Lalitpur Power Generation Company Ltd.

Lalitpur Thermal Power Plant

Unit 10
File Ident: MK.TP4.03
File: MK Product Technical Documentation (3/3)

Tab-Sheet: 10 Trouble-Shooting
Table of Contents (Tab-Sheet)

UNID Title Rev. Date of Issue

490979039 General - 2013-09-09
490979046 Stator and Generator Supervisory Equipment - 2013-09-09
490979251 Rotor - 2013-09-09
490979268 Cooler - 2013-09-09
490979275 Bearings - 2013-09-09

Date of Issue: 2014-02-20 Page 1 of 1

 Turbogenerators Fault Tracing
Trouble-Shooting General

The details given herein on faults, their possible causes and can be taken in accordance with the following instructions, the
the corrective measures cannot be considered complete in turbine-generator should be shut down and the hydrogen
every respect, since all possible troubles cannot be covered in should be replaced with inertgas. If required, the services of the
advance. In most cases, the operator will have to decide on the manufacturer should be requested. In most cases, however,
measures to be taken. The individual measures required sufficient details will be found in the Turbogenerator Manual.
depend on the mode of operation. Unless corrective measures
All Rights Reserved
e Siemens AG 2008 -
Copyright
Distribution: RESTRICTED

Siemens AG MK &MDB 2.3- 9000- 0001

Energy Sector 0808E
 Turbogenerators Fault Tracing
Trouble-Shooting Stator and Generator Supervisory Equipment

Fault/Cause Remedy

Differences in slot temperatures between individual

stator phase windings
The embedded RTDs should be checked when different
slot temperatures are indicated while stator currents are of
equal magnitude in all the three phases. Such a check should
only be made with the generator at standstill and in non-excited
condition. The check should include resistance measure-
ments as well as testing of the detector leads, the measuring
point selector switches and the indicators. Care should be ta-
ken during resistance measurements of the embedded RTDs
to ensure that they are not heated as this will distort the results.
In many cases, a fault can be cleared by recalibration of the
RTDs.

High hot gas temperature

and/or
High cold gas temperature
All Rights Reserved

NOTE:
If the cold gas temperature continues to rise,
the mechanical equipment protection system
is tripped.
e Siemens AG 2010 -

J Faulty hydrogen temperature control. Insufficient cooling Verify cause of fault by checking analog indicators (uniform
water flow volume through hydrogen coolers. rise of temperatures in all coolers). See 2.3- 9280 for remedial
action.
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J Insufficient cooling water volume flow through a single
hydrogen cooler.
Verify cause of fault by checking analog indicators (uniform
rise of temperatures at one coolers).
Check positions of cooling water valves at the
corresponding cooler. Check to ensure that the cooling water
inlet valve is fully open. Lower cold gas temperature of
defective cooler by adjusting the cooling water volume flow
with the cooling water outlet valve. Ensure that cold gas
temperatures downstream all hydrogen coolers are equal.

Unbalanced load due to unequal phase loading of the

system connected to generator
If the generator is operated with unbalanced load due to
particular system conditions, care must be taken that the
continuously permissible unbalanced load is not exceeded
(see also 2.1- 1607). The unbalanced load is defined as the
ratio of negative sequence current to rated current. The
permissible rated stator current should not be exceeded in any
Distribution: RESTRICTED

stator phase. When the unbalanced load is higher than the

continuously permissible unbalanced load, steps should be
taken for bringing about a uniform system load. The generator
should be shut down if it is impossible to distribute the system
load more uniformly over the three phases.

Siemens AG MKA &MDC 2.3- 9200- 0029 / 1

Energy Sector 0210E
Fault/Cause Remedy

Liquid in generator
NOTE:
If two of the three parallel-connected liquid de-
tectors (see Fig. 1, Item 1) signal the ingress of
liquid, the mechanical equipment protection is tripped.

The liquid in the generator casing should be inspected to

determine its origin, i.e. defective hydrogen cooler section, oil
from shaft seals, primary water or condensate.

DANGER
Fire and explosion hazard due to escaping hydrogen gas.
The pipes of the liquid detector rack are H2-filled and
under pressure.
To prevent H2 leaks, close the shutoff valves before the
level detectors before draining the liquid.

To do this
J Close shutoff valve(s) upstream of level detector which
activated the alarm.
J Remove drain plug from drain valve downstream of the
corresponding level detector.
J Drain the liquid via the drain valve and inspect liquid.
J Then close drain valve and reopen shutoff valve upstream
of level detector.
J Repeat this procedure until no liquid is discharged from the
drain valve.
J Close drain valve downstream of the level detector and
open shutoff valve upstream of level detector. Insert and
tighten drain plug to seal the system (gastight).

1 2 3 4 5 6

1 Liquid from terminal box, top

2 Liquid from terminal box, bottom
3 Liquid from stator frame, center
4 Liquid from cooling header, coolers A/B
5 Liquid from cooling header, center
6 Liquid from cooling header, coolers C/D
7 Shutoff valve upstream level detector
8 Level detector
9 Drain valve downstream level detector

Fig. 1 Level Detector Rack

Siemens AG 2.3- 9200- 0029 / 2

Energy Sector 0210E
Fault/Cause Remedy

If the liquid cannot be drained from the generator in this

manner within a reasonable period of time, which will be the
case in the event of major leaks, the generator should be shut
down immediately.

J Moisture condensate Very small water quantities are indicative of condensate.

Place gas dryer in operation.
A hydrogen sample should be extracted from the generator
and examined in a laboratory to determine its moisture
content.

J Cooling water from a defective hydrogen cooler Lager amounts of water point to a leaking cooler section.
Identify defective cooler section. Reduce generator load
(see also 2.3- 8170) and take cooler section out of service by
closing the shutoff valves. Than take measures outlined in the
corresponding instructions (see also 2.3- 9440).

J Primary water Since the primary water pressure is lower than the H2
casing pressure during generator operation at rated hydrogen
pressure, liquid accumulation in the generator can only occur
in case of a major leak (tube failure, burst Teflon hose). The
leakage water quantities require, however, a shutdown of the
turbine-generator.
As soon as the generator has been disconnected from the
system and is de-excited, take primary water pumps out of
service and close control valve upstream of the stator winding
and bushings. Remove hydrogen from the generator
immediately and fill with inert gas. Fault tracing and corrective
action may be started as soon as the generator is filled with air
at atmospheric pressure.

J Oil Oil level control in seal oil tank is faulty.

Prechambers in generator are overflowing.
Take corrective actions as described in (see also 2.3- 9561)
immediately.

Siemens AG 2.3- 9200- 0029 / 3

Energy Sector 0210E
 Turbogenerators Fault Tracing
Operation Rotor

Fault/Cause Remedy

Sudden deterioration of rotor running condition

Check whether the deteriorated running condition
originated due to the turbine or whether the rotor bearings are
damaged. A deterioration of the running condition may be
caused by a change in the balancing condition or by a rotor
winding short. Unload and shut down turbine generator as
soon as feasible if cause cannot be located and corrected for
severe condition. Since it is very difficult in most cases to find
a definite cause, it is advisable to obtain the help of
manufacturers product service personnel.
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Distribution: RESTRICTED

Siemens AG MKA40 &MDC 2.3- 9310- 0001

Energy Sector 1208E
 Turbogenerators Fault Tracing
Operation Cooler

Fault/Cause Remedy

Cooling water in generator

J Leak or tube rupture in H2 cooler tube bundle
DANGER
Risk of explosion and fire due to leaking hydrogen. The
generator is filled with hydrogen. Do not unfasten any
screws or bolts at the coolers while the generator is filled
with pressurized hydrogen. Do not start any work on the
cooler until the hydrogen has been completely removed
from the generator and the generator is filled with air at
atmospheric pressure.

Shut down the generator and seal off the cooling water
supply to the H2 cooler section.

Reduce the H2 pressure in the generator to atmospheric

pressure. The hydrogen must be removed from the generator
All Rights Reserved

by purging the unit with carbon dioxide or argon. Subse-

quently scavenge the generator with air to remove the carbon
dioxide or argon.

Identify the defective cooler section. Drain the cooling

e Siemens AG 2005 -

water from the defective section. Ensure that the water is com-
pletely drained, if necessary use compressed air at low pres-
sure to force any remaining water from the cooler.

Open the TE cover of the defective section and then care-

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fully remove the TE return water channels. The EE inlet/outlet

water channel must also be removed. Care must be taken to
ensure that the gaskets are not damaged so that they can be
reused.
2 3 4 5 6 7 8

1 Container 5 Cooler section

2 Water 6 Tube
3 Hose 7 Seal plug
4 Hollow plug 8 Tubesheet

Fig. 1 Locating the Ruptured Tube

Distribution: RESTRICTED

Siemens AG MKA70 &MDC 2.3- 9440- 0029 / 1

Energy Sector 0305E
Fault/Cause Remedy

In order to locate the defective tube, plug all tubes at the

TE (multi-shaft systems) or at the gas-turbine end (single-
shaft systems) of the cooler, and then reinstall the TE cover
complete with gasket.
Pressurize the generator with air up to approx. 1 bar
(100 kPa, 14.5 psig).
At the EE of the tubes, insert a hollow plug with a hose as
shown in Fig. 1. Hold the other end of the hose into a container
filled with water. If bubbles appear from the container, the
cooler tube is defective. Ensure that the generator gauge
pressure is kept at 1 bar for the duration of the test.
Plug the defective tube at both ends as shown in Fig. 2.
Suitable materials for the plugs are hardwood, copper or
brass. Force the plugs into the tube by lightly striking them
with a suitable mallet. Note that no more than 5% of the tubes
of a single cooler section may be sealed. Remove the seal
plugs from the other tubes. Reinstall the return and inlet/outlet
water channels, fill the cooler section with water, and vent.

Cut off here

X
4 3 2 1
Detail X

d+1*)
2.5

40
1 Plug 3 Cooler tube
2 EE tubesheet 4 TE tubesheet

Fig. 2 *) d = see 2.1- 1620

Plugging a Defective Cooler Tube

Siemens AG 2.3- 9440- 0029 / 2

Energy Sector 0305E
 Turbogenerators Fault Tracing
Operation Bearings

Fault/Cause Remedy

Generator bearing temperatures vary

Temperature variations at the generator bearings may be
due to different causes. Turbogenerator can be kept in
operation as long as permissible bearing temperature is not
exceeded. When a variation is noted, the operating temper-
atures should be carefully monitored to ensure the limit
temperature is not exceeded.

WARNING
WARNUNG
Risk of personal injury. Faulty oil cooling can lead to unallo-
wably high or low lube oil temperatures. This can cause
damage to the rotor bearings and bearing oil can leak at high
pressure and flow rate. Damaged shaft bearings can also lead
to damage of the shaft journals and can cause severe personal
injury due to ejected parts. Check the oil quality and oil filters
as per the corresponding maintenance schedule. Ensure com-
pliance with the instructions for changing the bearing oil and
All Rights Reserved

flushing the oil system. Check the cooler data as per the corre-
sponding maintenance schedule and ensure compliance with
the information about and instructions for the oil system in the
turbine maintenance manual.
If a deviation occurs, first check cold oil temperature (oil
e Siemens AG 2010 -

temperature after cooler) and bearing oil pressure for deviation

from normal. If bearing temperature rise does not result from
a variation of these values, the oil pressure indicated in the
shaft lift oil pipe should be checked. If bearing temperature
exceeds permissible value, turbogenerator should be shut
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down.

Bearing oil pressure indicated in the shaft lift oil pipe

drops
Oil pressure depends in part on the bearing oil inlet temper-
ature. Check first to determine whether the pressure drop was
caused by an oil temperature variation. If not, the shaft lift oil
system should be checked for leakages. The fault may be due
to a leak at the check valve in the lift oil pipe. To determine if
the check valve is leaking, close globe valve in the lift oil line.
Prior to closing valve, check and record the setting (throttling
valve as set for operation). This check is performed by
counting the number of turns or by measuring the travel.
If, on closing the globe valve, the pressure gauge shows an
increase over the previous operating value, the check valve is
leaking. Replace or repair the check valve at the next shut-
down or inspection. A precise adjustment of the throttling ele-
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ment will again be necessary during recommissioning.

Siemens AG MKD &MDC 2.3- 9450- 0001

Energy Sector 0710E