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OPERATION & MAINTENANCE

MANUAL

FOR

500 MW TURBOGENERATOR

WITH WATER COOLED STATOR WINDING & DIRECT HYDROGEN COOLED ROTOR WINDING

Project : NCTPP Stage -2 DADRI-2 x 490MW

Customer : NTPC

BHEL Order no : 10550A12901 DADRI UNIT 1 10554A12901 DADRI UNIT 2

no : 10550A12901 DADRI UNIT 1 10554A12901 DADRI UNIT 2 HARIDWAR BHARAT HEAVY ELECTRICALS LIMITED Heavy

HARIDWAR

BHARAT HEAVY ELECTRICALS LIMITED Heavy Electrical Equipment Plant

Turbogenerators General Table of Contents

Turbogenerators

General

Table of Contents

Cover Sheet 0.0-0000 Stator End Shields Generator Terminal Box 2.1-2150 2.1-2170 GENERAL Hydraulic Testing and
Cover Sheet
0.0-0000
Stator End Shields
Generator Terminal Box
2.1-2150
2.1-2170
GENERAL
Hydraulic Testing and Anchoring of Stator
Anchoring of Generator on Foundation
2.1-2190
2.1-2191
Table of Contents
2.0-0010
Stator Core
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2.1-2200
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Notes on the Use of the Manual
Operation Beyond Contract Commitment
Safe Disposal of Turbogenerator Items
Preface
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2.0-0030
2.0-0040
Mounting of Stator Core in Stator Frame
Spring Support of Stator Core
2.1-2201
2.1-2220
2.0-0050
Stator Winding
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2.1-2300
2.0-0200
Connection Diagram of Stator Winding
2.1-2301
DESCRIPTION
Brief Description
Rating Plate Data
Generator Cross Section
Generator Outline Diagram
Exciter Outline Diagram
Design and Cooling System
2.1-1002
2.1-1050
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Transposition of Stator Bars
Micalastic High Voltage Insulation
Construction of High Voltage Insulation
Corona Protection
Coil and End Winding Support System
Stator End
Stator Slot
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2.1-2303
2.1-2305
2.1-2320
2.1-2321
2.1-2330
2.1-2340
2.1-2341
2.1-1056
2.1-1058
2.1-2350
2.1-1100
2.1-2351
Generator Cooling Gas Circuit
2.1-1150
2.1-2370
Stator
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2.1-1210
Stator Winding .
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2.1-1230
2.1-2371
Rotor
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2.1-1300
2.1-2372
Hydrogen Cooler
2.1-1440
Electrical Connection of Bars, Water Supply
and Phase Connectors
Electrical Bar Connections and Water Supply
Terminal
PW Connection for Terminal Bushings and
Phase Connectors
Cooling of Terminal Bushings
Components for Water Cooling of Stator
Bearings
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2.1-1450
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Grounding of Stator Cooling Water Manifold
Winding
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2.1-2380
Shaft Seals
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2.1-1460
2.1-2389
Oil Supply for Bearings and Shaft Seals
Seal Oil System (Simplified Diagram)
2.1-1510
2.1-1511
Rotor
Gas System
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Gas System (Simplified Diagram)
Primary Water System
Primary Water System (Simplified Diagram) .
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2.1-1520
2.1-1521
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Cooing of Rotor Winding
Cooling Scheme of Rotor Winding
Rotor Shaft .
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2.1-3000
2.1-1530
2.1-3100
2.1-1531
2.1-3101
Rotor Winding.
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2.1-3300
Technical Data
Rotor Slot .
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2.1-3301
2.1-3310
General and Electrical Data
Mechanical Data
2.1-1810
2.1-1820
Rotor End Winding
Rotor Retaining Ring
Rotor Field Connections
2.1-3350
2.1-3370
Seal Oil
System
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2.1-1825
Electrical and Mechanical Connection of EE
Gas System
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Primary Water System
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2.1-1826
Coupling
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2.1-3373
2.1-1827
Rotor Fan
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2.1-3600
Waste Gas System
Excitation System
2.1-1828
2.1-1829
Cooler
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Reactive Capability Curve
Load Characteristic of pilot exciter
Gas Specification
Primary Water Specification
Specification for Ion Exchange Resins
Additive Specification forAlkalizer Unit
Cooler Data
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2.1-1830
2.1-1850
2.1-4000
2.1-1860
Hydrogen Cooler (Description)
Hydrogen Cooler (Drawing)
2.1-4001
2.1-1883
2.1-1885
Generator Bearings
2.1-1887
2.1-1888
Generator Bearing (Description)
Generator Bearing (Drawing)
Measurement of Bearing Temperature
Generator Bearing Insulation
2.1-5000
2.1-5001
Stator
2.1-5003
2.1-5005
Stator Frame
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2.1-2100
Shaft Seal . Shaft Seal (Drawing) Shaft Seal . . . . . . .
Shaft Seal
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Shaft Seal (Drawing)
Shaft Seal
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2.1-6000
2.1-6001
Tripping Scheme for Generator Electrical
Protection
Rotor Grounding System
Arrangement of Brush Holders for Rotor
Grounding
2.1-8331
2.1-8350
2.1-8351
Seal Oil System
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Differential pressure Valve A
Differential Pressure Valve C
Pressure Equalizing Control
Seal Oil System Schematic Diagram .
List of Valves for Seal Oil
Bearing Vapour
Seal Oil
Seal Oil Cooler and Seal Oil
Seal oil Cooler (Drawing)
Seal Oil Filter (Drawing)
Differential Pressure Meter
Seal Oil System
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2.1-7100
Measuring Devices and Supervisory
Equipment
2.1-7101
2.1-7103
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2.1-8400
2.1-7104
2.1-8410
2.1-7111
2.1-8420
2.1-7112
2.1-8422
2.1-7120
2.1-8423
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2.1-7123
2.1-7130
2.1-7131
2.1-7132
2.1-7150
Introduction.
Temperature
Supervision of
Generator measuring
List of Valves for Generator
Supervision of
Supervision of Seal Oil
Supervision of Gas
Supervision of Primary Water System
Supervision of
Exciter Measuring
2.1-8440
2.1-8450
2.1-8460
2.1-8470
2.1-8490
2.1-8491
Gas System
Excitation System
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Gas System Schematic
Gas System.
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2.1-7200
2.1-7211
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Basic Arrangement of Brushless Excitation
System.
Rectifier
Rectifier Wheels and
Permanent-Magnet Pilot Exciter Rotor & Fan
Exciter Cross
Exciter Cooling Air
Stroboscope for Fuse Monitoring
Exciter
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2.1-9100
List of Valve for Gas
2.1-7212
CO2
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Gas Dryer (Refrigeration type)
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2.1-7230
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2.1-9101
2.1-7270
2.1-9102
2.1-9103
Primary Water System
2.1-9104
2.1-9110
Primary Water
Primary Water System Schematic
List of Valves for Primary Water System
Primary Water
Primary Water
Primary Water Treatment
Alkalizer Unit for Primary Water Circuit
Primary Water
Primary Water Main
Primary Water Fine
2.1-7300
2.1-9120
2.1-7311
2.1-9140
2.1-7312
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Ground Fault Detection System for Exciter
Field
Arrangement of Bursh Holders for Ground
Fault Detection System
Brush Holders for Ground Fault Detection
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Exciter Drying
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2.1-9150
2.1-7320
2.1-7330
2.1-9180
2.1-7340
2.1-7341
2.1-9181
2.1-7343
2.1-7344
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2.1-9182
2.1-7345
Protective Screens at Primary Water Inlet
Operation
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2.1-7349
Operating and Setting Values-General 2.3-4000
Automatic Controls
Gas
Measuring Point List of Generator
Running
Operating Log-Generator Supervision
Operating Log-Seal Oil System
Operating Log-Gas System
2.3-4010
2.3-4030
Coolant Temperature
2.1-8010
2.3-4100
2.3-4120
Protective Devices
2.3-4150
2.3-4160
Safety Equipment for Hydrogen
Waste Gas
2.1-8310
Operating Log-Primary Water System 2.3-4170
2.1-8311
Operating Log-Exciter Supervision
2.3-4190

List of Valves for Waste Gas System . 2.1-8312

Generator Waste Fluid System

Generator Mechanical Equipment Protection. 2.1-8320 Tripping Scheme for Generator Mechanical

2.1-8315

Equipment Protection

2.1-8321

Generator Mechanical Equipment Protection . 2.1-8323

2.1-8330

Generator Electrical

2.0-0010-10550/2

Start-up

Preparations for Starting-Introduction 2.3-5000

Hints for Cooler Filling and Initial Operation of Air Side Seal

2.3-5003

Oil
Oil

Turbogenerators

Circuit.

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2.3-5110

Voltage and Frequency Deviations Generator Capability With Hydrogen Coolers out of Service on Water Side

2.3-8181

Filling and Initial Operation of Hydrogen

General

Side Seal Oil Circuit

 

2.3-5120

2.3-8184

Venting of Seal Oil Setting of Seal Oil

 

2.3-5130

Unbalanced Load-Time Curve Current Overload Capability Runback for loss of stator coolant Unloading schedule for increased cooling water inlet temperature

2.3-8187

2.3-5150

2.3-8188

Setting of Operating Values for Seal Oil System 2.3-5160 Measurement of Seal Oil Volume Flows 2.3-5163 Functional Testing of Pumps and Exhausters 2.3-5180

2.3-8190

2.3-8191

   

2.3-5210

Startup of Air Side Seal Oil Circuit Startup of Hydrogen Side Seal Oil

Venting of Seal Oil Circuits and Checking of Seal Oil Pressures Checking Automatic Operation of Seal Oil

2.3-5220

Shutdown

2.3-5230

Shutdown of Generator Generator Shutdown Diagram

2.3-8310

2.3-8311

Pumps.

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2.3-5280

Positions of Multi-Way Valves in Gas System 2.3-6107 Scavenging the Electrical Gas Purity Meter

Supervision of Generator during Standstill

System

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2.3-6110

General

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2.3-8400

Setting Electrical Zero of Electrical Gas Purity Meter System

Purity Measurement During CO2 Filling 2.3-6130

2.3-6120

. Seal Oil System

Coolers

. Shutdown of Seal Oil System

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2.3-8440

2.3-8500

2.3-8510

Purity Measurement During H2 Filling 2.3-6140

Draining the air Side Seal Oil Circuit

 

2.3-8520

Purity Measurement During H2 Operation

N2 Purging After Filling of Primary Water

 

2.3-6150

Draining the Hydrogen Side Seal Oil Circuit 2.3-8521

Gas Filling-Replacing Air With

2.3-6310

Draining the Seal Oil Signal Lines and Seal

Gas Filling-Replacing CO2 With

2.3-6320

Ring Relief Piping

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Gas System

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2.3-8522

2.3-8600

System .

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2.3-6810

Gas Removal-Lowering Hydrogen Gas

 

Pressure in Generator

2.3-8610

Filling and Initial Operation of Primary Water

Gas Removal-Replacing H2 with CO2

2.3-8620

System-

Gas Removal-Replacing CO2 With Air N2 Purging Before Draining of Primary

2.3-8630

Preparatory Work

 

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2.3-7100

Water System

2.3-8650

Filling External Part of Primary Water Circuit 2.3-7110

Primary Water System

2.3-8700

Filling the Water Treatment System

2.3-7120

Shutdown of Primary Water System for Less

Filling the Terminal Bushings and Phase

Than 48 Hours

Winding

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2.3-8720

Connectors

2.3-7150

Shutdown of Primary Water System for More

Filling the Stator Winding

2.3-7160

Than 48 Hours

2.3-8730

Filling Primary Water Coolers on Cooling Water Side Activating Primary Water System After a Shutdown of Less Than 48 Hours Activating Primary Water System After a

2.3-7180

2.3-7210

Draining the Primary Water System- PW Coolers (Cooling Water Side) Draining the Primary Water System- Stator

Draining the PW System-Terminal Bushings

2.3-8732

2.3-8734

Shutdown of More Than 48 Hours

2.3-7220

and Phase Connectors

2.3-8738

Activating the Primary Water Conductivity Meter System

2.3-7530

Draining the Primary Water System- Water Treatment System

2.3-8746

Activating the Primary Water Volume Flow Meter System

2.3-7540

Draining the Primary Water System- External Part of Primary Water Circuit

2.3-8748

Initial Operation of Primary Water System -

Generator .

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Exciter

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2.3-8900

Checks Prior to Startup

2.3-7610

Turning Gear Operation and Runup of

2.3-8010

Fault Tracing

. Generator Startup Diagram

 

2.3-8011

General

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2.3-9000

Permissible Synchronizing Criteria

2.3-8081

Stator and Generator Supervisory Equipment 2.3-9200

 

Coolant Temperature

 

2.3-9280

On-Load Running

 

Rotor

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2.3-9310

 

Coolers

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2.3-9440

Permissible Load Limits of Generator Permissible Loading at Rated PF During

 

2.3-8170

. Bearing Vapour Exhausters

Bearings

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2.3-9450

2.3-9521

Seal Oil Pumps

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2.3-9523

Seal Oil Pressures and Temperatures

 

2.3-9531

Relief Valves in Seal Oil System

2.3-9551

Oil Level in Seal Oil System

2.3-9561

. Gas Purity Meter System

Gas Pressures .

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2.3-9640

2.3-9680

Primary Water Pumps

2.3-9720

Water Pressures and Temperatures in Primary Water System

2.3-9730

Filters in Primary Water System

2.3-9740

Water Level in Primary Water Tank

2.3-9760

Conductivity in Primary Water System

2.3-9782

Volume Flow Rates in Primary Water System 2.3-9784

Alkalizer Unit for Primary Water System

 

2.3-9785

Fuses on Rectifier Wheels

2.3-9901

Exciter Temperatures

2.3-9911

Exciter Cooler .

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2.3-9914

 

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2.3-9941

Stroboscope Exciter Drying System

. Ground Fault Detection System in Exciter Field Circuit

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2.3-9955

2.3-9980

Maintenance and supervision-

 

Introduction.

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2.4-4200

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2.4-4210

Generator Coolers

2.4-4240

Bearings

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2.4-4250

. Seal Oil Pumps & Bearing Vapour Exhauster

Rotor

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2.4-4310

2.4-4520

Seal Oil Coolers

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2.4-4540

Seal Oil Filters

Gas Consumption

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2.4-4550

2.4-4610

Primary Water Pumps

2.4-4720

Primary Water Filters

2.4-4740

Primary Water

2.4-4750

Water Level in Primary Water Tank

 

2.4-4760

Concutivity Meter

2.4-4780

. Fuses on Rectifier

Alkalizer Unit

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2.4-4785

2.4-4910

. Ventilation and Make-Up Air Filters

Exciter

Dryer

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2.4-4925

2.4-4930

. Ground Fault Detection

Exciter Coolers .

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2.4-4940

2.4-4990

Inspection

. Determination of Dewpoint Temperature

Introduction.

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2.5-0010

2.5-0019

Packing,Transport, Storage of Gen Rotors 2.5-0030

Preventive Measures for Transport and Storage of Generator Rotors . Checking Desiccant in Gen Rotor Packing Insulation Resistance Measurements on Rotor and Exciter Preparation of Machinery Parts Checking the Bearing and Seal Insulation Test Norms During Overhaul

on Rotor and Exciter Preparation of Machinery Parts Checking the Bearing and Seal Insulation Test Norms
on Rotor and Exciter Preparation of Machinery Parts Checking the Bearing and Seal Insulation Test Norms
on Rotor and Exciter Preparation of Machinery Parts Checking the Bearing and Seal Insulation Test Norms
on Rotor and Exciter Preparation of Machinery Parts Checking the Bearing and Seal Insulation Test Norms
on Rotor and Exciter Preparation of Machinery Parts Checking the Bearing and Seal Insulation Test Norms

2.5-0031

2.5-0032

2.5-0033

2.5-0200

2.5-0300

2.5-0305

2.0-0010-10550/4

Leakage Tests of Generator and Gas System 2.5-0310

Flushing the Oil Piping

 

2.5-0320

Measures to Prevent Corrosion During Inspecitons Preventive Measures to Avoid Stress

 

2.5-1003

Corrosion .

. Inspection Schedule-Foreword

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2.5-1005

2.5-1010

Inspection Schedule-Stator

2.5-1020

Inspection Schedule-Rotor

2.5-1030

Inspection Schedule-Coolers

2.5-1040

Inspection Schedule-Bearings

2.5-1050

Inspection Schedule-Shaft Seals

2.5-1060

Inspection Schedule-Seal Oil System

2.5-1071

Inspection Schedule-Gas System

2.5-1072

Inspection Schedule-Primary Water System

2.5-1073

Inspection Schedule-Generator Supervisory

2.5-1080

Inspection Schedule-Excitation System

 

2.5-1090

Measures for Preservation of Generator During

2.5-1100

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2.5-2000

2.5-2120

Sealing Generator End Shield Joints .

2.5-2160

IR Measurements on Stator Winding

2.5-2300

Procedure for carrying out Tan delta test with End Winding Vibration probes in position

2.5-2305

Drying the Windings

2.5-2310

Test Instruction for Stator Slot Support System With Top Ripple Springs

2.5-2340

Stator Slot Support System-Radial Wedge Movements-Test Record

2.5-2341

Test Equipment for Stator Slot Support System 2.5-2342

Instructions for Checking the Stator Slot Support

 

2.5-2343

Rewedging of Stator

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2.5-2345

Cementing Stator Slot End Wedges at Turbine and Exciter

2.5-2346

Treatment of Bolted Contact Surfaces

2.5-2350

. Insulation Resistance Measurements on Rotor and Exciter Windings

2.5-3000

2.5-3300

Ultrasonic Examination of Rotor Retaining Rings at Power Plant

2.5-3357

Hydrogen

2.5-4000

Insertion and Removal of Hydrogen Coolers .

2.5-4100

2.5-5000

Shaft

Seals.

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2.5-6000

Seal Oil

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2.5-7100

Seal Oil Pumps & Bearing Vapour Exhausters 2.5-7120

Seal Oil Gas Primary Water

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2.5-7130

2.5-7200

2.5-7300

Primary Water

2.5-7320

Primary Water Coolers

2.5-7330

Treatment and Cleaning of Pipes in Primary Water Circuit

2.5-7381

Flushing External Part of Primary Water Circuit2.5-7382 Leakage Test of External Primary Water Circuit2.5-7384

Excitation System-Exciter

2.5-9000

Checking the Insulation Resistance of Heat Sink Insulation

2.5-9010

Turbogenerators General Preface

Turbogenerators

General

Preface

This manual contains information on operation and maintenance of Turbogenerator and its auxillary systems.

The information has been prepared on the assumption that the operating and maintenance personnel have a basic knowledge of power plant engineering and operation. It is an essential prerequisite for satisfactory operation and maintenance of the turbogenerator that the operating and

maintenance personnel are fully familiar with the design of the turbogenerator plant and have aquired thorough training in operation and maintaining the unit.

The manual is subdevided into following main sections

-General

-Description

-Operation

-Maintenance

-Inspection

Turbogenerators General Notes on the Use of the Mannual

Turbogenerators

General

Notes on the Use of the Mannual

The turbogenerator instruction manual consists of the following manual sections:

For the user of the manual, the identification number is a sufficient reference for locating a particular instruction number must be indicated.

2.0

General

2.1

Description

2.3

Operation

Instruction Number

2.4

2.5

Maintenanceand Supervision Inspection

The instruction number consists of the manual section number, the identification number, the variant number, the page number, and the date with the language symbol.

Each section contains a number of separate instructions.

The manual contains a Table of Contents together with a List of Effective Pages. Please check your manual against this list and advise if there are any omissions.

Identification Number

The identification number consists of the above mentioned section number, supplemented by a four- digit code number. It is indicated in the bottom most line of the pages.

It is indicated in the bottom most line of the pages. 2.0 - 0040 - 000

2.0 - 0040 - 00009 / 1 1205 E

most line of the pages. 2.0 - 0040 - 000 0 9 / 1 1205 E

Manual section number

Identification number

Variant number

Page number

Language (English)

Date (mm yy)

Turbogenerators General Operation Beyond Contract Commitment

Turbogenerators

General

Operation Beyond Contract Commitment

The Turbogenerator set has been designed and manufactured to meet the contract commitment as regards to the capability for the continuous operation or variable load operation below maximum continuous rating with an aim to achieve objective of securing long life and trouble free operation.

Because of the margin provided in the design, it may be possible to operate the turbogenerator at overloads for the time specified in the manual. However, such operations although possible for the short time will encroach upon the design margin built into the generator.

The Turbogenerator is designed to operate within the temperature rise in accordance with EC standard. Operating the generator in excess of the capability curves which are part of this O & M Manual will cause

increase in Copper temperature, thermal expansion and higher insulation stresses. Such operation is not permitted by the manufacturer.

Continued operation of unit without recommended scheduled maintenance will eventually result in increased maintenance and reduction in the useful life of the machine. BHEL cannot be responsible for any malfunctioning occurring as a result of operation beyond the contract limits and operation of machine without carrying out scheduled maintainance/ inspection. Such operation if undertaken by the user must be at his own risk.

BHEL reserves the right of changing the operation and maintainance instructions based on experience gained.

Turbogenerators General Safe Disposal of Turbogenerator Items

Turbogenerators

General

Safe Disposal of Turbogenerator Items

In line with ISO 14001 requirements HEEP-BHEL, Haridwar has adopted an Environmental policy and has pledged to fulfil its responsibility of protecting and conserving the environment around itself.

The materials, which are scrapped during inspections and capital overhaul after consumption of their useful life, are disposed in an environment friendly manner to protect our natural resources and control environment pollution.

Guidelines given in the following paragraphs can go a long way in planning the activity of scrapping the hazardous material effectively in an echo friendly manner.

A proper system of waste disposal should also be evolved and its compliance ensured and necessary precautions as published from time to time adhered to while disposing hazardous material.

Generator is manufactured mainly from three types of items namely,

1. Metals:

Structured steel, Cast steel, Forged steel, bronze etc.

2. Non Metals:

brass,

Rubber, insulation, plastics, glass etc.

3. Lubricating oil and Greases.

Disposal of Generator wastes:

1. Metals:

May be disposed as scrap metal for recycling and reuse.

2. Non- Metals:

a) Rubber:

Residue of fluoro-elastomer products, obtained by

exposure of fluoro-elastomers like O-rings, rubbers etc. at very high temperature above 400 degree C, in extreme case of fire etc, should be disposed with great care, such as very high incineration.

b) Insulation:

Insulation material should be disposed by very high incineration.

c) Plastics and glass:

May be disposed as scrap material for recycling and reuse.

3. Lubricating Oil and Grease:

These items can be disposed/recycled/ reused as follows:

a) Lubricating Oil :

To be recycled after cleaning as far as possible. After it has become unserviceable, it may be disposed as follows:

Send

the discarded oil to registered refiners who

have facilities to reclaim the oil by

- physio-chemical treatment for further use in noncritical applications.

- send the used oil to parties who are licensed to handle and dispose used lubricating oil.

- burn off the discarded oil in boiler furnace by mixing with fuel oil.

b) Grease:

It may be disposed for lubrication.

reuse as low-grade

Turbogenerators General Rating Plate Data for Generator

Turbogenerators

General

Rating Plate Data for Generator

Project name: NCTPP Stage-II DADRI

Unit-1

10550A12901

Unit-2

10554A12901

BHARAT HEAVY ELECTRICALS LTD

BHARAT HEAVY ELECTRICALS LTD

KW

:

490,000

P.F.

0.85 Lag

KVA : 577,000

 

Hz

:

50

R.P.M :

3000

Type:

THDF 115/59

Insulation : Class F

Spec.

IS: 5422

IEC: 34

 

I

I

Stator

Volts

21000

Phase

3

Amps

16200

Conn.

YY

Rotor

Volts

334

Coolant: Hydrogen & Water

Amps

3973

Gas Pressure : 3.5 Kg/cm 2 (g)

MADE IN INDIA

DIV : Haridwar

 
Turbogenerators Generator Cross Section General
Turbogenerators
Generator Cross Section
General

BHEL,Haridwar

2.1-1050-10550/1

0209E

Turbogenerators General General Outline Drawing

Turbogenerators

General

General Outline Drawing

Turbogenerators General General Outline Drawing BHEL,Haridwar 2.1-1056-10550/1 0209E
Turbogenerators General General Outline Drawing BHEL,Haridwar 2.1-1056-10550/1 0209E
Turbogenerators General General Outline Drawing BHEL,Haridwar 2.1-1056-10550/1 0209E
Turbogenerators General Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16

Turbogenerators

General

Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16

Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550
Exciter Outline Drawing ELR 70/90-30/6-20 ELR 50/42-30/16 Weights: Total Weight 39 300 kg Rotor 7 550

Weights:

Total Weight

39 300 kg

Rotor

7 550

kg

Coolers (without water)

1 860

kg

Turbogenerators General General Design Features Design and Cooling System

Turbogenerators

General

General Design Features Design and Cooling System

1. General

The two-pole generator uses direct water cooling for the stator winding, phase connectors and bushings and direct hydrogen cooling for the rotor winding. The losses in the remaining generator components, such as iron losses, windage losses and stray losses, are also dissipated through hydrogen. The generator frame is pressure-resistant and gas tight and equipped with one stator end shield on each side. The hydrogen coolers are arranged vertically inside the turbine end stator end shield. The generator consists of the following components :

• Stator

Stator frame

End shields

Stator core

Stator winding

Hydrogen coolers

• Rotor Rotor shaft Rotor winding Rotor retaining rings Field connections

• Bearings

Shaft seals

The following additional auxiliaries are required for generator operation :

Oil system

Gas system

Primary water system

Excitation system

2

Cooling System

The heat losses arising in the generator interior are dissipated to the secondary coolant (raw water, condensate etc.) through hydrogen and primary water. Direct cooling essentially eliminates hot spots and differential temperatures between adjacent components which could result in mechanical stresses, particularly to the copper conductors, insulation, rotor body and stator core.

3. Hydrogen Cooling Circuit

The hydrogen is circulated in the generator interior in a closed circuit by one multi-stage axial-flow fan arranged on the rotor at the turbine end. Hot gas is drawn

by the fan from the air gap and delivered to the coolers, where it is re-cooled and then divided into three flow paths after each cooler. Flow path I is directed into the rotor at the turbine end below the fan hub for cooling of the turbine end half of the rotor. Flow path II is directed from the coolers to the individual frame compartments for cooling of the stator core.

Flow path III is directed to the stator end winding space at the excitor end through guide ducts in the frame for cooling of the exciter end half of the rotor and of the core end portions. The three flows mix in the air gap. The gas is then returned to the coolers via the axial-flow fan. The cooling water flow through the hydrogen coolers should be automatically controlled to maintain a uniform generator temperature level for various loads and cold water temperatures.

4. Cooling of Rotor

For direct cooling of the rotor winding, cold gas is directed to the rotor end windings at the turbine and excitor ends. The rotor winding is symmetrical relative to the generator center line and pole axis. Each coil quarter is divided into two cooling zones. The first cooling zone consists of the rotor end winding and the second one of the winding portion between the rotor body end and the mid-point of the rotor. Cold gas is directed to each cooling zone through separate openings directly before the rotor body end. The hydrogen flows through each individual conductor in closed cooling ducts. The heat removal capacity is selected such that approximately identical temperatures are obtained for all conductors. The gas of the first cooling zone is discharged from the coils at the pole center into a collecting compartment within the pole area below the end winding. From there the hot gas passes into the air gap through pole face slots at the end of the rotor body. The hot gas of the second cooling zone is discharged into the air gap at mid-length of the rotor body through radial openings in the hollow conductors and wedges.

5. Cooling of Stator Core

For cooling of the stator core, cold gas is admitted to the individual frame compartments via separate cooling gas ducts. From these frame compartments the gas then flows into the air gap through slots in the core where it absorbs

the heat from the core. To dissipate the higher losses in the core ends, the cooling gas slots are closely spaced in the core end sections to ensure effective cooling. These ventilating ducts are supplied with cooling gas directly from the end winding space. Another flow path is directed from the stator end winding space past the clamping fingers between the pressure plate and core end section into the air gap. A further flow path passes into the air gap along either side of the flux shield. All the flows mix in the air gap and cool the rotor body and stator bore surfaces. The gas is then returned to the coolers via the axial-flow fan. To ensure that the cold gas directed to the exciter end cannot be directly discharged into the air gap, an air gap choke is arranged within the range of the stator end winding cover and the rotor retaining ring at the exciter end.

6. Primary Cooling water Circuit in the Generator

The treated water used for cooling of the stator winding phase connectors and bushings is designated as primary water in order to distinguish it from the secondary coolant (raw water, condensate, etc.). The primary water is circulated in a closed circuit and dissipates the absorbed heat to the secondary cooling water in the primary water cooler. The pump is supplied with hot primary water from the primary water tank and delivers the water to the generator via the coolers. The

2.1-1100-10550/2

0209E

cooled water flow is divided into two flow paths as described in the following paragraphs. Flow path 1 cools the stator windings. This flow path first passes to a water manifold on the excitor end of the generator and from there to the stator bars via insulated hoses. Each individual bar is connected to the manifold by a separate hose. Inside the bars the cooling water flows through hollow strands. At the turbine end, the water is passed through similar hoses to another water manifold and then returned to the primary water tank. Since a single pass water flow through the stator is used, only a minimum temperature rise is obtained for both the coolant and the bars. Relative movements due to different thermal expansions between the top and bottom bars are thus minimized. Flow path 2 cools the phase connectors and bushings. The bushings and phase connectors consist of thick-walled copper tubes through which the cooling water is circulated. The six bushings and the phase connectors arranged in a circle around the stator end winding are hydraulically interconnected so that three parallel flow paths are obtained. The primary water enters three bushings and exits from the three remaining bushings. The secondary water flow through the primary water cooler should be controlled automatically to maintain a uniform generator temperature level for various loads and cold water temperatures.

Turbogenerators General Generator Cooling Gas Circuit Section A-B Section E-F Note: The cross section may

Turbogenerators

General

Generator Cooling Gas Circuit

Section A-B Section E-F
Section A-B
Section E-F

Note:

The cross section may not match with the generator described in this manual

BHEL,Haridwar

2.1-1150-10550/1

0209E

Turbogenerators General General Design Features Stator

Turbogenerators

General

General Design Features Stator

1.

Stator Frame

The stator frame consists of a cylindrical section body and two end shields which make the stator gas- tight and pressure-resistant. The stator end shields are joined and sealed to the stator frame with an O-ring and bolted flange connection. The stator frame accommodates the electricity active parts of the stator, i.e., the stator core and the stator windings. Both the gas ducts and a large number of welded circular ribs provide for the rigidity of the stator frame. Ring-shaped supports for resilient core suspension are arranged between the circular ribs. The generator cooler is subdivided into cooler sections arranged vertically in the turbine side stator end shield. In addition, the stator end shields contain the shaft seal and bearing components. Feet are welded to the stator frame and end shields to support the stator on the foundation. The stator is firmly connected to the foundation with anchor bolts through the feet.

2.

Stator Core

The stator core is stacked from insulated electrical sheet-steel laminations and mounted in supporting rings over insulated dovetailed guide bars. Axial compression of the stator core is obtained by clamping fingers, pressure plates, and non-magnetic through-type clamping bolts, which are insulated from the core. The supporting rings form part of an inner frame cage. This cage is suspended in the outer frame by a large number of separate flat springs distributed over the entire core length. The flat springs are tangentially arranged on the circumference in sets with three springs each, i.e. two vertical supporting springs on both sides of the core and one horizontal stabilizing spring below the core. The springs are so arranged and tuned that forced vibrations of the core resulting from the magnetic field will not be transmitted to the frame and foundation. The pressure plates and end portions of the stator core are effectively shielded against stray magnetic fields. The flux shields are cooled by flow of hydrogen gas directly over the assembly.

Turbogenerators General General Design Features Stator Winding

Turbogenerators

General

General Design Features Stator Winding

1. Construction

Stator bars, phase connectors and bushings are designed for direct water cooling. In order to minimize the stray losses, the bars are composed of separately insulated strands which are transposed by 540° in the slot portion and bending, the end turns are likewise bonded together with baked synthetic resin fillers. The bars consist of hollow and solid strands distributed over the entire bar cross-section so that good heat dissipation is ensured. At the bar ends, all the solid strands are jointly brazed into a connecting sleeve and the hollow strands into a water box from which the cooling water enters and exits via teflon insulating connection between top and bottom bars is made by a bolted connection at the connecting sleeve. The water manifolds are insulated from the stator frame, permitting the insulation resistance of the water-filled winding to be measured. During operation, the water manifolds are grounded.

2. Micalastic High-Voltage Insulation

High-voltage insulation is provided according to the proven Micalastic system. With this insulating system, several half-overlapped continuous layers of mica tape are applied to the bars. The mica tape is built up from large area mica splittings which are sandwiched between two polyester backed fabric layers with epoxy as an adhesive. The number of layers, i.e., the thickness of the insulation depends on the machine voltage. The bars are dried under vacuum and impregnated with epoxy resin which has very good penetration properties due to its low viscosity. After impregnation under vacuum, the bars are subjected to pressure, with nitrogen being used

as pressurizing medium (VPI process). The impregnated bars are formed to the required shape in molds and cured in an oven at high temperature. The high-voltage insulation obtained is nearly void- free and is characterized by its excellent electrical, mechanical and thermal properties in addition to being fully waterproof and oil-resistant. To minimize corona discharges between the insulation and the slot wall, a final coat of semiconducting varnish is applied to the surfaces of all bars within the slot range. In addition, all bars are provided with an end corona protection, to control the electric field at the transition from the slot to the end winding and to prevent the formation of creepage spark concentrations.

3. Bar Support System

To protect the stator winding against the effects of magnetic forces due to load and to ensure permanent firm seating of the bars in the slots during operation, the bars are inserted with a top ripple spring located beneath the slot wedge. The gaps between the bars in the stator end windings are completely filled with insulating material which in turn is fully supported by the frame. Hot-curing conforming fillers arranged between the stator bars and the support ring ensure a firm support of each individual bar against the support ring. The bars are clamped to the support ring with pressure plates held by clamping bolts made from a high-strength insulating material. The support ring is free to move axially within the stator frame so that movements of the winding due to thermal expansions are not restricted. The stator winding connections are brought out to six bushings located in a compartment of welded non-magnetic steel below the generator at the exciter end. Current transformers for metering and relaying purposes can be mounted on the bushings.

Turbogenerators General General Design Features Rotor

Turbogenerators

General

General Design Features Rotor

1. Rotor Shaft

The rotor shaft is a single-piece solid forging manufactured from a vacuum casting. Slots for insertion of the field winding are milled into the rotor body. The longitudinal slots poles are obtained. The rotor poles are designed with transverse slots to reduce twice system frequency rotor vibrations caused by deflections in the direction of the pole and neutral axis. To ensure that only high-quality forging is used, strength tests, material analysis and ultrasonic tests are performed during manufacture of the rotor. After completion, the rotor is balanced in various planes at different speeds and then subjected to an overspeed test at 120% of rated for two minutes.

2. Rotor Winding

The rotor winding consists of several coils which are inserted into the slots and series connected such that two coil groups form one pole. Each coil consists of several series connected turns, each of which consists of two half turns which are connected by brazing in the end section. The rotor winding consists of silver-bearing deoxidized copper hollow conductors with two lateral cooling ducts. L-shaped strips of laminated epoxy glass fiber fabric with Nomex filler are used for slot insulation.

The slot wedges are made of high-conductivity material and extend below the shrunk seat of the retaining ring. The seat of the retaining ring is silver-plated to ensure a good electrical contact between the slot wedges and rotor retaining rings. This system has long proved to be a good damper winding.

3. Retaining Rings

The centrifugal forces of the rotor end windings are contained by single-piece rotor retaining rings. The retaining rings are made of non-magnetic high-strength steel in order to reduce stray losses. Each retaining ring with its shrink-fitted insert ring is shrunk onto the rotor body in an overhung position. The retaining ring is secured in the axial position by a snap ring.

4. Field Connections

The field current is supplied to the rotor winding through radial terminal bolts and two semicircular conductors located in the hollow bores of the exciter and rotor shafts. The field current leads are connected to the exciter leads at the exciter coupling with multicontact plug-in contact which allow for unobstructed thermal expansion of the field current leads.

Turbogenerators General General Design Features Hydrogen Cooler

Turbogenerators

General

General Design Features Hydrogen Cooler

The hydrogen cooler is a shell and tube type heat exchanger which cools the hydrogen gas in the generator. The heat removed from the hydrogen is dissipated through the cooling water. The cooling water flows through the tubes, while the hydrogen is passed around the finned tubes. The hydrogen cooler is subdivided into identical sections which are vertically mounted in the turbine-end stator end shield. The cooler sections are solidly bolted to the upper half stator end shield, while the attachment at the lower water channel permits them to move freely to allow for expansion. The cooler sections are parallel-connected on their water sides. Shut-off valves are installed in the lines before and after the cooler sections. The required cooling water flow depends on the generator output and it is adjusted by control valves on the hot water side. Controlling the cooling water flow on the outlet side ensures an uninterrupted water flow through the cooler sections so that proper cooler performance will not-be impaired.

so that proper cooler performance will not-be impaired. 1 2 1 Cooler 2 Stator end shield

1

2

1 Cooler

2 Stator end shield

Fig.1

Arrangement of Hydrogen Cooler

Turbogenerators General General Design Features Bearings

Turbogenerators

General

General Design Features Bearings

The sleeve bearings are provided with hydraulic shaft lift oil during start-up and turning gear operation. To eliminate shaft currents, all bearings are insulated from the stator and base plate, respectively. The temperature of the bearings is monitored with thermocouples embedded in the lower bearing sleeve so that the measuring points are located directly below the babbitt. Measurement and any required recording of the temperatures are performed in conjunction with the turbine supervision. The bearings have provisions for fitting vibration pickups to monitor bearing vibrations.

for fitting vibration pickups to monitor bearing vibrations. 1 2 3 1 Connection for shaft lift

1 2

3

1 Connection for shaft lift oil

2 Thermocouple

3 Bearing sleeve

Fig.1

Bearing

Turbogenerators General General Design Features Shaft Seals

Turbogenerators

General

General Design Features Shaft Seals

The points where the rotor shaft passes through the stator casing are provided with a radial seal ring. The seal ring is guided in the seal ring carrier which is bolted to the seal ring carrier flange and insulated to prevent the flow of shaft currents. The seal ring is lined with babbitt on the shaft journal side. The gap between the seal ring and the shaft is sealed withseal oil on hydrogen side and air side. The hydrogen side seal oil is supplied to the seal ring via an annular groove in the seal guide. This seal oil is fed to the hydrogen side annular groove in the seal ring and from there to the sealing gap via several bores uniformly distributed on the circumference. The air side seal oil is supplied to

the sealing gap from the seal ring chamber via radial bores and the air side annular groove in the seal ring. To ensure effective sealing, the seal oil pressures in the annular gap are maintained at a higher level than the gas pressures within the generator casing. The air side seal oil pressure is set at slightly higher than the hydrogen side seal oil pressure. The hydrogen side seal oil is returned to the seal oil system through ducts below the bearing compartments. The oil drained on the air side is returned to the seal oil storage tank together with the bearing oil. On the air side, pressure oil is supplied laterally to the seal ring via an annular groove. This ensures free movement of the seal ring in the radial direction.

free movement of the seal ring in the radial direction. Fig.1 1 Seal ring carrier flange

Fig.1

1 Seal ring carrier flange

2

3

4 Seal ring chamber

5 Inner labyrinth ring

6 Seal strip

Seal

Insulation

Shaft Seal

7 Rotor shaft

8

9

10 Annular groove for hydrogen side seal oil

11 Seal oil inlet bore (H 2 side)

12 Annular groove for hydrogen side seal oil

Oil wiper ring (H 2 side) Seal ring carrier

13 Annular groove for air side seal oil

14

15

16 Annular groove for pressure oil

17 Oil wiper ring (air side)

18 Seal oil groove

Babbit

Seal ring

Turbogenerators General General Design Features Oil supply for Bearings and Shaft Seals

Turbogenerators

General

General Design Features Oil supply for Bearings and Shaft Seals

1

Bearing Oil System

The hydrogen side seal oil pressure required at the

The generator and exciter bearings are connected to the turbine lube oil supply.

seals is controlled separately for each shaft seals by respective pressure equalizing valves, according to the preset pressure difference between the hydrogen side and air side seal oil.

2

Seal Oil System

Oil drained from the hydrogen side is returned to the seal oil tank via the generator pre-chambers. Two

2.1

Construction

float-operated valves keep the oil level at a

The shaft seals are supplied with seal oil from two seal oil circuits which consist of the following principal components. Hydrogen Side Seal Oil Circuit :

predetermined level, thus preventing gas from entering the suction pipe of the seal oil pump (hydrogen side). The low level float-operated valve compensates for the low oil level in the tank by admitting oil from the air side

 

Seal oil tank

seal oil circuit. The high level float-operated valve drains excess oil into the seal oil storage tank. The hydrogen

Seal oil pump

entrapped in the seal oil comes out of the oil in the seal

Oil cooler 1

oil storage tank and is extracted by the bearing vapor

Oil cooler 2

exhauster for being vented to the atmosphere above the

Seal oil filter

power house roof. During normal operation, the high level

Differential pressure valve C

float-operated drain valve is usually open to return the

Pressure equalizing valve TE

excess air side seal oil, which flowed to the hydrogen

Pressure equalizing valve EE.

side via the annular gaps of the shaft seals, to the air side seal oil circuit.

Air Side Seal Oil Circuit :

2.3 Air Side Seal Oil Circuit

 

Seal oil storage tank

The air side seal oil is drawn from the seal oil

Seal oil pump 1

storage tank and delivered to the seals via a cooler and

Seal oil pump 2

filter by seal oil pump 1. In the event of its failure, seal

Standby seal oil pump

oil pump 2 automatically takes over the seal oil supply.

Oil cooler 1

Upon failure of seal oil pump 2, the standby seal oil pump

Oil cooler 2

is automatically started and takes over the seal oil supply

Seal oil filter

to the shaft seals. In the event of a failure of the seal oil

Differential pressure valve A1

pump of the hydrogen side seal oil circuit, the seal oil is

Differential pressure valve A2

taken from the air side seal oil circuit. The air side seal oil pressure required at the seals

2.2

Hydrogen Side Seal Oil Circuit

is controlled by differential pressures valve A1 according

The seal oil drained towards the hydrogen side is collected in the seal oil tank. The associated seal oil pump returns the oil to the shaft seals via a cooler and filter. The hydrogen side seal oil pressure required downstream of the pump is controlled by differential pressure valve C according to the preset reference value, i.e. the preset difference between air side and hydrogen side seal oil pressures.

to the preset value, i.e. the required pressure difference between seal oil pressure and hydrogen pressure. In the event of a failure, i.e. when the seal oil for the seals is obtained from the standby seal oil pump, differential pressure valve A2 takes over this automatic control function. The seal oil drained from the air side of the shaft seals is directly returned to the seal oil storage tank.

Turbogenerators General Seal Oil System (Simplified Diagram)

Turbogenerators

General

Seal Oil System (Simplified Diagram)

General Seal Oil System (Simplified Diagram) Air side seal oil circuit 1 Seal ring 2 Seal

Air side seal oil circuit

1 Seal ring

2 Seal oil storage tank

3

4

5

6

Seal oil pump “A” valve Seal oil cooler Seal oil filter

Hydrogen side seal oil circuit

7 Generator Prechamber

8 Pressure equalizing control valve

9

Seal oil tank Seal oil filter “C” valve Seal oil cooler

10

11

12

13 Seal oil pump

Hydrogen side seal oil“C” valve Seal oil cooler 10 11 12 13 Seal oil pump Air side seal oil

Air side seal oiloil cooler 10 11 12 13 Seal oil pump Hydrogen side seal oil Pressure oil for

Pressure oil for seal ring relief10 11 12 13 Seal oil pump Hydrogen side seal oil Air side seal oil Hydrogen

Hydrogenpump Hydrogen side seal oil Air side seal oil Pressure oil for seal ring relief BHEL,Haridwar

Turbogenerators General General Design Features Gas System

Turbogenerators

General

General Design Features Gas System

1 General

The gas system contains all equipment necessary for filling the generator with CO 2 , hydrogen or air and removal of these media, and for operation of the generator filled with hydrogen. In addition, the gas system includes a nitrogen (N 2 ) supply. The gas system consists of :

H 2 supply

CO 2 supply

N 2 supply

Pressure reducers

Pressure gauges

Miscellaneous shutoff valves

Purity metering equipment

Gas dryer

CO 2 flash evaporator

Flowmeters

following reasons.

3

To prevent the formation of a vacuum due to different thermal expansions of the primary water & tank.

To ensure that the primary water in the pump suction line is at a pressure above atmospheric pressure so as to avoid pump cavitation.

To ensure that the primary water circuit is at a pressure above atmospheric pressure so as to avoid the ingress of air on occurrence of a leak.

Carbon Dioxide (CO 2 ) Supply

As a precaution against explosive hydrogen air mixtures, the generator must be filled with an inert gas (CO 2 ) prior to H 2 filling and H 2 removal. The generator must be filled with CO 2 until it is positively ensured that no explosive mixture will form during the subsequent filling or emptying procedures.

2

Hydrogen (H 2 ) Supply

4

Compressed Air Supply

2.1

Generator Casing

The heat losses arising in the generator are dissipated through hydrogen. The heat dissipating capacity of hydrogen is eight times higher than that of air. For more effective cooling, the hydrogen in the generator is pressurized.

2.2 Primary Water Tank

A nitrogen environment is maintained above the primary water in the primary water tank for the

To remove CO 2 from the generator, compressed air is to be admitted into the generator. The compressed air must be clean and dry. For this reason, a compressed air filter is installed in the filter line.

5 Nitrogen (N 2 ) Supply

Nitrogen is required for removing the hydrogen or air during primary water filling and emptying procedures.