main slot insulation is of glass cloth impregnated with
Epoxy resin. The inter turn insulation consists of layers of
prepped glass cloth glued to the bottom of each conductor.
The end windings are packed with blocks of glass laminates
to separate and support the coils and to restrict their
movement under stress. The end windings are insulated from
the retaining rings with the help of glass epoxy molded
segments.
SHAFT MOUNTED FANS
For circulating the cooling gas inside the generator
propeller type fans are shaft mounted on either end of
rotor body. Fan hubs are made of alloy steel forging and
a shrunk fit on the rotor shaft. The alloy steel cast
blades are machined in the tail portion to suit the fan
and held in position with the help of conical pins.
blades can be easily removed from or assembled in the
hub. Fan shields fixed to the end shields guide the
flow.

two
the
are
fan
hub
The
fan
gas

RETAINING RINGS:
The end windings are held in position by retaining rings of
floating type shrunk fit on the rotor body. The rings are
screwed to prevent axial movement by locking nuts.
SLIP RINGS:
The slip rings consists of helically grooved alloy steel
rings shrunk on the rotor shaft and insulated from it. They
are mounted on a single, common steel bush, which has an
insulating jacket pre-molded on it. The complete bush with
sliprings are provided with inclined holes for self
ventilation. The helical grooves cut on the outer surface
help improve the brush performance.

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SHEET 4 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

FIELD LEAD:
The slip rings are connected to the field winding through
semi-flexible copper leads and current carrying bolts,
placed radially in the shaft. Two semicircular hard copper
bars insulated from each other and from the rotor shaft are
placed in the central bore or the rotor joining the two sets
of current carrying bolts with special profiled precision
conical threads.
GAS COOLERS
Four longitudinally mounted gas coolers are mounted in the
stator body. They are made out of admiralty brass with
coiled copper wire wound on them staggered form so as to
expose maximum surface area to hydrogen.
BEARINGS:
Generator bearings are of pedestal type with spherical
seating to allow self alignment and are supported on a
separate pedestal on slip ring side and in the L.P casing on
the turbine side, Bearing bush is of cast steel lined with
white metal. Oil catchers and deflectors are provided to
prevent axial leakage of oil. To prevent shaft currents slip
ring side bearing and connecting pipes are insulated from
earth.
SHAFT SEALS:
In order to prevent leakage of hydrogen from the generator
casing radial thrust type shaft seals are provided on either
side where the shaft extends out from the generator. The
seal consists of seal liner with babbit pressing against the
shaft caller of the rotor. Seals are defined in testing
schedule of seal oil system.

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SHEET 5 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

NAME PLATE DETAILS

RATED DATA & O/P
APPARENT POWER
ACTIVE POWER
CURRENT
VOLTAGE
FREQUENCY
PF
STATOR WDG CONN
HYDROGEN PRESS
CONT PERM UNBAL
LOAD
RATED FIELD
VOLTAGE
CURRENT

TURBO GEN.
588
MVA
500 MW
16166 A
21 + 1.05 KV
50 HZ
0.85(LAG)
YY
3.5 BAR
8 %
340 V
4040 A

MAIN EXCITER
-----3780 KW
6300 A
600 V
-------------------------

PILOT EXCITER
65 KVA
-----195 A
220 + 22 V
400 HZ
------------------

------

-------

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SHEET 6 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

2. TESTING OBJECTIVE :
TO TEST THE GENERATOR EQUIPMENT AND MAKE IT READY FOR
EXCITATION AND SYNCHRONIZATION.

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SHEET 7 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

3.0 PROPOSAL
3.1

Tests as detailed in item-8 shall be carried out on

generator, confirming the manufacturers test reports.

3.2

Insulation resistance tests on generator rotor, stator

and bearing pedestals shall be carried out.

3.3

Winding resistances for both stator and rotor will be

measured and recorded.

3.4

Impedance of rotor windings shall be measured and

recorded.

3.5

Checks/Tests shall be carried out all the embedded

resistance temperature detectors.

3.6

The brush gear assembly shall be checked tested as per

its standard checklist and test procedure.

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SHEET 8 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

4. SERVICES REQUIRED

4.1

Laboratory equipments/test sets for measurement of

electrical parameters required in specific tests (5KV
motorized megger, Kelvins bridge or micro ohm meter).

4.2

Illumination at required locations.

4.3

240 V A.C power supply for testing.

4.4

Communication facility at test area.

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SHEET 9 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

5.0

S A F E T Y PRECAUTIONS:

5.1

The test area shall be clearly defined and

cordoned off.

5.2

The test team leader is fully aware of the

nature, location, and probable duration of the
tests.

5.3

The other agencies working in the test area are

informed about the test in progress.

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SHEET 10 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

6.

EMERGENCY PROCEDURE :

6.1

Shock

treatment

chart

and

first

aid

box

shall

be

available.
6.2

Emergency telephone numbers of fire and hospital shall

be prominently displayed near by.

6.3

The test in progress shall immediately be stopped and

all line apparatus disconnected and equipment suitably
earthed in case of a accident or abnormality.

Such

instruction will be received from the team leader.

6.4

The test team is fully aware of measures to be taken in

the event of injuries to any personnel / damage to any
machinery.

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SHEET 11 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

7.

STATE OF PLANT :

7.1

Generator
erection

Erection
test

complete

results/log

and

sheets

satisfactory.
available

for

All
the

following :
-

Mounting of embedded parts and foundation plates.

Erection of stator.

Gas tightness and Hydraulic tests.

Measurement of insulation resistances of various

parts

of

generator,

D.C.

resistances

and

impedances.
-

Continuity, D.C. resistance and IR checks of RTDs.

Purge tests of rotor ventilation canals.

Rotor insertion tests.

Bearing adjustment tests.

Alignment or generator rotor.

Inclination or shaft journal test results.

Coupling alignment results of generator and LP

rotor.
Magnetic Axis adjustment results.

Fan and shield clearance results.

DTI checks on generator rotor.

Shaft seal adjustment results.

Temperature monitoring system.

Centering and offset-setting of brush gear.

Fixing of brush holder and brushes.

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SHEET 12 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

7.2

Following

Testing/Commissioning

schedules

completed

satisfactorily and results/records available :

-

Generator Gas Tightness Test.

Hydraulic

test

and

oil

flushing

of

seal

oil

system.
-

Seal Oil System Circulation

Hydraulic

test

and

flushing

of

primary

water

system.
7.3

All

the

systems

mentioned

in

7.2

are

in

totally

normalised condition and available for generator testing.

7.4

Fire protection system (CO2 system) is made available.

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SHEET 13 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

8.

T E S T METHOD :

8.1

INSULATION RESISTANCE OF GENERATOR WINDINGS :

8.1.1

Measure

and

record

insulation

resistance

stator windings.
Megger used : __________ KV Motorized
Serial NO.

: __________ Range : _______

Ambient Temp. __________________

Relative Humidity : _______________
(if practical)
BETWEEN
C1 E
C2 E
C3 E

VOLTAGE
APPLIED

I.R.
1 MIN.

IR
10
MIN.

IR10
P.I.=-------IR1

of

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SHEET 14 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

8.1.2

Measure

&

record

rotor

winding

insulation

resistance.
Megger used

:_____________ KV

Motorized/Hard

:_____________

Serial NO.

:_____________

Ambient Temp.

:_____________

BETWEEN

INSULATION
RESISTANCE

VOLTAGE APPLIED

Rotor Terminal&
earth

8.2. RESISTANCE MEASUREMENT OF GENERATOR WINDINGS :

Using a Kelvins bridge/suitable test set measure and
record generator winding resistances.
Test set used and details of test set.
Measured
between

Temperature

Resistance

Corrected
Resistance
at oC

Test
Certificate
value.

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SHEET 15 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

C4 C1
C5 C2
C6 C3
ROTOR
W
I
N
D
I
N
G
S
NOTE : Rotor Winding resistance measurement to be taken from
main exciter winding terminals
REMARKS :
8.2

Test

on

Generator

embedded

resistance

temperature

detectors.
Measure

continuity

resistance

of

resistance

Generator

RTDS.

and

Insulation

Record

observation

below :
Megger used ______________
Ohm meter used ____________
Sl.
NO.

RTD
No.

LOCATION

CONTI
NUITY

RESISTANCE

IR

REMARKS

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SHEET 16 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

Sl.
NO.

RTD
No.

LOCATION

CONTI
NUITY

RESISTANCE

IR

REMARKS

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SHEET 17 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

9. COMPLETION CRITERIA :
9.1

THE RECORD VALUES OF TESTING CARRIED OUT ON GENERATOR

ARE

COMPLETED AND KEPT ALONG WITH THIS TESTING

SCHEDULE.
9.2

GENERATOR AUX SYSTEM FOR RUNNING GENERATOR ARE LISTED

AND KEPT ALONG WITH THIS SCHEDULE.

9.3

GENERATOR IS READY FOR COMMISSIONING.

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SHEET 18 OF 18

PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR

10. APPENDICES
DRAWINGS: I.

II.

SCHEMATIC DRAWINGS OF :
1.
Generator RTDs
2.
Primary water system.
3.
Hydrogen Gas filling.
FACTORY TEST REPORT OF GENERATOR :

LOG SHEETS :
I)

IR VALUES, WR VALUES OF GENERATOR

II)

LIST

OF

PROTECTIONS INCLUDED

III)

READINESS OF AUX. SYSTEMS