O&M Manual 500 MW TurboGenerator
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Transcript of O&M Manual 500 MW TurboGenerator
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HARIDWAR
BHARAT HEAVY ELECTRICALS LIMITED
Heavy Electrical Equipment Plant
OPERATION & MAINTENANCE
MANUAL
FOR
500 MW TURBOGENERATOR
WITH
WATER COOLED STATOR WINDING &
DIRECT HYDROGEN COOLED ROTOR WINDING
Project :NCTPP Stage -2 DADRI-2 x490MW
Customer :NTPC
BHEL Order no : 10550A12901 DADRI UNIT 1
10554A12901 DADRI UNIT 2
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BHEL,Haridwar
Turbogenerators
General
Table of Contents
2.0-0010-10550/1
0209E
Cover Sheet 0.0-0000
GENERAL
Table of Contents . . . . . . . . . . . . . . . . . . 2.0-0010
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0-0030
Notes on the Use of the Manual . . . . . . . . . 2.0-0040
Operation Beyond Contract Commitment . . 2.0-0050
Safe Disposal of Turbogenerator Items 2.0-0200
DESCRIPTION
Brief Description
Rating Plate Data . . . . . . . . . . . . . . . . . . . 2.1-1002Generator Cross Section . . . . . . . . . . . . 2.1-1050
Generator Outline Diagram . . . . . . . . . . 2.1-1056
Exciter Outline Diagram . . . . . . . . . . . . . 2.1-1058
Design and Cooling System . . . . . . . . . 2.1-1100
Generator Cooling Gas Circuit . . . . . . . 2.1-1150
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-1210
Stator Winding . . . . . . . . . . . . . . . . . . . . . 2.1-1230
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-1300
Hydrogen Cooler . . . . . . . . . . . . . . . . . . . 2.1-1440
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-1450
Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . 2.1-1460
Oil Supply for Bearings and Shaft Seals . . 2.1-1510
Seal Oil System (Simplified Diagram) 2.1-1511
Gas System . . . . . . . . . . . . . . . . . . . . . . . 2.1-1520
Gas System (Simplified Diagram) . . . . 2.1-1521
Primary Water System . . . . . . . . . . . . . . 2.1-1530
Primary Water System (Simplified Diagram) . 2.1-1531
Technical Data
General and Electrical Data . . . . . . . . . 2.1-1810
Mechanical Data . . . . . . . . . . . . . . . . . . 2.1-1820
Seal Oil System . . . . . . . . . . . . . . . . . . . 2.1-1825
Gas System . . . . . . . . . . . . . . . . . . . . . . . 2.1-1826
Primary Water System . . . . . . . . . . . . . . 2.1-1827Waste Gas System . . . . . . . . . . . . . . . . 2.1-1828
Excitation System . . . . . . . . . . . . . . . . . . 2.1-1829
Cooler Data . . . . . . . . . . . . . . . . . . . . . . . 2.1-1830
Reactive Capability Curve . . . . . . . . . . . 2.1-1850
Load Characteristic of pilot exciter . . . 2.1-1860
Gas Specification . . . . . . . . . . . . . . . . . . 2.1-1883
Primary Water Specification . . . . . . . . . 2.1-1885
Specification for Ion Exchange Resins 2.1-1887
Additive Specification for Alkalizer Unit 2.1-1888
Stator
Stator Frame . . . . . . . . . . . . . . . . . . . . . . 2.1-2100
Stator End Shields . . . . . . . . . . . . . . . . . 2.1-2150
Generator Terminal Box . . . . . . . . . . . . 2.1-2170
Hydraulic Testing and Anchoring of Stator 2.1-2190Anchoring of Generator on Foundation 2.1-2191
Stator Core . . . . . . . . . . . . . . . . . . . . . . . . 2.1-2200
Mounting of Stator Core in Stator Frame 2.1-2201
Spring Support of Stator Core . . . . . . . . 2.1-2220
Stator Winding . . . . . . . . . . . . . . . . . . . . . 2.1-2300
Connection Diagram of Stator Winding 2.1-2301
Stator Slot . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-2303
Transposition of Stator Bars . . . . . . . . . 2.1-2305
Micalastic High Voltage Insulation . . . . 2.1-2320
Construction of High Voltage Insulation 2.1-2321
Corona Protection . . . . . . . . . . . . . . . . . . 2.1-2330
Coil and End Winding Support System 2.1-2340Stator End Winding. . . . . . . . . . . . . . . . . 2.1-2341
Electrical Connection of Bars, Water Supply
and Phase Connectors . . . 2.1-2350
Electrical Bar Connections and Water Supply 2.1-2351
Terminal Bushings. . . . . . . . . . . . . . . . . 2.1-2370
PW Connection for Terminal Bushings and
Phase Connectors . . . . . . . . . . 2.1-2371
Cooling of Terminal Bushings . . . . . . . 2.1-2372
Components for Water Cooling of Stator
Winding . . . . . . . . . . . . . . . . . . 2.1-2380
Grounding of Stator Cooling Water Manifold . . 2.1-2389
Rotor
Rotor Shaft . . . . . . . . . . . . . . . . . . . . . . . . 2.1-3000
Cooing of Rotor Winding . . . . . . . . . . . . 2.1-3100
Cooling Scheme of Rotor Winding . . . . 2.1-3101
Rotor Winding. . . . . . . . . . . . . . . . . . . . . . 2.1-3300
Rotor Slot . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-3301
Rotor End Winding . . . . . . . . . . . . . . . . . 2.1-3310
Rotor Retaining Ring . . . . . . . . . . . . . . . 2.1-3350
Rotor Field Connections . . . . . . . . . . . . 2.1-3370
Electrical and Mechanical Connection of EE
Coupling . . . . . . . . . . . . . . . . . 2.1-3373
Rotor Fan . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-3600
Cooler
Hydrogen Cooler (Description) . . . . . . . 2.1-4000
Hydrogen Cooler (Drawing) . . . . . . . . . 2.1-4001
Generator Bearings
Generator Bearing (Description) . . . . . 2.1-5000
Generator Bearing (Drawing) . . . . . . . . 2.1-5001
Measurement of Bearing Temperature 2.1-5003
Generator Bearing Insulation . . . . . . . . 2.1-5005
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2.0-0010-10550/2
0209E
Shaft Seal
Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-6000
Shaft Seal (Drawing) . . . . . . . . . . . . . . . 2.1-6001
Seal Oil System
Seal Oil System . . . . . . . . . . . . . . . . . . . 2.1-7100
Differential pressure Valve A . . . . . . . . . 2.1-7101
Differential Pressure Valve C . . . . . . . . 2.1-7103
Pressure Equalizing Control Valve. . . 2.1-7104
Seal Oil System Schematic Diagram . 2.1-7111
List of Valves for Seal Oil System. . . . 2.1-7112
Bearing Vapour Exhauster. . . . . . . . . . . 2.1-7120
Seal Oil Pumps. . . . . . . . . . . . . . . . . . . . 2.1-7123
Seal Oil Cooler and Seal Oil Filter. . . . 2.1-7130
Seal oil Cooler (Drawing) . . . . . . . . . . . 2.1-7131
Seal Oil Filter (Drawing) . . . . . . . . . . . . 2.1-7132
Differential Pressure Meter Syste. . . . 2.1-7150
Gas System
Gas System. . . . . . . . . . . . . . . . . . . . . . . 2.1-7200
Gas System Schematic Diagram. . . . 2.1-7211
List of Valve for Gas System. . . . . . . . . 2.1-7212
CO2 Vaporiser. . . . . . . . . . . . . . . . . . . . 2.1-7230
Gas Dryer (Refrigeration type) . . . . . . 2.1-7270
Primary Water System
Primary Water System. . . . . . . . . . . . . . 2.1-7300
Primary Water System Schematic Diagram. . 2.1-7311List of Valves for Primary Water System 2.1-7312
Primary Water Pumps. . . . . . . . . . . . . . 2.1-7320
Primary Water Cooler. . . . . . . . . . . . . . . 2.1-7330
Primary Water Treatment System. . . . 2.1-7340
Alkalizer Unit for Primary Water Circuit 2.1-7341
Primary Water Filters. . . . . . . . . . . . . . . 2.1-7343
Primary Water Main Filter. . . . . . . . . . . . 2.1-7344
Primary Water Fine Filter. . . . . . . . . . . . 2.1-7345
Protective Screens at Primary Water Inlet
and Outlet. . . . . . . . . . . . . . . . . 2.1-7349
Automatic Controls
Coolant Temperature Control. . . . . . . . 2.1-8010
Protective Devices
Safety Equipment for Hydrogen Operation. . 2.1-8310
Waste Gas System. . . . . . . . . . . . . . . . . 2.1-8311
List of Valves for Waste Gas System . 2.1-8312
Generator Waste Fluid System . . . . . . 2.1-8315
Generator Mechanical Equipment Protection. 2.1-8320
Tripping Scheme for Generator Mechanical
Equipment Protection 2.1-8321
Generator Mechanical Equipment Protection . 2.1-8323
Generator Electrical Protection. . . . . . . 2.1-8330
Tripping Scheme for Generator Electrical
Protection . . . . . . . . . . . . . 2.1-8331
Rotor Grounding System . . . . . . . . . . . 2.1-8350
Arrangement of Brush Holders for Rotor
Grounding System. . . . . . . . . 2.1-8351
Measuring Devices and SupervisoryEquipment
Introduction. . . . . . . . . . . . . . . . . . . . . . . . 2.1-8400
Temperature Transducers. . . . . . . . . . . 2.1-8410
Supervision of Generator. . . . . . . . . . . . 2.1-8420
Generator measuring points. . . . . . . . . 2.1-8422
List of Valves for Generator System. . . . . 2.1-8423
Supervision of Bearings. . . . . . . . . . . . . 2.1-8440
Supervision of Seal Oil System. . . . . . 2.1-8450
Supervision of Gas System. . . . . . . . . 2.1-8460
Supervision of Primary Water System 2.1-8470
Supervision of Exciter. . . . . . . . . . . . . . 2.1-8490Exciter Measuring Points. . . . . . . . . . . 2.1-8491
Excitation System
Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-9100
Basic Arrangement of Brushless Excitation
System. . . . . . . . . . . . . . . 2.1-9101
Rectifier Wheels. . . . . . . . . . . . . . . . . . . 2.1-9102
Rectifier Wheels and Coupling. . . . . . 2.1-9103
Permanent-Magnet Pilot Exciter Rotor & Fan 2.1-9104
Exciter Cross Section. . . . . . . . . . . . . . 2.1-9110
Exciter Cooling Air Circuit. . . . . . . . . . . 2.1-9120
Stroboscope for Fuse Monitoring . . . . 2.1-9140Exciter Drying . . . . . . . . . . . . . . . . . . . . . 2.1-9150
Ground Fault Detection System for Exciter
Field Circuit. . . . . . . . . . . . . 2.1-9180
Arrangement of Bursh Holders for Ground
Fault Detection System . . 2.1-9181
Brush Holders for Ground Fault Detection
System. . . . . . . . . . . . . . 2.1-9182
Operation
Operating and Setting Values-General 2.3-4000
Gas Quantities. . . . . . . . . . . . . . . . . . . . 2.3-4010Measuring Point List of Generator . . . 2.3-4030
Running Routine-General. . . . . . . . . . 2.3-4100
Operating Log-Generator Supervision 2.3-4120
Operating Log-Seal Oil System . . . . . 2.3-4150
Operating Log-Gas System . . . . . . . . 2.3-4160
Operating Log-Primary Water System 2.3-4170
Operating Log-Exciter Supervision . . 2.3-4190
Start-up
Preparations for Starting-Introduction 2.3-5000
Hints for Cooler Operation. . . . . . . . . . 2.3-5003
Filling and Initial Operation of Air Side Seal
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Turbogenerators
General
2.0-0010-10550/3
0209E
Oil Circuit. . . . . . . . . . . . . . . . . 2.3-5110
Filling and Initial Operation of Hydrogen
Side Seal Oil Circuit . . . 2.3-5120
Venting of Seal Oil Circuits. . . . . . . . . . 2.3-5130
Setting of Seal Oil Pressures. . . . . . . 2.3-5150
Setting of Operating Values for Seal Oil System2.3-5160
Measurement of Seal Oil Volume Flows 2.3-5163Functional Testing of Pumps and Exhausters 2.3-5180
Startup of Air Side Seal Oil Circuit . . . 2.3-5210
Startup of Hydrogen Side Seal Oil Circuit. . . . 2.3-5220
Venting of Seal Oil Circuits and Checking of
Seal Oil Pressures . . 2.3-5230
Checking Automatic Operation of Seal Oil
Pumps. . . . . . . . . . . . . . . . 2.3-5280
Positions of Multi-Way Valves in Gas System 2.3-6107
Scavenging the Electrical Gas Purity Meter
System . . . . . . . . . . . . . 2.3-6110
Setting Electrical Zero of Electrical Gas Purity
Meter System . . . . . . . . 2.3-6120
Purity Measurement During CO2 Filling 2.3-6130
Purity Measurement During H2 Filling 2.3-6140
Purity Measurement During H2 Operation 2.3-6150
Gas Filling-Replacing Air With CO2. . . . . . 2.3-6310
Gas Filling-Replacing CO2 With H2. . . . . . 2.3-6320
N2 Purging After Filling of Primary Water
System . . . . . . . . . . . . . . . . . . 2.3-6810
Filling and Initial Operation of Primary Water
System-
Preparatory Work . . . . . . . . . . . . . . . . . . 2.3-7100
Filling External Part of Primary Water Circuit 2.3-7110Filling the Water Treatment System . . 2.3-7120
Filling the Terminal Bushings and Phase
Connectors . . . . . . . . . . . . . 2.3-7150
Filling the Stator Winding . . . . . . . . . . . 2.3-7160
Filling Primary Water Coolers on Cooling
Water Side . . . . . . . . . . . . . 2.3-7180
Activating Primary Water System After a
Shutdown of Less Than 48 Hours 2.3-7210
Activating Primary Water System After a
Shutdown of More Than 48 Hours 2.3-7220
Activating the Primary Water Conductivity
Meter System . . . . . . 2.3-7530Activating the Primary Water Volume Flow
Meter System . . . . . . . . . . . . . 2.3-7540
Initial Operation of Primary Water System -
Checks Prior to Startup . . 2.3-7610
Turning Gear Operation and Runup of
Generator . . . . . . . . . . . . . . . . . . . . . 2.3-8010
Generator Startup Diagram . . . . . . . . . 2.3-8011
Permissible Synchronizing Criteria . . 2.3-8081
On-Load Running
Permissible Load Limits of Generator 2.3-8170
Permissible Loading at Rated PF During
Voltage and Frequency Deviations . . 2.3-8181
Generator Capability With Hydrogen Coolers
out of Service on Water Side 2.3-8184
Unbalanced Load-Time Curve . . . . . . 2.3-8187
Current Overload Capability . . . . . . . . . 2.3-8188
Runback for loss of stator coolant . . 2.3-8190
Unloading schedule for increased cooling water inlet temperature . . 2.3-8191
Shutdown
Shutdown of Generator . . . . . . . . . . . . . 2.3-8310
Generator Shutdown Diagram . . . . . . 2.3-8311
Supervision of Generator during Standstil l
General . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-8400
Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-8440
Seal Oil System . . . . . . . . . . . . . . . . . . . 2.3-8500
Shutdown of Seal Oil System . . . . . . . 2.3-8510
Draining the air Side Seal Oil Circuit 2.3-8520
Draining the Hydrogen Side Seal Oil Circuit 2.3-8521
Draining the Seal Oil Signal Lines and Seal
Ring Relief Piping . . . . . 2.3-8522
Gas System . . . . . . . . . . . . . . . . . . . . . . 2.3-8600
Gas Removal-Lowering Hydrogen Gas
Pressure in Generator . . . . . . . 2.3-8610
Gas Removal-Replacing H2 with CO2 2.3-8620
Gas Removal-Replacing CO2 With Air 2.3-8630
N2 Purging Before Draining of Primary
Water System . . . . . . . . . . 2.3-8650
Primary Water System . . . . . . . . . . . . . 2.3-8700Shutdown of Primary Water System for Less
Than 48 Hours . . . . . . . . 2.3-8720
Shutdown of Primary Water System for More
Than 48 Hours . . . . . . . . 2.3-8730
Draining the Primary Water System- PW
Coolers (Cooling Water Side) . . . . 2.3-8732
Draining the Primary Water System- Stator
Winding . . . . . . . . . . . . . . . . . 2.3-8734
Draining the PW System-Terminal Bushings
and Phase Connectors 2.3-8738
Draining the Primary Water System- Water
Treatment System . . . . . . . . 2.3-8746Draining the Primary Water System- External
Part of Primary Water Circuit 2.3-8748
Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-8900
Fault Tracing
General . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-9000
Stator and Generator Supervisory Equipment 2.3-9200
Coolant Temperature Control. . . . . . . 2.3-9280
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-9310
Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-9440
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-9450
Bearing Vapour Exhausters . . . . . . . . . 2.3-9521
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2.0-0010-10550/4
0209E
Seal Oil Pumps . . . . . . . . . . . . . . . . . . . 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 Pressures . . . . . . . . . . . . . . . . . . . 2.3-9640
Gas Purity Meter System . . . . . . . . . . . 2.3-9680
Primary Water Pumps . . . . . . . . . . . . . . 2.3-9720Water 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 . . . . . . . . . . . . . . . . . . . . . 2.3-9914
Stroboscope . . . . . . . . . . . . . . . . . . . . . . 2.3-9941
Exciter Drying System . . . . . . . . . . . . . 2.3-9955
Ground Fault Detection System in Exciter
Field Circuit . . . . . . . . . . . . . 2.3-9980
Maintenance and supervision-
Introduction. . . . . . . . . . . . . . . . . . . . 2.4-4200
Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4-4210Generator Coolers . . . . . . . . . . . . . . . . . 2.4-4240
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 2.4-4250Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4-4310Seal Oil Pumps & Bearing Vapour Exhauster 2.4-4520Seal Oil Coolers . . . . . . . . . . . . . . . . . . . 2.4-4540
Seal Oil Filters . . . . . . . . . . . . . . . . . . . . 2.4-4550Gas Consumption . . . . . . . . . . . . . . . . . 2.4-4610Primary Water Pumps . . . . . . . . . . . . . . 2.4-4720Primary Water Filters . . . . . . . . . . . . . . . 2.4-4740Primary Water Coolers. . . . . . . . . . . . . 2.4-4750Water Level in Primary Water Tank . . . 2.4-4760Concutivity Meter System. . . . . . . . . . . . 2.4-4780Alkalizer Unit . . . . . . . . . . . . . . . . . . . . . . 2.4-4785Fuses on Rectifier Wheels. . . . . . . . . . 2.4-4910Exciter Dryer . . . . . . . . . . . . . . . . . . . . . . 2.4-4925Ventilation and Make-Up Air Filters 2.4-4930Exciter Coolers . . . . . . . . . . . . . . . . . . . . 2.4-4940Ground Fault Detection System. . . . . . 2.4-4990
Inspection
Introduction. . . . . . . . . . . . . . . . . . . . . . . . 2.5-0010Determination of Dewpoint Temperature 2.5-0019Packing,Transport, Storage of Gen Rotors 2.5-0030Preventive Measures for Transport and
Storage of Generator Rotors . 2.5-0031Checking Desiccant in Gen Rotor Packing 2.5-0032Insulation Resistance Measurements on
Rotor and Exciter Windings. . . . 2.5-0033Preparation of Machinery Parts . . . . . . 2.5-0200
Checking the Bearing and Seal Insulation . . 2.5-0300Test Norms During Overhaul . . . . . . . . 2.5-0305
Leakage Tests of Generator and Gas System 2.5-0310Flushing the Oil Piping . . . . . . . . . . . . . 2.5-0320Measures to Prevent Corrosion During
Inspecitons . . . . . . . . . . . . . 2.5-1003Preventive Measures to Avoid Stress
Corrosion . . . . . . . . . . . . . . . 2.5-1005
Inspection Schedule-Foreword . . . . . . 2.5-1010Inspection Schedule-Stator . . . . . . . . . 2.5-1020Inspection Schedule-Rotor . . . . . . . . . 2.5-1030Inspection Schedule-Coolers . . . . . . . 2.5-1040Inspection Schedule-Bearings . . . . . . 2.5-1050Inspection Schedule-Shaft Seals . . . . 2.5-1060Inspection Schedule-Seal Oil System 2.5-1071Inspection Schedule-Gas System . . . 2.5-1072Inspection Schedule-Primary Water System 2.5-1073Inspection Schedule-Generator Supervisory
Equipment. . . . . . . . . . 2.5-1080Inspection Schedule-Excitation System 2.5-1090Measures for Preservation of Generator
During Standstill. . . . . . . . . . . . . . . . . 2.5-1100Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5-2000Cementing the Joints of Profiled Gaskets. . 2.5-2120
Sealing Generator End Shield Joints . 2.5-2160IR Measurements on Stator Winding 2.5-2300Procedure for carrying out Tan delta test with
End Winding Vibration probes in position 2.5-2305Drying the Windings . . . . . . . . . . . . . . . 2.5-2310Test Instruction for Stator Slot Support System
With Top Ripple Springs . . 2.5-2340Stator Slot Support System-Radial Wedge
Movements-Test Record . . 2.5-2341
Test Equipment for Stator Slot Support System 2.5-2342Instructions for Checking the Stator Slot Support System. . . . . . . . . . . . . 2.5-2343
Rewedging of Stator Winding. . . . . . . . 2.5-2345Cementing Stator Slot End Wedges at Turbine
and Exciter Ends. . . . . . 2.5-2346Treatment of Bolted Contact Surfaces 2.5-2350Rotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5-3000Insulation Resistance Measurements on Rotor
and Exciter Windings 2.5-3300Ultrasonic Examination of Rotor Retaining
Rings at Power Plant . . . 2.5-3357Hydrogen Coolers. . . . . . . . . . . . . . . . . . 2.5-4000
Insertion and Removal of Hydrogen Coolers 2.5-4100Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . 2.5-5000Shaft Seals. . . . . . . . . . . . . . . . . . . . . . . . 2.5-6000Seal Oil System. . . . . . . . . . . . . . . . . . . . 2.5-7100Seal Oil Pumps & Bearing Vapour Exhausters 2.5-7120Seal Oil Coolers. . . . . . . . . . . . . . . . . . . 2.5-7130Gas System. . . . . . . . . . . . . . . . . . . . . . . 2.5-7200Primary Water System. . . . . . . . . . . . . . 2.5-7300Primary Water Pump. . . . . . . . . . . . . . . . 2.5-7320Primary Water Coolers . . . . . . . . . . . . . 2.5-7330Treatment and Cleaning of Pipes in Primary
Water Circuit . . . . . . . . . 2.5-7381Flushing External Part of Primary Water Circuit2.5-7382
Leakage Test of External Primary Water Circuit2.5-7384Excitation System-Exciter . . . . . . . . . . . 2.5-9000Checking the Insulation Resistance of Heat
Sink Insulation . . . . . . . . . . 2.5-9010Checking the Insulation at Rectifier Wheels 2.5-9011
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Preface
2.0-0030-10550/1
0209E
This manual conta ins in format ion on
operation and maintenance of Turbogeneratorand its auxillary systems.
The information has been prepared on the
assumpt ion tha t the opera t ing 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 operat ing and
maintenance personnel are fully familiar with
the design of the turbogenerator plant andhave aquired thorough training in operation
and maintaining the unit.
The manual is subdevided into following
main sections
-General
-Description
-Operation
-Maintenance
-Inspection
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Notes on the Use of the Mannual
The turbogenerator instruction manual consists
of the following manual sections:
2.0 General
2. 1 Desc ri pti on
2.3 Operation
2.4 Maintenanceand Supervision
2.5 Inspection
Each sect ion contains a number of separate
instructions.
The manual contains a Table of Contents together
with a List of Effect ive Pages . Please check your
manual against this list and advise if there are any
omissions.
Identif icat ion 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.
For the user of the manual, the identification
number is a suf f ic ient reference for locat ing aparticular instruction number must be indicated.
Instruct ion Number
The instruction number consists of the manual
section number, the identificati on number, the variant
number, the page number, and the date with the
language symbol.
2.0 - 0040 - 00009 / 1
1205 E
Manual section number
Identification number
Variant number
Page number
Language (English)
Date (mm yy)
2.0-0040-10550/1
0209E
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Operation Beyond Contract
Commitment
The Turbogenerator set has been designed and
manufactured to meet the contract commitment asregards 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 notpermitted 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.
2.0-0050-10550/1
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In lin e with ISO 14001 requi rements HEEP-BHEL,
Haridwar has adopted an Environmental policy and
has pledged to fulfil its responsibi lity of protecting
and conserving the environment around itself.
The mater ials, which are scrapped dur ing
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 friendlymanner.
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, brass,bronze etc.
2. Non Metals:
Rubber, insulation, plastics, glass etc.
3. Lubri cating oi l and Greases.
Dispos al 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. Lubricatin g 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:
I t may be disposed for reuse as low-grade
lubrication.
2.0-0200-10550/1
0209E
Safe Disposal of Turbogenerator Items
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Rating Plate Data for Generator
Project name: NCTPP Stage-II DADRI Unit-1 10550A12901
Unit-2 10554A12901
IEC: 34
BHARAT HEAVY ELECTRICALS LTD
KW : 490,000
Gas Pressure : 3.5 Kg/cm2(g)
P.F. 0.85 Lag
R.P.M : 3000
Insulation : Class F
KVA : 577,000 Hz : 50
Type: THDF 115/59
StatorVolts 21000
Amps 16200
Phase 3
Conn. Y Y
Spec. IS: 5422
I I
RotorAmps 3973
Volts 334
DIV : HaridwarMADE IN INDIA
Coolant: Hydrogen & Water
2.1-1002-10550/1
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General Outline Drawing
2.1-1056-10550/1
0209E
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Weights:
Total Weight 39 300 kg
Rotor 7 550 kg
Coolers (without water) 1 860 kg
Exciter Outline Drawing
ELR 70/90-30/6-20ELR 50/42-30/16
2.1-1058-10550/1
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General Design Features
Design and Cooling System
2.1-1100-10550/1
0209E
1. General
The two-pole generator uses direct water coolingfor 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
BearingsShaft 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 aredissipated 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 Coo ling Ci rcu i t
The hydrogen is circulated in the generator interior
in a closed circuit by one multi-stage axial-flow fanarranged 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. Coo li ng of Rot or
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 coilquarter 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 theend 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. Cool ing of St at or Co re
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
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0209E
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 Cool ing water Circui t 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
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.
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Note: The cross section may not match with the generator described in this manual
Section A-B
Section E-F
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1. Stat or Fr am e
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 intocooler 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 f rom insulated
electrical sheet-steel laminations and mounted in
supporting rings over insulated dovetailed guide bars.
Ax ia l 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 supportingsprings 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.
2.1-1210-10550/1
0209E
General Design Features
Stator
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as pressur iz ing med ium (VPI p rocess) . 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. B ar Su pp or t Sy st em
To protect the stator winding against the effects
of magnet ic forces due to load and to ensure
permanent firm seating of the bars in the slots duri ng
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 ringensure 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 exci ter
end. Current transformers for metering and relaying
purposes can be mounted on the bushings.
General Design Features
Stator Winding
1. Construct ion
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 tefloninsulating 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 insulatingsystem, 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 penetrat ion propert ies due to i ts low
viscosity. After impregnation under vacuum, the bars
are subjected to pressure, with nitrogen being used
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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 complet ion, the rotor is balanced in various
planes at different speeds and then subjected to anoverspeed test at 120% of rated for two minutes.
2. Ro tor Wi ndi ng
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 si lver-bearing
deoxidized copper hollow conductors with two lateralcooling ducts. L-shaped strips of laminated epoxy glass
fiber fabric with Nomexfiller 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. Retai ni ng Ri ng s
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 rotorbody in an overhung position. The retaining ring is
secured in the axial position by a snap ring.
4. Fi el d Co nn ec ti on s
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
mul t i con t ac t plug- in contact which al low for
unobstructed thermal expansion of the field currentleads.
2.1-1300-10550/1
0209E
General Design Features
Rotor
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1 Cooler
2 Stator end shield
Fig.1 Arrangement of Hydrogen Cooler
1 2
2.1-1440-10550/1
0209E
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 linesbefore 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.
General Design Features
Hydrogen Cooler
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1 Connection for shaft lift oil
2 Thermocouple
3 Bearing sleeve
Fig.1 Bearing
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 bear ings is moni tored wi th
thermocouples embedded in the lower bearing sleeve
so that the measuring points are located directly below
the babbit t. Measurement and any required recording
of the temperatures are performed in conjunction with
the turbine supervision. The bearings have provisions
for f i t t ing v ibrat ion p ickups to moni tor bear ing
vibrations.
1 2 3
General Design Features
Bearings
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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 isbolted 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
13 Annular groove for air side seal oil
14 Babbit
15 Seal ring
16 Annular groove for pressure oil
17 Oil wiper ring (air side)
18 Seal oil groove
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 theannular 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.
Fig.1 Shaft Seal
1 Seal ring carrier flange
2 Seal
3 Insulation
4 Seal ring chamber
5 Inner labyrinth ring
6 Seal strip
7 Rotor shaft
8 Oil wiper ring (H2side)
9 Seal ring carrier
10 Annular groove for hydrogen side seal oil
11 Seal oil inlet bore (H2side)
12 Annular groove for hydrogen side seal oil
2.1-1460-10550/1
0209 E
General Design Features
Shaft Seals
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1 Beari ng Oi l Sy stem
The generator and exciter bearings are connected
to the turbine lube oil supply.
2 Seal Oil System
2.1 Const ruc tion
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 :
Seal oil tank Seal oil pump
Oil cooler 1
Oil cooler 2
Seal oil filter
Differential pressure valve C
Pressure equalizing valve TE
Pressure equalizing valve EE.
Air Side Seal Oil Circuit :
Seal oil storage tank
Seal oil pump 1 Seal oil pump 2
Standby seal oil pump
Oil cooler 1
Oil cooler 2
Seal oil filter
Differential pressure valve A1
Differential pressure valve A2
2.2 Hydrogen Side Seal Oil Circuit
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.
General Design Features
Oil supply for Bearings and Shaft Seals
2.1-1510-10550/1
0209E
The hydrogen side seal oil pressure required at the
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.
Oil drained from the hydrogen side is returned to
the seal oil tank via the generator pre-chambers. Two
float-operated valves keep the oi l level at a
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 circuit. The high level float-operated valve drains
excess oil into the seal oil storage tank. The hydrogenentrapped in the seal oil comes out of the oil in the seal
oil storage tank and is extracted by the bearing vapor
exhauster for being vented to the atmosphere above the
power house roof. During normal operation, the high level
float-operated drain valve is usually open to return the
excess air side seal oil, which flowed to the hydrogen
side via the annular gaps of the shaft seals, to the air
side seal oil circuit.
2.3 Air Side Seal Oil Circuit
The air side seal oil is drawn from the seal oil
storage tank and delivered to the seals via a cooler andfilter by seal oil pump 1. In the event of its failure, seal
oil pump 2 automatically takes over the seal oil supply.
Upon failure of seal oil pump 2, the standby seal oil pump
is automatically started and takes over the seal oil supply
to the shaft seals. In the event of a failure of the seal oil
pump of the hydrogen side seal oil circuit, the seal oil is
taken from the air side seal oil circuit.
The air side seal oil pressure required at the seals
is controlled by differential pressures valve A1 according
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.
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General
Seal Oil System
(Simplified Diagram)
2.1-1511-10550/1
0209 E
Hydrogen side seal oil
Air side seal oil
Pressure oil for seal ring relief
Hydrogen
Hydrogen side seal oil circuit
7 Generator Prechamber
8 Pressure equalizing control valve
9 Seal oil tank
10 Seal oil filter
11 C valve
12 Seal oil cooler
13 Seal oil pump
Air side seal oil circuit
1 Seal ring
2 Seal oil storage tank
3 Seal oil pump
4 A valve
5 Seal oil cooler
6 Seal oil filter
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General
1 General
The gas sys tem conta ins a l l equ ipment
necessary for filling the generator with CO2, 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 (N2) supply. The gas
system consists of :
H2supply CO2supply N2supply Pressure reducers
Pressure gauges Miscellaneous shutoff valves Purity metering equipment Gas dryer CO2flash evaporator Flowmeters
2 Hydrogen (H2) Supply
2 .1 Genera to r Casing
The heat losses arising in the generator are
dissipated through hydrogen. The heat dissipating
capacity of hydrogen is eight times higher than thatof air. For more effective cooling, the hyd rogen in the
generator is pressurized.
2.2 Pr imary Water Tank
A nit rogen envi ronment is maintained above the
pr imary water in the pr imary water tank for the
General Design Features
Gas System
2.1-1520-10550/1
0209E
following reasons.
To prevent the formation of a vacuum due todifferent thermal expansions of the primary water& tank.
To ensure that the primary water in the pumpsuction line is at a pressure above atmospheric
pressure so as to avoid pump cavitation.
To ensure that the primary water circuit is at apressure above atmospheric pressure so as to
avoid the ingress of air on occurrence of a leak.
3 Car bo n Di ox id e (CO2) Supply
As a precaution against explosive hydrogen air
mixtures, the generator must be filled with an inert
gas (CO2) prior to H
2filling and H
2 removal.
The generator must be filled with CO2until it is
positively ensured that no explosive mixture will form
during the subsequent filling or emptying procedures.
4 Co mp res sed Ai r Su pp ly
To remove CO2from 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 Nit rogen (N2) Supply
Nitrogen is required for removing the hydrogen
or air dur ing pr imary water f i l l ing and emptying
procedures.
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General
Gas System
Simplified Diagram
2.1-1521-10550/1
0209 E
1 H2bottle
2 H2pressure reducer
3 N2
bottle
4 N2pressure reducer
5 Primary water tank
6 Pressure controller
7 Upper generator gas header
8 Lower generator gas header
9 Gas drier heater
10 Gas drier fan
11 Gas drier chamber
12 CO2
/H2
purity transmitter
13 Dehydrating filter for measuring gas
14 Pressure reducer for measuring gas
15 Compressed air hose
16 Compressed air filter
17 CO2flash evaporator
18 CO2bottle
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General
1 General
The pr imary water requ i red fo r coo l ing is
circulated in a closed circuit by a separate pump. To
ensure uninterrupted generator operation, two full-
capacity pumps are provided. In the event of a failure
of one pump, the standby pump is immediately ready
for service and cuts in automatically. Each pump is
driven by a separate motor.
Al l va lves , pipes and inst ruments coming in to
contact with the primary water are made from stainless
steel material.
The pr imary water system consists of the
following principal components :
Primary water tank Primary water pumps Cooler Primary water filter Fine filter Ion exchanger Alkalyser unit
As i l lustra ted in th e diagra m, the pri mar y wate r
admitted to the pump from the tank is first passed via
the cooler and fine filter to the water manifold in thegenerator interior and then to the bushings. After
having performed its cooling function, the water is
General Design Features
Primary Water System
2.1-1530-10550/1
0209E
returned to the primary water tank. The gas pressure
above the water level in the primary water tank is
maintained constant by a pressure regulator.
2 Pri mary Wat er Tan k
The primary water tank is located on top of the
stator frame on an elastic support, thus forming the
highest point of the entire primary water circuit in
terms of static head.
3 Pr imar y Wat er Tr ea tmen t Sys t em
The direct contact between the primary water andthe high-voltage windings calls for a low conductivity
of the primary water. During operation, the electrical
conductivity should be maintained below a value of
approximately 1 mho/cm. In order to maintain such
a low conductivity i t is necessary to provide for
continuous water treatment. During operation, a small
quantity of the primary water flow should therefore
be continuously passed through the ion exchanger
located in the bypass of the main cooling circuit. The
ion exchanger resin material required replacement
during operation of the generator, since with the water
treatment system out of service, the conductivity will
rise very slowly.
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General
Primary water circuit, general
Coolant flow : stator winding
Coolant flow : main bushings and phase connectors
Water treatment
Waste gasHydrogen
7 Bypass line
8 Cooling water for stator winding
9 Ion exchanger
10 Cooling water for main bushings and phase connectors
11 Teflon hose
12 Cooling water manifold
13 Alkaliser unit
1 Primary water tank
2 Pressure regulator
3 Waste gas to atmosphere
4 Pump
5 Cooler
6 Filter
Primary Water System
(Simplified Diagram)
2.1-153110550/1
0209 E
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Description
Technical Data
General and Electrical Data
2.1-1810-10550/1
0209E
General
Project name NCTPP DADRI Stage II unit I &2
Generator Type THDF 115/59
Main Exciter Type ELR 70/90-30/6-20
Pilot exciter Type ELP 50/42-30/16
Year of manufacture 2008-09
Rated Data and Outputs Turbogenerator Main Exciter Pilot Excitor
Apparent power 577MVA - 65 kVA
Active power 490MW 3780 kW -
Current 15.85 kA 6300 A 195 A
Voltage 21 kV + 1.05 kV 600 V 220 V + 22 V
Speed 50s-1 50s-1 50 s-1
Frequency 50 Hz - 400 Hz
Power factor 0.85 (lag) - -
Inner connection of stator winding YY - -
H2pressure 3.5 bar (g) - -
Cont. perm. unbalanced Load 8% - -
Rated field current for rated output 3973 A - -
Rated field voltage 334 V - -
The machines are designed in conformity with IEC-34 and should be operated according to these specifications.
The field current is no criterion of the load carrying capacity of the turbogenerator.
Resistance in Ohms at 20C Turbogenerator Main Excitor Pilot Excitor
U-X 0.001445 ohms U-0 0.002518 ohms
Stator Winding V-Y 0.001445 ohms F1-F2 0.592 ohms V-0 0.002538 ohms
W-Z 0.001445 ohms W-0 0.002529 ohms
U-V 0.00046 ohms
Rotor Winding F1-F2 0.06700 ohms U-W 0.00046 ohms
V-W 0.00046 ohms
Rectifier Wheel
Number of fuses 30
per rectifier wheel (800 V, 800 A)
-
Fuse, resistance approx. 150 ohms -
Number of diodes
per rectifier wheel 60-
Action Required:
Number of fuses blown per 2 fuses Switch off field forcing
bridge arm and rectifier wheel 3 fuses Shutdown turbine-generator, replace
fuses and diodes.
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Description
Technical Data
Mechanical Data
2.1-1820-10550/1
0209 E
Torques, Cri t ical Speed etc. Torques and Units
Speeds
Maximum short-circuit torque of stator at
line-to-line single-phase short-circuit 14585 knm
Moment of inertia of generator rotor shaft 10000 kgm2
hhhhh1 864
Critical speed (calculated) hhhhh
2 2388 RPM
(Generator + Exciter coupled) hhhhh3 4680
Generator Volume and Fi l l ing Quant i t ies Volume Units
Generator volume (gas volume) 80 m3
CO2filling quantity*** 160 m3(s.t.p.)*
H2filling quantity (to 3.5 bar)** 480 m3(s.t.p.)*
Weights Weight units
Stator with end shields and coolers 360000 kg
Shipping weight of stator 265000 kg
Stator end shield, upper part TE 22066 kg
Stator end shield, upper part EE 6665 kg
Stator end shield, lower part, TE 24200 kg
Stator end shield, lower part, EE 9950 kg
Rotor 68000 kg
H2cooler section, including water channels 1770 kg
Gas dryer 950 kg
One seal oil cooler (air side) 320 kg
One seal oil cooler (H2side) 250 kg
One primary water cooler 90 kg
Exciter rotor 7550 kg
Component Material Component Material
Rotor shaft 26NiCrMoV145 Electrical sheet-steel 1.5 W/Kg at 1 Tesla 0.5 mm TK
Rotor copper CuAg0.1PF25 Stator copper E-Cu58F20
Rotor wedges CuCoBeZr Bearing babbitt Babbitt V 738
Retaining rings X8CrMnN1818K Seal rings babbitt Babbitt V 738
Damper wedges CuAg0.1F25
* s.t.p. = Standard temperature and pressure, 0oC and 1.013 bar to DIN 1343
** Volume required with unit at standstill. With the unit on the turning gear, the volume will be higher.
*** CO2 quantity kept on stock must always be sufficient for removal of the existing hydrogen filling.
All values are approximate.
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Description
Technical Data
Seal Oil System
2.1-1825-10550/1
0209E
Seal oil pumps -1,2 (Air Side) MKW 11 AP 001 andMKW 21 AP 001
Kind of pump
Type
Capacity
Discharge pressure
Pump motor
Rating
Voltage/ frequency
Current
Speed
Type of enclosure
Nos.
Seal oil pump -3 ( Air side) MKW 31 AP 001
Kind of pump
Type
Capacity
Discharge pressure
Pump motor
Rating
Voltage
Current Armature
Speed
Type of enclosure
Nos.
Seal oil pump (H2side) MKW 13 AP 001
Kind of pump
Type
Capacity
Discharge pressure
Pump motor
Rating
Voltage/ frequency
Current
Speed
Type of enclosureNos.
Seal oil filters MKW 51 BT 001, MKW 51 BT 002,
MKW 53 BT 001 & MKW 53 BT 002
Kind of filter
Type
Volumetric flow rate
Degree of filtration
Pressure drop across filter
Nos. for air side
Nos. for H2side
Three Screw pump
T3S - 52/54
258 LPM
12Kg/Cm2
CGL, ND132M
7.5 KW
415V, 3 Ph AC 50Hz
13.6 A
1455 RPM
TEFC, IP55
2x100% capacity
Three Screw pump
T3S - 52/54
258 LPM
12 Kg/cm2
CGL, AFS 225L
8.5 KW
220 V DC
67 A
1450 RPM
TEFC , IP551x100% capacity
Three Screw pump
T3S - 52/46
130 LPM
12 kg/cm2
CGL, ND 132M
4 KW
415V, 3 Ph AC 50Hz
9.3 A
945 RPM
TEFC, IP55
1x100% capacity
Strainer-type filter
2.32.9 Ma (M/s Boll & Kirch)
4.16 dm3/s
100 microns
0.3 bar with clean filter *
2x100% capacity
2x100% capacity
* 1.2 bar with 100% blockage
Design Data
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Description
Technical Data
Gas System
2.1-1826-10550/1
0209 E
CO2vapou riser MKG 51 AH 001
Rating
Voltage
Heat transfer liquid
Volume of heat transfer liquid
Hole in orifice
Relief valve on high-pressure side
Relief valve on low-pressure side
Nos.
Refrigeratio n type gas drier
Rating and parameters
Compr essed air fi lter MGK 25 BT 001
Volume of activated carbon
Service hours
Throughput
Nos.
18 kW
415V, 3 Ph AC 50Hz
HYTHERM 500 (M/s HPCL)
25 dm3
2.8 mm
175 bar
8 bar
2x100% capacity
As per sub-supplier s manual
3 dm3
approx. 1500 h to 2000 h
80 m3/hr at 8 bar
1x100% capacity
Design Data
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Description
Technical Data
Primary Water System
2.1-1827-10550/1
0209 E
Design Data
Primary water pumps MKF12AP001 and MKF22AP001
Kind of pump Centrifugal pump
Type CZ 65-250 (M/s Sulzer Pumps)
Speed 2950 RPM
Capacity 70 m3/Hr
Discharge head 80 m
Pump motor ND200 L (M/s Crompton Greaves Ltd)
Rating 37KW
Voltage 415V, 3 Ph AC 50Hz
Frequency 50 Hz
Speed 2950 RPMType of enclosure TEFC
Nos. 2x100% capacity
Main fi lters MKF 52 BT 001 and MKF 52 BT 002
Kind of filter Strainer-type filter with magnet bars
Type 1.53.1 (M/s Boll & Kirch)
Volumetric flow rate 25 dm3/s max.
Degree of filtration 150 mm
Pressure drop across filter 0.1 bar with clean filter
1.2 bar with 100% fouling
Nos. 2x100% capacity
Fine fil ter MKF 60 BT 001
Kind of filter 1 plug. 1 cartridge
Type 1.55.1 (M/s Boll & Kirch)
Volumetric flow rate 0.42 dm3/s max.
Pressure drop across filter 0.15 bar with clean filter
1.2 bar with 100% fouling
Nos. 1x100% capacity
Ion exchanger MKF 60 BT 001
Volume 83 litres
Resin Lewatit
Resin volume 56 litres (45 kg)
Nos. 1x100% capacity
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Description
Technical Data
Excitation System
2.1-1829-10550/1
0209 E
A-wheel (negat ive polarity )
No./Type of diodes
No./Type of fuses
Resistance/voltage/current per fuse
No. of RC networks
B-wheel (positive polarity)
No./Type of diodes
No./Type of fuses
Resistance/voltage/current per fuseNo. of RC networks
Stroboscope
Type
Voltage
Frequency
No. of stroboscope
Exciter air dryer
Type
Rating
Voltage
Frequency
Adsorption air flow rate
Regeneration air flow rate
No. of dryer
60 Nos./BHdL 1220 (BHEL EDN,Bangalore make)
30 Nos./3NC 9 538
approx. 150 , 800 V, 800 A
6 Nos.
60 Nos./BHdL 1320(BHEL EDN,Bangalore make)
30 Nos./3NC 9 538
approx. 150 , 800 V, 800 A6 Nos.
LX5-30/36-2
240 V
50/60 Hz
1 No.
BA-1.5 A (M/S BRYAIR MAKE)
4,6 kW
230 V
50 Hz
120 m3/h
35 m3/h
1 No.
Design Data
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Description
Technical Data
Cooler Data
Note:The specified cooler data refer to max. cooling water inlet temperatures. During operation the operatingvalues of the coolers may deviate from above design data.
Materials and PressuresUnits
Design Data for One Seal Oil Cooler (H2Side)
Drg. No. 0-165-03-70005 C (1 x100% )Materials and PressuresUnits
3.5 Bar (g)
33 m3/s
4640 kW
45 C
72 C
700 Pa
540 m3/hr
38 C
45.4 C3.0 MWC
Design Data for the H2Cooler,
Drg. No. 0-166-01-70006C(4 x 25% each)
Materials
Fins Copper
Tubes 90/10 Cu-Ni
Tubesheets Carbon steel
Water channels Carbon steel
Pressures (Tube Side)
Design pressure 10 kg/cm2
Test pressure 15 kg/cm2
Hydrogen pressure
Gas flow (Total)
Heat dissipating capacity (Rated)
Cold gas temperature
Hot gas temperature (max.)
Gas pressure drop (approx.)
Cooling water flow (Total for 4 sections)
Cooling water inlet temperature (design)
Water outlet temperatureWater pressure drop
Design Data for One Seal Oil Cooler (Air Side)
Drg. No. 0-165-03-70006 C(1 x 100% )Units Mater ials and Pressures
Oil flow
Heat dissipating capacity (Rated)
Oil inlet temperature
Oil Outlet temperature
Oil pressure drop (approximate)
Cooling water flow
Cooling water inlet temperature (design)
Water outlet temperature
Water pressure drop (approximate)*
15 m3/hr
140 kW
70 C
50 C
0.833 Bar
35 m3/hr
38 C
41.4 C
6.8 mWC
Materials
Tubes Admiralty Brass
Tubesheets Carbon steel
Water channels Carbon steel
Cooling water Pressures
Design pressure 16 kg/cm2
Test pressure 24 kg/cm2
Oil Side Pressures
design pressure 16 kg/cm2
Test pressure 24 kg/cm2
Oil flow
Heat dissipating capacity (Rated)
Oil inlet temperature
Oil outlet temperature
Oil pressure drop (approximate)
Cooling water flow
Cooling water inlet temperature (design)
Water outlet temperature
Water pressure drop (approximate)*
7.8 m3/hr
90 kW
70 C
50 C
0.85 Bar
22 m3/hr
38 C
41.5 C
7.1 mWC
Materials
Tubes Admiralty Brass
Tubesheets Carbon steel
Water channels Carbon steel
Cooling Water Pressures
Design pressure 16 kg/cm2
Test pressure 24 kg/cm2
Oil Side Pressures
Design pressure 16 kg/cm2
Test pressure 24 kg/cm2
2.1-1830-10550/1
0209 E
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Materials and PressuresUnits
65 m3/hr
1715 kW
71.7 C
49 C
1160 mBar
250 m3/hr
38 C
43.9 C
2.0 mWC
Design Data for the Primary Water
Cooler, Drg. No. 0-165-41-70013 C
(2x 100% )
Materials
Shell SS
Tubes SS
Tubesheets SS
Water channels Carbon Steel
Primary Water Side Pressures
Design pressure 10 kg/cm2
Test pressure 15 kg/cm2
Cooling Water Side Pressures
Design pressure 10 kg/cm2
Test pressure 15 kg/cm2
Primary water flow
Heat dissipating capacity (Rated)
Primary water inlet temperature
Primary water outlet temperature
Primary water pressure drop
Cooling water flow
Maximum cooling water inlet temperature
Cooling water outlet temperature
Water pressure drop*
* Flange-to-flange of equipment only
Materials and PressuresUnits
1 Bar (g)
15.5 m3/s
500 kW
45 C
74 C
700 Pa
200 m3/hr
38 C40.2 C
3.0 mWC
Design Data for the Exciter Ai r Cooler,Drg. No. 0-166-05-70003C
(2 x 50% each)
Materials
Fins Copper
Tubes 90/10 Cu-Ni
Tubesheets Carbon steel
Water channels Carbon steel
Pressures (Tube Side)
Design pressure 10 kg/cm2
Test pressure 15 kg/cm2
Air pressure
Air flow (Total)
Heat dissipating capacity (Rated)
Cold air temperature
Hot air temperature (max.)
Air pressure drop (approx.)
Cooling water flow
Cooling water inlet temperature (design)Water outlet temperature
Water pressure drop*
2.1-1830-10550/2
0209 E
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Description
2.1-1850-10550/1
0209E
t TECHNICAL DATA
Reactive Capability Curve
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Description
Technical Data
Load Characteristic of Pilot Exciter
2.1-1860-10550/1
0209 E
PMG Pilot Exciter Characteristic
2 0 0
2 0 5
2 1 0
2 1 5
2 2 0
2 2 5
2 3 0
2 3 5
2 4 0
0 5 0 1 0 0 1 5 0 2 0 0 2 5 0
PMG field current (amps)
PMGVoltage(volts)
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DescriptionGas Specification
1. Comp res sed Ai r
The compressed air shall be free of-
corrosive contaminants and
hazardous gases, flammable or toxic.
The maximum total oil or hydrocarbon content,
exclusive of non-condensables, shall be as close
to zero (0) w/w or v/v as possible, and under no
circumstances shall it exceed one (1) ppm w/w or
v/v under normal operating conditions.
The compressed air shall be practically free of dust.
The maximum particle size in the air stream shall be
five (5) micrometers.
The oxygen content of the expanded air shall be
between 20 and 21% v/v.
The dew point at line pressure shall be at least 15 K
below the minimum possible generator temperature.
In no case should the dew point at line pressure
exceed 10 C.
The compressed air shall be available at a gauge
pressure between 6 and 9 bar.
Volumetric flow rate: 144 to 216 m3/h.
2. Car bon Diox ide (CO2)
Carbon dioxide shall be made available with a purity
99.9 % v/v. The remaining 0.1 % v/v shall be free of
corrosive contaminants: traces of ammonia (NH3) and
sulphur dioxide (SO2) shall not be detectable by
analysis.
If obtained from a central bulk supply, the gas shall be
made available at the following conditions:
Gauge pressure : 1 to 2.5 bar
Temperature : 20 to 30 0C
Volumetric flow rate : 144 to 216 m3/h.
3 Hydrogen (H2)
The hydrogen gas shall be made available with a purity
99.9% v/v. The remaining 0.1 % v/v shall be free of
corrosive contaminants: traces of ammonia (NH3) and
sulphur dioxide (SO2) shall not be detectable byanalysis.
If obtained from a central bulk supply, the hydrogen
gas shall be made available at the following conditions:
Gauge pressure : 8 to 9 bar
Volumetric flow rate : 144 to 216 m3/h.
4 Nitrogen (N2)
The nitrogen gas shall be made available with a purity
of 99.99 % v/v.
Contaminants (O2, H
2O): not applicable
The remaining 0.01% v/v shall be free of corrosive
contaminants; traces of ammonia (NH3) and sulphur
dioxide (SO2) shall not be detectable by analysis.
1)s.t.p. = standard temperature and pressure. 00C and 1.013 bar to DIN 1343.
The gauge pressures and temperatures indicated are those at the inlets of the generator gas supply units.
2.1-1883-10550/1
0209E
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Description Specification for
Ion Exchange Resins
1. General
The primary water must have a low condictivity since it
comes into direct contact with the high-voltage winding.
To maintain a low conductivity the primary water requires
continuous treatment. This is achieved by continuously
passing a small primary water volume flow through a mixed
bed ion exchanger arranged in the bypass of the main
cooling circuit. The ion exchange resins must be replaced
at certain intervals. The resins may be replaced while the
generator is in operation, since with the water treatment
system out of service the conductivity will continue to rise
only very slowly.
2. Res in Sp ec if ic at io n
The resins should contain no impurities or soluble
substances having a detrimental effect on the materials
used in the primary water circuit and thus on the availability
of the generator.
Our recommendation to use Lewatit ion exchange
resins is based on many years of service experience and
the close cooperation between the resin supplier and many
power plant operators as well as the high quality standard
of the resins.
The initial charge of the mixed-bed ion exchanger
consists of the following types of resins.
Lewatit S 100 KR/H/chloride-free
Lewatit M 500 KR/OH/chloride-free
When replacing the resins, use either the above types
or resins available from other manufacturers which must
comply with the specification below.
Cation exchanger Anion exchanger
(Lewatit S100KR/H/chlori de-free) (Lewatit M500 KR/OH/chlorid e-free)
Functional group Strongly acidic Very strongly basic
Grain shape Beads Beads
Particle size (0.3 - 1.25) mm (0.3 - 1.25) mm
Bulk density of swollen resin (800 - 900) g/dm3 (670 - 750) g/dm3
Resin form H-ions OH-ions
Specific load up to 40 dm3/h dm3 40 dm3/h dm3
Total capacity of swollen resin (1.9 - 2.2) mol/dm3 (1.1 - 1.6) mol/dm3
Useful capacity min. 50 gCaO/dm3 16 gCaO/dm3
Chloride content up to 50 mg/dm3 50 mg/dm3
Thermal stability up to 1200C 700C
Stability in pH range Unlimited Unlimited
Shelf life min.
(in original packing 5 years 3 yearsat temperatures of +1oC to +40oC
2.1-1887-10550/1
0209 E
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7/24/2019 O&M Manual 500 MW TurboGenerator
43/447
BHEL,Haridwar
Turbogenerators
Description
A lso ref er to the fo l lowing in fo rmat ion
[1] 2.1-7341 Alkalizer Unit for Primary Water Circuit
[2] 2.1-1885 Primary Water Specification
Despite the use of oxygen-poor water, corrosion of
copper in the primary water circuits of water-cooled
windings, cannot be completely avoided, and in isolated
cases the corrosion products can reduce the cross-
sectional flow area of the water distribution system.
The sever ity of the corrosion attack can be
substantially reduced by alkalizing the oxygen-poor water.
In addition, the system becomes less susceptible to
disturbances resulting from air in-leakage.
Operating the generator with alkal ine water at pH 8 to
9 will improve the reliability and availability of the turbine
generator.
For operation of the alkalizer unit [1 ] , dilute sodium
hydroxide for continuous injection into the primary water
circuit and lime are required.
1 Sod ium Hydrox ide So lut ion
The sodium hydroxide solution should have a
concentration of 10 to 20 g of NaOH per dm3.
Sodium hydroxide solution should be prepared from :
Caustic Soda [NaOH] of P.A. quality, containing.
NaOH : > 98%
Carbonates [Na2CO
3] : < 1%
Water in conformity with the primary water
specification[2] .
2 L ime
A lime filter to be provided in the NaOH tank vent serves
to bind the carbon dioxide (CO2) contained in the inlet air in
order to prevent the formation of carbonates in the sodium
hydroxide solution.
The lime filter consists of equal parts of sodium
hydroxide (NaOH) and calcium hydroxide (Ca(OH)2). This
mixture is commercially available and known as soda lime.
Addi t ive Spec i f icai ton
for Al kal izer Unit
2.1-1888-10550/1
0209 E
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7/24/2019 O&M Manual 500 MW TurboGenerator
44/447
BHEL,Haridwar
Turbogenerators
Description
2.1-2100-10550/1
0209 E
Stator Frame
To facilitate manufacture, erection and transport, the
stator consists of the following main components:
Stator frame
End shields
Bushing compartment
The stator frame with flexible core suspension
components, core, and stator winding is the heaviest
component of the entire generator. A rigid frame is
required due to the forces and torques arising during
operation. In addition, the use of hydrogen for the
generator cooling requires the frame to be pressure-
resistant up to an internal pressure of approximately 10
bar (130 psi g).The welded stator frame consists of the cylindrical
frame housing, two flanged rings and axial and radial
ribs. Housing and ribs within the range of the phase
connectors of the stator winding are made of non-
magnetic steel to prevent eddy current losses, while the
remaining frame parts are fabricated from structural
steel.
1 2 3 4
1 Stator End shield 2 Bushing compartment
3 Frame housing 4 Stator foot
Fig:1 Stator frame
The arrangement and dimensionally of the ribs are
determined by the cooling gas passages and the required
mechanical strength and stiffness. Diminishing is also
dictated by vibrational considerations, resulting partly in
greater wall thickness then required, from the point of
view of mechanical strength. The natural frequency of
the frame does not correspond to any exciting frequency.
Two lateral supports for flexible core suspension in
the frame are located directly adjacent to the points
where the frame is supported on the foundation. Due to
the rigid design of the supports and foot portion, the
forces due to weight and short-circuits will not result in
any over-stressing of the frame.
Manifolds are arranged inside the stator frame at the
bottom and top for filling the generator with CO2and H
2
. The connections of the manifolds are located side by
side in the lower part of the frame housing.
Addi tional openings in the housing, which are sealed
gastight by pressure-resistant covers, afford access to
the core clamping flanges of the flexible core suspension
system and permit the lower portion of the core to be
inspected. Access to the end winding compa