Generator Manual

OPERATION & MAINTENANCE
MANUAL
FOR
600 MW TURBOGENERATOR
WITH
WATER COOLED ST ATOR WINDING &
DIRECT HYDROGEN COOLED ROTOR WINDING
Project :2X600 MW TPP AT DERANG,ANGUL,ORISSA
Customer : JINDAL INDIA THERMAL POWER LTD.
BHEL Order no : Unit -1 10597P12901

Unit -2 10598P12901
HARIDWAR
BHARAT HEAVY ELECTRICALS LIMITED

Heavy Electrical Equipment Plant
Turbogenerators Table of Contents
General
Cover Sheet 0.0-0000 Stator End Shields . . . . . . . . . . . . . . . . . 2.1-2150

Generator Terminal Box . . . . . . . . . . . . 2.1-2170
GENERAL Hydraulic Testing and Anchoring of Stator 2.1-2190
Anchoring of Generator on Foundation 2.1-2191
Table of Contents . . . . . . . . . . . . . . . . . . 2.0-0010 Stator Core . . . . . . . . . . . . . . . . . . . . . . . . 2.1-2200
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0-0030 Mounting of Stator Core in Stator Frame 2.1-2201
Notes on the Use of the Manual . . . . . . . . . 2.0-0040 Spring Support of Stator Core . . . . . . . . 2.1-2220
Operation Beyond Contract Commitment . . 2.0-0050 Stator Winding . . . . . . . . . . . . . . . . . . . . . 2.1-2300
Safe Disposal of Turbogenerator Items 2.0-0200 Connection Diagram of Stator Winding 2.1-2301
Stator Slot . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-2303
DESCRIPTION Transposition of Stator Bars . . . . . . . . . 2.1-2305
Micalastic High Voltage Insulation . . . . 2.1-2320
Brief Description Construction of High Voltage Insulation 2.1-2321
Corona Protection . . . . . . . . . . . . . . . . . . 2.1-2330
Rating Plate Data . . . . . . . . . . . . . . . . . . . 2.1-1002 Coil and End Winding Support System 2.1-2340
Generator Cross Section . . . . . . . . . . . . 2.1-1050 Stator End Winding. . . . . . . . . . . . . . . . . 2.1-2341
Generator Outline Diagram . . . . . . . . . . 2.1-1056 Electrical Connection of Bars, Water Supply
Exciter Outline Diagram . . . . . . . . . . . . . 2.1-1058 and Phase Connectors . . . 2.1-2350
Design and Cooling System . . . . . . . . . 2.1-1100 Electrical Bar Connections and Water Supply 2.1-2351
Generator Cooling Gas Circuit . . . . . . . 2.1-1150 Terminal Bushings. . . . . . . . . . . . . . . . . 2.1-2370
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-1210 PW Connection for Terminal Bushings and
Stator Winding . . . . . . . . . . . . . . . . . . . . . 2.1-1230 Phase Connectors . . . . . . . . . . 2.1-2371
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-1300 Cooling of Terminal Bushings . . . . . . . 2.1-2372
Hydrogen Cooler . . . . . . . . . . . . . . . . . . . 2.1-1440 Components for Water Cooling of Stator
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-1450 Winding . . . . . . . . . . . . . . . . . . 2.1-2380
Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . 2.1-1460 Grounding of Stator Cooling Water Manifold . . 2.1-2389
Oil Supply for Bearings and Shaft Seals . . 2.1-1510
Seal Oil System (Simplified Diagram) 2.1-1511 Rotor
Gas System . . . . . . . . . . . . . . . . . . . . . . . 2.1-1520
Gas System (Simplified Diagram) . . . . 2.1-1521 Rotor Shaft . . . . . . . . . . . . . . . . . . . . . . . . 2.1-3000
Primary Water System . . . . . . . . . . . . . . 2.1-1530 Cooing of Rotor Winding . . . . . . . . . . . . 2.1-3100
Primary Water System (Simplified Diagram) . 2.1-1531 Cooling Scheme of Rotor Winding . . . . 2.1-3101
Rotor Winding. . . . . . . . . . . . . . . . . . . . . . 2.1-3300
Technical Data Rotor Slot . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-3301
Rotor End Winding . . . . . . . . . . . . . . . . . 2.1-3310
General and Electrical Data . . . . . . . . . 2.1-1810 Rotor Retaining Ring . . . . . . . . . . . . . . . 2.1-3350
Mechanical Data . . . . . . . . . . . . . . . . . . 2.1-1820 Rotor Field Connections . . . . . . . . . . . . 2.1-3370
Seal Oil System . . . . . . . . . . . . . . . . . . . 2.1-1825 Electrical and Mechanical Connection of EE
Gas System . . . . . . . . . . . . . . . . . . . . . . . 2.1-1826 Coupling . . . . . . . . . . . . . . . . . 2.1-3373
Primary Water System . . . . . . . . . . . . . . 2.1-1827 Rotor Fan . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-3600
Waste Gas System . . . . . . . . . . . . . . . . 2.1-1828
Excitation System . . . . . . . . . . . . . . . . . . 2.1-1829 Cooler
Cooler Data . . . . . . . . . . . . . . . . . . . . . . . 2.1-1830
Reactive Capability Curve . . . . . . . . . . . 2.1-1850 Hydrogen Cooler (Description) . . . . . . . 2.1-4000
Load Characteristic of pilot exciter . . . 2.1-1860 Hydrogen Cooler (Drawing) . . . . . . . . . 2.1-4001
Gas Specification . . . . . . . . . . . . . . . . . . 2.1-1883
Primary Water Specification . . . . . . . . . 2.1-1885 Generator Bearings
Specification for Ion Exchange Resins 2.1-1887
Additive Specification for Alkalizer Unit 2.1-1888 Generator Bearing (Description) . . . . . 2.1-5000
Generator Bearing (Drawing) . . . . . . . . 2.1-5001
Stator Measurement of Bearing Temperature 2.1-5003
Generator Bearing Insulation . . . . . . . . 2.1-5005
Stator Frame . . . . . . . . . . . . . . . . . . . . . . 2.1-2100
BHEL,Haridwar 2.0-0010-0 6 0 0 /1
1111E
Shaft Seal Protection . . . . . . . . . . . . . 2.1-8331
Rotor Grounding System . . . . . . . . . . . 2.1-8350
Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-6000 Arrangement of Brush Holders for Rotor
Shaft Seal-Insulating and Sealing of Grounding System. . . . . . . . . 2.1-8351
Seal ring Carrier . . . . . . . . . . . . . . . 2.1-6005
Measuring Devices and Supervisory
Seal Oil System Equipment
Seal Oil System 2.1-7100 Introduction. . . . . . . . . . . . . . . . . . . . . . . . 2.1-8400

Constant Pressure Controller. 2.1-7101 Temperature Transducers. . . . . . . . . . . 2.1-8410
Seal Oil Unit ....................... 2.1-7105
Differential Pressure Valve . 2.1-7108 Supervision of Generator. . . . . . . . . . . . 2.1-8420
Regulator for Seal Ring Relief Oil.. 2.1-7109 Generator measuring points. . . . . . . . . 2.1-8422
Seal Oil Diagram ................ 2.1-7111 List of Valves for Generator System. . . . . 2.1-8423
Bearing Vapor Exhauster ... 2.1-7120 Supervision of Bearings. . . . . . . . . . . . . 2.1-8440
Seal Oil Pumps .................. 2.1-7123 Supervision of Seal Oil System. . . . . . 2.1-8450
Vacuum Pumps. ................. 2.1-7126
Seal Oil Cooler and Seal Oil Filter. 2.1-7130 Supervision of Gas System. . . . . . . . . 2.1-8460
Seal Oil Cooler ................... 2.1-7131 Supervision of Primary Water System 2.1-8470
Seal Oil Filter ...................... 2.1-7132 Supervision of Exciter. . . . . . . . . . . . . . 2.1-8490
Vacuum Regulating Valve............ 2.1-7133 Exciter Measuring Points. . . . . . . . . . . 2.1-8491
Gas System
Excitation System
Gas System. . . . . . . . . . . . . . . . . . . . . . . 2.1-7200
Gas System Schematic Diagram. . . . 2.1-7211 Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-9100
List of Valve for Gas System. . . . . . . . . 2.1-7212 Basic Arrangement of Brushless Excitation
CO2 Vaporiser. . . . . . . . . . . . . . . . . . . . 2.1-7230 System. . . . . . . . . . . . . . . 2.1-9101
Gas Dryer (Refrigeration type) . . . . . . 2.1-7270 Rectifier Wheels. . . . . . . . . . . . . . . . . . . 2.1-9102
Rectifier Wheels and Coupling. . . . . . 2.1-9103
Primary Water System Permanent-Magnet Pilot Exciter Rotor & Fan 2.1-9104
Exciter Cross Section. . . . . . . . . . . . . . 2.1-9110
Primary Water System. . . . . . . . . . . . . . 2.1-7300 Exciter Cooling Air Circuit. . . . . . . . . . . 2.1-9120
Primary Water System Schematic Diagram. . 2.1-7311 Stroboscope for Fuse Monitoring . . . . 2.1-9140
List of Valves for Primary Water System 2.1-7312 Exciter Drying . . . . . . . . . . . . . . . . . . . . . 2.1-9150
Primary Water Pumps. . . . . . . . . . . . . . 2.1-7320 Ground Fault Detection System for Exciter
Primary Water Cooler. . . . . . . . . . . . . . . 2.1-7330 Field Circuit. . . . . . . . . . . . . 2.1-9180
Primary Water Treatment System. . . . 2.1-7340 Arrangement of Bursh Holders for Ground
Alkalizer Unit for Primary Water Circuit 2.1-7341 Fault Detection System . . 2.1-9181
Primary Water Filters. . . . . . . . . . . . . . . 2.1-7343 Brush Holders for Ground Fault Detection
Primary Water Main Filter. . . . . . . . . . . . 2.1-7344 System. . . . . . . . . . . . . . 2.1-9182
Primary Water Fine Filter. . . . . . . . . . . . 2.1-7345
Protective Screens at Primary Water Inlet Operation
and Outlet. . . . . . . . . . . . . . . . . 2.1-7349
Operating and Setting Values-General 2.3-4000
Automatic Controls Gas Quantities. . . . . . . . . . . . . . . . . . . . 2.3-4010
Operating and setting vlaues
Coolant Temperature Control. . . . . . . . 2.1-8010 Generator Supervision. . . 2.3-4020
Seal Oil System................. 2.3-4050
Protective Devices Gas System........................ 2.3-4060
Primary Water System....... 2.3-4070
Safety Equipment for Hydrogen Operation. . 2.1-8310 Exciter Supervision ....... 2.3-4090
Waste Gas System. . . . . . . . . . . . . . . . . 2.1-8311
List of Valves for Waste Gas System . 2.1-8312 Running Routine-General. . . . . . . . . . 2.3-4100
Generator Waste Fluid System . . . . . . 2.1-8315 Operating Log-Generator Supervision 2.3-4120
Generator Mechanical Equipment Protection. 2.1-8320 Operating Log-Seal Oil System . . . . . 2.3-4150
Tripping Scheme for Generator Mechanical Operating Log-Gas System . . . . . . . . 2.3-4160
Equipment Protection 2.1-8321 Operating Log-Primary Water System 2.3-4170
Generator Mechanical Equipment Protection . 2.1-8323 Operating Log-Exciter Supervision . . 2.3-4190
Generator Electrical Protection. . . . . . . 2.1-8330
Tripping Scheme for Generator Electrical
2.0-0010-0 6 0 0 /2
1111E
Turbogenerators
Start-up
General On-Load Running
Preparations for Starting-Introduction 2.3-5000
Hints for Cooler Operation. . . . . . . . . . 2.3-5003 Permissible Load Limits of Generator 2.3-8170
Filling and Initial Operation of Seal Permissible Loading at Rated PF During
Oil System-Prepatory work. . . . . . . . . . . . . . . 2.3-5100 Voltage and Frequency Deviations . . 2.3-8181
Filling and Initial Operation of Air Generator Capability With Hydrogen Coolers
Side Seal Oil Circuit . . . 2.3-5110 out of Service on Water Side 2.3-8184
Placing Vaccum Pump in Service 2.3-5113 Unbalanced Load-Time Curve . . . . . . 2.3-8187
Venting of Seal Oil Circuits. . . . . . . . . . 2.3-5130 Current Overload Capability . . . . . . . . . 2.3-8188
Setting of Seal Oil Pressures. . . . . . . 2.3-5150 Runback for loss of stator coolant . . 2.3-8190
Setting of Operating Values for Seal Oil System 2.3-5160
Measurement of Seal Oil Volume Flows 2.3-5163
Activating the Measuring Device for Vacuum Shutdown
in seal oil tank 2.3-5165
Functional Testing of pumps and Exhausters . .2.3-5180 Shutdown of Generator . . . . . . . . . . . . . 2.3-8310
Start-up of Seal Oil System 2.3-5210 Generator Shutdown Diagram . . . . . . 2.3-8311
Activating the Level Detector System for
Seal oil and Generator Supervision 2.3-5510 Supervision of Generator during Standstill
Positions of Multi-Way Valves in Gas System 2.3-6107
Scavenging the Electrical Gas Purity Meter General . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-8400
System . . . . . . . . . . . . . 2.3-6110 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-8440
Setting Electrical Zero of Electrical Gas Purity Seal Oil System . . . . . . . . . . . . . . . . . . . 2.3-8500
Meter System . . . . . . . . 2.3-6120 Shutdown of Seal Oil System . . . . . . . 2.3-8510
Purity Measurement During CO2 Filling 2.3-6130 Draining Seal Oil Circuit 2.3-8520
Purity Measurement During H2 Filling 2.3-6140 Gas System . . . . . . . . . . . . . . . . . . . . . . 2.3-8600
Purity Measurement During H2 Operation 2.3-6150 Gas Removal-Lowering Hydrogen Gas
Gas Filling-Replacing Air With CO2. . . . . . 2.3-6310 Pressure in Generator . . . . . . . 2.3-8610
Gas Filling-Replacing CO2 With H2. . . . . . 2.3-6320 Gas Removal-Replacing H2 with CO2 2.3-8620
N2 Purging After Filling of Primary Water Gas Removal-Replacing CO2 With Air 2.3-8630
System . . . . . . . . . . . . . . . . . . 2.3-6810 N2 Purging Before Draining of Primary
Water System . . . . . . . . . . 2.3-8650
Filling and Initial Operation of Primary Water Primary Water System . . . . . . . . . . . . . 2.3-8700
System- Shutdown of Primary Water System for Less
Than 48 Hours . . . . . . . . 2.3-8720
Preparatory Work . . . . . . . . . . . . . . . . . . 2.3-7100 Shutdown of Primary Water System for More
Filling External Part of Primary Water Circuit 2.3-7110 Than 48 Hours . . . . . . . . 2.3-8730
Filling the Water Treatment System . . 2.3-7120 Draining the Primary Water System- PW
Filling the Terminal Bushings and Phase Coolers (Cooling Water Side) . . . . 2.3-8732
Connectors . . . . . . . . . . . . . 2.3-7150 Draining the Primary Water System- Stator
Filling the Stator Winding . . . . . . . . . . . 2.3-7160 Winding . . . . . . . . . . . . . . . . . 2.3-8734
Filling Primary Water Coolers on Cooling Draining the PW System-Terminal Bushings
Water Side . . . . . . . . . . . . . 2.3-7180 and Phase Connectors 2.3-8738
Activating Primary Water System After a Draining the Primary Water System- Water
Shutdown of Less Than 48 Hours 2.3-7210 Treatment System . . . . . . . . 2.3-8746
Activating Primary Water System After a Draining the Primary Water System- External
Shutdown of More Than 48 Hours 2.3-7220 Part of Primary Water Circuit 2.3-8748
Activating the Primary Water Conductivity Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-8900
Meter System . . . . . . 2.3-7530
Activating the Primary Water Volume Flow Fault Tracing
Meter System . . . . . . . . . . . . . 2.3-7540
Initial Operation of Primary Water System - General . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-9000
Checks Prior to Startup . . 2.3-7610 Stator and Generator Supervisory Equipment 2.3-9200
Turning Gear Operation and Runup of Coolant Temperature Control. . . . . . . 2.3-9280
Generator . . . . . . . . . . . . . . . . . . . . . 2.3-8010 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-9310
Generator Startup Diagram . . . . . . . . . 2.3-8011 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-9440
Permissible Synchronizing Criteria . . 2.3-8081 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-9450
BHEL,Haridwar 2.0-0010-0 6 0 0 /3
1111E
Bearing Vapour Exhausters . . . . . . . . . 2.3-9521 Leakage Tests of Generator and Gas System 2.5-0310
Seal Oil Pumps . . . . . . . . . . . . . . . . . . . 2.3-9523 Flushing the Oil Piping . . . . . . . . . . . . . 2.5-0320
Seal Oil Pressures and Temperatures 2.3-9531 Measures to Prevent Corrosion During
Oil Level in Seal Oil System . . . . . . . . 2.3-9561 Inspecitons . . . . . . . . . . . . . 2.5-1003
Gas Pressures . . . . . . . . . . . . . . . . . . . 2.3-9640 Preventive Measures to Avoid Stress
Gas Purity Meter System . . . . . . . . . . . 2.3-9680 Corrosion . . . . . . . . . . . . . . . 2.5-1005
Primary Water Pumps . . . . . . . . . . . . . . 2.3-9720 Inspection Schedule-Foreword . . . . . . 2.5-1010
Water Pressures and Temperatures in Inspection Schedule-Stator . . . . . . . . . 2.5-1020
Primary Water System . . . . . . . . 2.3-9730 Inspection Schedule-Rotor . . . . . . . . . 2.5-1030
Filters in Primary Water System . . . . . 2.3-9740 Inspection Schedule-Coolers . . . . . . . 2.5-1040
Water Level in Primary Water Tank . . . 2.3-9760 Inspection Schedule-Bearings . . . . . . 2.5-1050
Conductivity in Primary Water System 2.3-9782 Inspection Schedule-Shaft Seals . . . . 2.5-1060
Volume Flow Rates in Primary Water System 2.3-9784 Inspection Schedule-Seal Oil System 2.5-1071
Alkalizer Unit for Primary Water System 2.3-9785 Inspection Schedule-Gas System . . . 2.5-1072
Fuses on Rectifier Wheels . . . . . . . . . 2.3-9901 Inspection Schedule-Primary Water System 2.5-1073
Exciter Temperatures . . . . . . . . . . . . . . 2.3-9911 Inspection Schedule-Generator Supervisory
Exciter Cooler . . . . . . . . . . . . . . . . . . . . . 2.3-9914 Equipment. . . . . . . . . . 2.5-1080
Stroboscope . . . . . . . . . . . . . . . . . . . . . . 2.3-9941 Inspection Schedule-Excitation System 2.5-1090
Exciter Drying System . . . . . . . . . . . . . 2.3-9955 Measures for Preservation of Generator
Ground Fault Detection System in Exciter During Standstill. . . . . . . . . . . . . . . . . 2.5-1100
Field Circuit . . . . . . . . . . . . . 2.3-9980 Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5-2000
Cementing the Joints of Profiled Gaskets. . 2.5-2120
Maintenance and supervision- Sealing Generator End Shield Joints . 2.5-2160
IR Measurements on Stator Winding 2.5-2300
Introduction. . . . . . . . . . . . . . . . . . . . 2.4-4200 Procedure for carrying out Tan delta test with
End Winding Vibration probes in position 2.5-2305
Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4-4210
Drying the Windings . . . . . . . . . . . . . . . 2.5-2310
Generator Coolers . . . . . . . . . . . . . . . . . 2.4-4240
Test Instruction for Stator Slot Support System
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 2.4-4250
With Top Ripple Springs . . 2.5-2340
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4-4310
Stator Slot Support System-Radial Wedge
Seal Oil Pumps & Bearing Vapour Exhauster 2.4-4520
Movements-Test Record . . 2.5-2341
Seal Oil Coolers . . . . . . . . . . . . . . . . . . . 2.4-4540
Test Equipment for Stator Slot Support System 2.5-2342
Seal Oil Filters . . . . . . . . . . . . . . . . . . . . 2.4-4550
Instructions for Checking the Stator Slot
Gas Consumption . . . . . . . . . . . . . . . . . 2.4-4610
Support System. . . . . . . . . . . . . 2.5-2343
Primary Water Pumps . . . . . . . . . . . . . . 2.4-4720
Rewedging of Stator Winding. . . . . . . . 2.5-2345
Primary Water Filters . . . . . . . . . . . . . . . 2.4-4740
Cementing Stator Slot End Wedges at Turbine
Primary Water Coolers. . . . . . . . . . . . . 2.4-4750
and Exciter Ends. . . . . . 2.5-2346
Water Level in Primary Water Tank . . . 2.4-4760
Treatment of Bolted Contact Surfaces 2.5-2350
Concutivity Meter System. . . . . . . . . . . . 2.4-4780
Rotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5-3000
Alkalizer Unit . . . . . . . . . . . . . . . . . . . . . . 2.4-4785
Insulation Resistance Measurements on Rotor
Fuses on Rectifier Wheels. . . . . . . . . . 2.4-4910
and Exciter Windings 2.5-3300
Exciter Dryer . . . . . . . . . . . . . . . . . . . . . . 2.4-4925
Ultrasonic Examination of Rotor Retaining
Ventilation and Make-Up Air Filters 2.4-4930
Rings at Power Plant . . . 2.5-3357
Exciter Coolers . . . . . . . . . . . . . . . . . . . . 2.4-4940
Hydrogen Coolers. . . . . . . . . . . . . . . . . . 2.5-4000
Ground Fault Detection System. . . . . . 2.4-4990
Insertion and Removal of Hydrogen Coolers 2.5-4100
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . 2.5-5000
Inspection
Shaft Seals. . . . . . . . . . . . . . . . . . . . . . . . 2.5-6000
Seal Oil System. . . . . . . . . . . . . . . . . . . . 2.5-7100
Introduction. . . . . . . . . . . . . . . . . . . . . . . . 2.5-0010
Seal Oil Pumps & Bearing Vapour Exhausters 2.5-7120
Determination of Dewpoint Temperature 2.5-0019
Vacuum Pumps .......................... 2.5-7121
Packing,Transport, Storage of Gen Rotors 2.5-0030
Gas System. . . . . . . . . . . . . . . . . . . . . . . 2.5-7200
Preventive Measures for Transport and
Primary Water System. . . . . . . . . . . . . . 2.5-7300
Storage of Generator Rotors . 2.5-0031
Primary Water Pump. . . . . . . . . . . . . . . . 2.5-7320
Checking Desiccant in Gen Rotor Packing 2.5-0032
Treatment and Cleaning of Pipes in Primary
Insulation Resistance Measurements on
Water Circuit . . . . . . . . . 2.5-7381
Rotor and Exciter Windings. . . . 2.5-0033
Flushing External Part of Primary Water Circuit2.5-7382
Preparation of Machinery Parts . . . . . . 2.5-0200
Leakage Test of External Primary Water Circuit2.5-7384
Checking the Bearing and Seal Insulation . . 2.5-0300
Excitation System-Exciter . . . . . . . . . . . 2.5-9000
Test Norms During Overhaul . . . . . . . . 2.5-0305
Checking the Insulation Resistance of Heat
Sink Insulation . . . . . . . . . . 2.5-9010
2.0-0010-0 6 0 0 /4 Checking the Insulation at Rectifier Wheels 2.5-9011
1111E
Turbogenerators
Preface
General
This manual contains information on maintenance personnel are fully familiar with
operation and maintenance of Turbogenerator the design of the turbogenerator plant and
and its auxillary systems. have aquired thorough training in operation
and maintaining the unit.
The information has been prepared on the
assumption that the operating and The manual is subdevided into following
maintenance personnel have a basic main sections
knowledge of power plant engineering and -General
operation. It is an essential prerequisite for -Description
satisfactory operation and maintenance of the -Operation
turbogenerator that the operating and -Maintenance
-Inspection
2.0-0030-0600/1
BHEL,Haridwar 1111E
Turbogenerators
Notes on the Use of the Mannual
General
The turbogenerator instruction manual consists For the user of the manual, the identification
of the following manual sections: n u m b e r i s a s u ff i c i e n t r e f e r e n c e f o r l o c a t i n g a
particular instruction number must be indicated.
Q 2.0 General
Q 2.1 Description
Q 2.3 Operation Instruction Number
Q 2.4 Maintenanceand Supervision
Q 2.5 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. Manual section number
The manual contains a Table of Contents together Identification number

with a List of Effective Pages. Please check your
Variant number
manual against this list and advise if there are any
omissions. Page number
Identification Number 2.0 - 0040 - 0009 / 1

1205 E
The identification number consists of the above
mentioned section number, supplemented by a four-
Language (English)
digit code number. It is indicated in the bottom most
line of the pages. Date (mm yy)
BHEL,Haridwar 2.0-0040-0600/1
1111E
Turbogenerators Operation Beyond Contract
Commitment
General
The Turbogenerator set has been designed and increase in Copper temperature, thermal expansion
manufactured to meet the contract commitment as and higher insulation stresses. Such operation is not
regards to the capability for the continuous operation permitted by the manufacturer.
or variable load operation below maximum continuous
rating with an aim to achieve objective of securing Continued operation of unit without recommended
long life and trouble free operation. scheduled maintenance will eventually result in
increased maintenance and reduction in the useful
Because of the margin provided in the design, it life of the machine. BHEL cannot be responsible for
may be possible to operate the turbogenerator at any malfunctioning occurring as a result of operation
overloads for the time specified in the manual. beyond the contract limits and operation of machine
However, such operations although possible for the without carrying out scheduled maintenance/
short time will encroach upon the design margin built inspection. Such operation if undertaken by the user
into the generator. must be at his own risk.
The Turbogenerator is designed to operate within BHEL reserves the right of changing the operation
the temperature rise in accordance with EC standard. and maintenance instructions based on experience
Operating the generator in excess of the capability gained.
curves which are part of this O & M Manual will cause
BHEL,Haridwar 2.0-0050-0600/
1111 E
Turbogenerators Safe Disposal of Turbogenerator Items
General
In line with ISO 14001 requirements HEEP-BHEL, exposure of fluoro-elastomers like O-rings, rubbers etc.
Haridwar has adopted an Environmental policy and at very high temperature above 400 degree C, in extreme
has pledged to fulfil its responsibility of protecting case of fire etc, should be disposed with great care, such
and conserving the environment around itself. as very high incineration.
The materials, which are scrapped during b) Insulation:

inspections and capital overhaul after consumption of
their useful life, are disposed in an environment friendly Insulation material should be disposed by very high
manner to protect our natural resources and control incineration.
environment pollution.
c) Plastics and glass:
Guidelines given in the following paragraphs can
go a long way in planning the activity of scrapping the May be disposed as scrap material for recycling and
hazardous material effectively in an echo friendly reuse.
manner.
3. Lubricating Oil and Grease:
A proper system of waste disposal should also be
evolved and its compliance ensured and necessary These items can be disposed/recycled/ reused as
precautions as published from time to time adhered to follows:
while disposing hazardous material.
a) Lubricating Oil :
Generator is manufactured mainly from three
types of items namely, To be recycled after cleaning as far as possible. After
it has become unserviceable, it may be disposed as
1. Metals:
follows:
Structured steel, Cast steel, Forged steel, brass,
bronze etc. Send the discarded oil to registered refiners who
have facilities to reclaim the oil by
2. Non Metals:
Rubber, insulation, plastics, glass etc. - physio-chemical treatment for further use in
noncritical applications.
3. Lubricating oil and Greases.
- send the used oil to parties who are licensed to
Disposal of Generator wastes: handle and dispose used lubricating oil.
1. Metals: - burn off the discarded oil in boiler furnace by
mixing with fuel oil.
May be disposed as scrap metal for recycling and
reuse. b) Grease:
2. Non- Metals:
It may be disposed for reuse as low-grade
a) Rubber: lubrication.
Residue of fluoro-elastomer products, obtained by
BHEL,Haridwar 2.0-0200-0600/
1111 E
Turbogenerators Rating Plate Data for Generator
General
Project name: 2 X 600 MW TPP AT DERANG, ANGUL , ORISSA
BHARAT HEAVY ELECTRICALS LTD
KW 600,000 R.P.M 3000
P.F. 0.85 LAG Hz 50
KVA 705,900 Phase 3

Type: THDF 115/67 Connections : YY
Volts 21000 Coolant : Hydrogen & Water

Stator
Amps 19407 Gas Pressure : 5 Kg/cm2 (g)
Volts 413 Insulation : Class F

Rotor
Amps 5192 Specn.: IS:5422 IEC:34
MADE IN INDIA Division: Haridwar
BHEL,Haridwar 2.1-1002-0 6 0 0 /1
1111E
Turbogenerators General Design Features
General Design and Cooling system
1 General 3 Hydrogen Cooling System

The two- pole generator uses direct water cooling for The hydrogen is circulated though the generator interior
the stator winding, phase connectors and bushings in a closed system by means of a single multi-stage axial-
and direct hydrogen cooling for the rotor winding. The flow fan which is arranged at the TE rotor end. The fan
losses in the other generator components, such as draws the hot gas from the air gap and the core and
core losses, friction and windage losses as well as delivers it to the coolers.Downstream of each cooler, the
stray losses are dissipated to the hydrogen. gas is divided into several flow paths as follows:
The generator frame is pressure-resistant and Flow path I routes the cold gas through ducts in the
gastight and equipped with end shields at the turbine stator frame and the terminal box to the EE end-winding
end as well as the exciter end. The hydrogen coolers space where the cold gas flows along the clamping fingers
are arranged vertically inside of the cooler section at before entering the axial bores in the core. For this purpose,
the turbine end.The generator comprises the following the clamping fingers and pressure plates are desigened
components: as gas ducts to enable the cold gas to be routed between
clamping fingers and end lamination into the stator core.
Stator Along its path through the stator core from the EE to the
Outer casing TE, the gas absorbs the heat given off by the stator core
Stator core and winding assembly before exiting the core at the turbine end via the ducts
Cooler section along the clamping fingers and entering the stator end-
Hydrogen coolers winding space from where it is returned to the coolers by
End shields the axial flow fans.
Flow path II routes the cold gas under the hub of the fan
Rotor into the rotor end-winding space for direct cooling of the
Rotor shaft TE half of the rotor winding. The rotor winding is
Rotor winding symmetrical relative to the generator center and the rotor
Rotor retaining rings axis.
Field connections Each winding is divided into eight cooling zone.
The first cooling zone includes the slot portion from the
Bearings end to the center of the rotor body, and the second cooling
zone extends across half of the end winding. These two
Shaft seals cooling zones are repeated four times in a symmetrical
arrangement around the rotor.
The following auxiliary equipment is required for The cooling gas for the slot portion enters the
operation. hollow conductors through openings in the end winding
and flows through these conductors to the center of the
Oil system rotor body. The hot gas is then discharged into the air
Gas system gap between the rotor body and stator through radial
Primary water system openings in the conductors and the rotor slot wedges.
Excitation system The cooling gas holes are arranged at different levels in
the conductor assembly to give each hollow conductor
2 Cooling system its own cooling gas outlet. The cooling gas for the end
winding is admitted through the end face and flows through
The heat losses generated in the generator the conductors up to approximately the pole center, where
interior are dissipated to the secondary coolant (such it passes into a collection compartment and is then
as raw water or condensate) via the hydrogen and discharged into the air gap via slots in the end of the rotor
primary water. body.
The generator is exclusively cooled by direct Flow path III routes the hydrogen to the EE rotor end-
cooling where the heat is dissipated directly to the winding space for direct cooling of the exciter-end half of
coolant. This means that hot spots and large the rotor winding. Because of the symmetrical configuration
temperature differentials between adjacent of the cooling gas flow, the cooling is performed in the
components which could lead to different thermal same manner as for the turbine-end half of the rotor
expansion are largely eliminated thus minimizing winding. The hot gas also flows to the center of the rotor
mechanical stresses particularly with regard to the befor being discharged to the air gap.
copper conductor, insulation, rotor and the stator core.
1111E
Flow path IV routes the cold gas through the flux Flow path 1 is used for cooling the stator winding.
shield in the TE stator end-winding space. This flow path routes the water to the manifold at the
exciter end and from there to the stator bars via
Flow path V routes the cold gas through the flux insulating hoses. Each stator bar is connected to
shield in the EE stator end-winding space. the manifold by a separate hose. The cooling water
flows through hollow conductors towards the turbine
Flow path VI routes the cold gas radially into the TE end of the generator. After exiting the stator bars, the
core end. This flow is required since the gas for axial water flows through insulating hoses to a water
core cooling flows from the exciter end to the turbine manifold from where it is rerouted to the primary water
end which meand that it has already absorbed heat tank. Since the water flows through the stator bars in
when it exits the core at the turbine end. one direction only, the temperature rise of the coolant
(and thus of the bars) is minimized which, in turn,
Following heat absorption, the six flows are means that the relative movments between the top
mixed before being returned to the coolers by means and bottom bars due to different thermal expansions
of the axial flow fan. are also minimized.
3.1 Coolant Temperature Control Flow path 2 is used for cooling the phase connectors
The cooling water flow through the hydrogen and bushing. The bushings and phase connectors
coolers is automatically controlled to maintain a are made of thick-walled copper tubes carrying the
uniform temerature level for all loads and cold water cooling water. The 6 bushings and the phase
temerature. The cold gas temerature is used as connectors, which are arranged in circular fashion
referance variable. around the stator-end winding, are interconnected in
such a manner that 3 parallel flow paths are
4 Primary Cooling Water System established. The cooling water is admitted from
ouside the generator through 3 bushings and exits
The treated water used for cooling the stator through the other 3 bushings.
winding, phase connectors and bushings is referred
to as primary water in order to distinguish it from the The secondary water flow through the primary
secondary coolant (raw water, or condensate). The water cooler is automatically controlled to ensure that
primary water is circulated in a closed system and the generator temperature is maintained at a constant
dissipates the absorbed heat to the secondary cooling level under different load conditions.
water. The pump is supplied with hot primary water
from the primary water tank, and delivers the water to
the generator via the coolers. Upstream of the
generator, the cooling water flow is divided into the
two following paths:
2.1-1100-0600/2
1111E
Turbogenerators Generator Cooling Gas Circuit
General
2.1-1150-0600/1
BHEL,Haridwar 1111E
Stator
Operation
1 Stator 3 Stator Frame (Inner Frame)
The Stator comprises a stator frame as well as the The inner frame of the Stator comprises the core
stator core and winding assembly. and the winding .The spring baskets form part of the
Manufacture of the stator frame is performed inner cage which is suspended in the outer frame by a
independently of the stator core and winding assembly large number of flat springs distributed over the entire
production and prior to the installation of the winding , core length.The flat springs are tangentially arranged
the core is linked to the stator frame by means of the over the circumference in sets of three springs each
flat springs. on either side of the core and a single horizontal
stabilizing spring below the core.Its an alternative , the
springs below the core can be omitted.The springs are
2 Stator Frame (Outer Frame) so arranged and turned that forced vibration resulting
from the magnetic field will not be transmitted to the
The Stator frame is a gastight and pressure resistant frame and foundation.
welded construction and houses the stator core , the
stator winding and the hydrogen coolers which are 3.1 Stator Core
arranged vertically in a seperate cooler housing at the
Turbine end. The stator core is stacked from insulated electrical
A cage of circular and axial ribs on the inside of the sheet-steel laminations with a low loss coefficient and
outer frame ensures the rigidity of the shell.End shields mounted in spring baskets over insulated core bars.Axial
containing the shaft seal and bearing components are compression of the stator core is obtained by clamping
bolted to the stator frame .A high viscosity sealant is fingers, core press ring and non-magnetic through type
injected in sealing grooves to ensure that the flanged clamping bolts which are insulated from the core.
joints are sealed airtight. The core press ring and end zones of the stator
The core portion of the stator frame is divided into core core are effectively shielded against stray magnetic
compartments which houses the springs for suspending fields by means of cooled flux shields
the stator core.The cold gas for cooling the stator core
and the exciter end rotor winding flows through gas
ducts welded to inside surface of the shell. 3.2 Stator Winding
Feet are welded to the stator frame to support the
stator on steel plates embedde in the foundation.The The stator winding is fractional pitch two layer type
stator is firmly anchored to the plates with anchor bolts winding which is made up of individual bars.The bars
through the feet. are so located in rectangular slots uniformly distributed
over the entire circumference of the stator core.
BHEL, Haridwar 2.1-1210-0600/1

1111E
Stator Winding
Operation
1 Design
Stator bars,phase connectors and bushings are ensures a virtually void free high voltage insulation
designed for direct water cooling.In order to mininmize which is characterized by excellent electrical ,
the stray losses,the bars are composed of seperately mechanical and thermal properties in addition to being
insulated strands which are transposed by 540 in the fully water proof and oil resistant. To minimize corona
slot portion and consolidated with epoxy resin in heated discharges between the insulation and the slot walls ,
molds.After bending , the end turns are consolidated a final coat of semiconducting varnish is applied to the
with baked synthetic resin fillers. surface of the slot portion of all the bars.In addition , all
The bars comprise of hollow and solid strands bars are provided with end corona protection to control
distributed over the entire bar cross section to ensure the electric field at the transition point from the slot
good heat dissipation.At the bar ends , the solid strands portion of the bar to the end winding section and to
are brazed to a connecting sleeve and the hollow prevent arcing.
strands to a water box which is linked to water manifold
by an insulating hose made of polytetrafluoroethylene
(PTFE). The electrical connection between the top and 3 Bar support System
bottom bars is made by bolted connections at the
connecting sleeve. To protect the stator winding against the effects of
The water manifolds are insulated from the stator load induced magnetic forces and to ensure permanent
frame so that the dielectric resistance of the winding firm seating of the bars in the slots during operation ,
can be measured without having to remove the water. the bars are provided with side ripple spring , a slot
During operation, the water manifolds are grounded. bottom equalizing strip and a top ripple spring located
under the slot wedge.The gaps between the bars in the
2 Micalastic High-Voltage Insulation stator end windings are filled with insulating material
and cured following installation.The ends of the bars
The proven Micalastic system is used for the high thus form a cone-shaped end winding.For radial
voltage insulation of the stator bars.With this system , support, the end windings are clamped to a rigid support
several layers of half-overlapping mica tape are applied ring made of insulating material which is fully supported
to the bars.The mica tape is composed of a thin high- by the stator frame.
strength backing material to which the mica is bonded Curable filler material is arranged between the stator
by a small amount of epoxy resin.The number of layers bars and the support ring to ensure firm support of
and consequently the thickness of the insulation each individual bar by the support ring.The bars are
depends on thr generator voltage.Following application clamped to the support ring with pressure plates held
of the mica tape, the bars are dried under vacuum and by bolts made from high strength insulating material.The
impregnated with epoxy resin which exhibits very good stator end winding and support ring thus form a rigid
penetration properties due to its low viscosity. short circuit proof structure which does not restrict
During next stage of this impregnation process the movements of the winding due to thermal expansion
bars are pressurized with nitrogen to complete the because the support ring is allowed to move axially
vacuum-pressure inpregnation (VPI) process.The within the stator frame.
impregnated bars are then formed to a required shape The stator winding connection are routed to six
in molds and cured in an oven at high temperature.This bushings located in a compartment of welded non
magnetic steel below the generator at the exciter end.

1111E
General Rotor
1. Rotor Shaft The slot wedges are made of high-conductivity material

and extend below the shrunk seat of the retaining ring.
The rotor shaft is a single-piece solid forging The seat of the retaining ring is silver-plated to ensure a
manufactured from a vacuum casting. Slots for insertion good electrical contact between the slot wedges and
of the field winding are milled into the rotor body. The rotor retaining rings. This system has long proved to be
longitudinal slots poles are obtained. The rotor poles are a good damper winding.
designed with transverse slots to reduce twice system
frequency rotor vibrations caused by deflections in the 3. Retaining Rings
direction of the pole and neutral axis.
To ensure that only high-quality forging is used, The centrifugal forces of the rotor end windings are
strength tests, material analysis and ultrasonic tests are contained by single-piece rotor retaining rings. The
performed during manufacture of the rotor. retaining rings are made of non-magnetic high-strength
After completion, the rotor is balanced in various steel in order to reduce stray losses. Each retaining ring
planes at different speeds and then subjected to an with its shrink-fitted insert ring is shrunk onto the rotor
overspeed test at 120% of rated for two minutes. body in an overhung position. The retaining ring is
secured in the axial position by a snap ring.
2. Rotor Winding
4. Field Connections
The rotor winding consists of several coils which
are inserted into the slots and series connected such The field current is supplied to the rotor winding
that two coil groups form one pole. Each coil consists of through radial terminal bolts and two semicircular
several series connected turns, each of which consists conductors located in the hollow bores of the exciter and
of two half turns which are connected by brazing in the rotor shafts. The field current leads are connected to
end section. the exciter leads at the exciter coupling with
The rotor winding consists of silver-bearing multicontact plug-in contact which allow for
deoxidized copper hollow conductors with two lateral unobstructed thermal expansion of the field current
cooling ducts. L-shaped strips of laminated epoxy glass leads.
fiber fabric with Nomex filler are used for slot insulation.
1111E
Hydrogen Cooler
Operation
The hydrogen cooler is a shell and tube type heat exchanger To maintain the cold gas temperature at an approximately
which cools the hydrogen gas in the generator.The heat conatant level under all operating conditions , a motor operated
removed from the hydrogen is dissipated through the cooling control valve is arranged , in the common cooling water outlet
water.The cooling water flows through the tubes , while the line.This control valve is activated by temperature transmitters
hydrogen is passed around the finned tubes. located upstream and downstream of the cooler section.
The hydrogen cooler is subdivided into sections
which are vertically mounted in the cooler housing.The cooler
sections are fixed at upper end by bolting the upper tube
plate with generator frame and are freely movable at the
lower end for taking up thermal expansion.
The cooler sectins are parallel-connected on their
water sides.Shutoff valves are installed in lines upstream of
the cooler sections. All parallel connected water paths must
have equal flow resistance to ensure a uniform cooling water
supply to the cooler sections and equal cold gas temperatures
downstream of the individual sections. The required cooling
water volume flow is adjusted by control valves on the hot
water side.Controling the cooling water volume flow on the
outlet side ensures an uninterrupted water flow through the
cooler sections so that proper cooler performance will not be
impaired.
1 Stator frame
2 Cooler
3 Cooler housing
Fig.1 Arrangement of hydrogen cooler .

1111E
General 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.
1 2 3
1 Connection for shaft lift oil

2 Thermocouple
3 Bearing sleeve
Fig.1 Bearing
1111E
Shaft Seals
Operation
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 whih is bolted
to the end shield 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 with seal oil.The seal oil is
supplied to the sealing gap from the seal ring chamber
of the seal ring carrier via radial bores and an annular
groove in the seal ring.To ensure effective sealing, the
seal oil pressure in the annular gap is maintained at a
higher level than the gas pressure in the generator
casing.The oil drained on the hydrogen and air sides of
the seal rings is returned to the seal oil system through
drains in the stator end shields.In the seal oil system,the
oil is regenerated by a vacuum treatment , cooled ,
filtered and then returned to the shaft seals.
On the air side, pressure oil is supplied laterally to
the seal ring via an annular groove.This ensures always
free movement of the seal ring in the radial direction.

1111E
Description Seal Oil System for Shaft Seals
1 Construction of the Seal Oil System A vacuum pump keeps the seal oil in the seal oil
tank under vacuum and largely extracts the gas absorbed
The shaft seals are supplied with seal oil from the
by the oil while passing through the hydrogen and air
seal oil system which consists of the following principal
atmospheres. A deterioration of the hydrogen purity in
components:
the generator is thus largely avoided.
Seal oil storage tank (in bearing oil drain line)
Seal oil tank incl. vacuum pump
2.3 Seal Oil Pumps
Intermediate oil tank
Two seal oil pumps are directly connected to the
Seal oil pumps (2 x 100%)
seal oil tank on their suction sides.
Standby seal oil pump (1 x 100%)
One of the two seal oil pumps is always in operation
Pressure controller downstream of each pump
while the second one remains activated for starting. If
Seal oil coolers (2 x 100%)
neither of the two pumps can establish the specified seal
Seal oil filters (2 x 100 %)
oil pressure, the standby seal oil pump is automatically
Differential pressure control valves (2 x 100%)
started. It is directly connected to the seal oil storage
Except for the seal oil storage tank, all the above
tank.
major components are combined in one unit.
The seal oil pressure downstream of each full-capacity
seal oil pump is maintained constant by one pressure
2 Seal Oil Circuit controller each while the respective pump is in service.
The seal oil is drawn from the seal oil tank by the
seal oil pump in service and passed to the shaft seals 2.4 Seal Oil Pressure Regulation
via coolers, filters and differential pressure regulating The seal oil pressure required upstream of the shaft
valve. seals is controlled by the differential pressure control
valve according to the preset value, i.e., the specified
difference between the seal oil pressure and the hydrogen
2.1 Seal Oil Storage Tank pressure.
The seal oil storage tank is a larger-diameter pipe For reasons of availability, two differential pressure
section in the bearing oil return line of the generator. After control valves with graded settings are provided.
the bearing oil supply system has been taken into
operation, the seal oil storage tank will always be partly
filled, which ensures continuous operation of the seal oil 3. Seal Oil Drain
system. The seal oil storage tank and the seal oil tank
are interconnected by piping. 3.1 Hydrogen Side Seal Oil Drain
The exhauster of the waste gas system maintains a The seal oil drained from the hydrogen side is passed
slight vacuum in the seal oil storage tank. to the intermediate oil tank via the generator
prechambers. The intermediate oil tank acts as a gas
barrier. A float-operated valve in the drain line keeps the
2.2 Seal Oil Tank oil level in the Intermediate oil tank at a predetermined
The seal oil tank is arranged below the seal oil level, thus preventing gas from entering the oil drain
storage tank. The oil from the seal oil storage tank is system. During normal operation, the float-operated valve
available at oil column pressure upstream of the float- remains continuously activated to return the hydrogen
operated valve in the seal oil tank inlet. side seal oil to the seal oil circuit. The seal oil leaving the
The float-operated valve in the inlet pipe keeps the intermediate oil tank is admitted into the seal oil tank by
oil level in the seal oil tank at a predetermined level and the action of the vacuum maintained in the seal oil tank.
compensates for a low oil level in the tank by admitting
oil from the seal oil storage tank and the intermediate oil
tank. During normal operation, the float-operated valve 3.2 Air Side Seal Oil Drain
remains continuously activated to admit the volume of The seal oil drained from the air side of the shaft
oil drawn by the seal oil pump in service. seals flows directly into the bearing oil return line for being
returned to the seal oil storage tank.

1111E
Description Seal Oil System (Simplified Diagram)
Single Flow Seal Oil System
Fig. 1. Simplified Diagram for Single Flow Seal Oil System
1. Seal oil storage tank 8. Seal oil cooler

2. Vacuum pump 9. Seal oil filter
3. Seal oil tank 10. Differential pressure control valve
4. Pressure controller 11. Shaft seal
5. Main seal oil pump 12. Generator prechamber
6. Check valve 13. Intermediate seal oil tank
7. Standby seal oil pump 14. Flow control valve for seal oil ring relief

1111E
Operation Gas System
1 General
The gas system contains all equipment necessary 2 Carbon Dioxide (CO2 ) Supply
for filling the generator with CO 2 , hydrogen or air and
removal of these media, and for operation of the As a precaution against explosive hydrogen air
generator filled with hydrogen. In addition, the gas mixtures, the generator must be filled with an inert gas
system includes a nitrogen (N 2) supply. The gas system (CO 2) prior to H 2 filling and H2 removal.
consists of : The generator must be filled with CO 2 until it is
positively ensured that no explosive mixture will form
• H 2 supply during the subsequent filling or emptying procedures.
• CO2 supply
• N 2 supply 4 Compressed Air Supply

• Pressure reducers
• Pressure gauges To remove CO2 from the generator, compressed air

• Miscellaneous shutoff valves is to be admitted into the generator.
• Gas analyzer The compressed air must be clean and dry. For
• Gas dryer this reason, a compressed air filter is installed in the
• CO 2 flash evaporator filter line.
• Flowmeters
5 Nitrogen (N 2 ) Supply
2 Hydrogen (H 2 ) Supply
Nitrogen is required for removing the hydrogen or
2.1 Generator Casing air during primary water filling and emptying procedures
The heat losses arising in the generator are A nitrogen environment is maintained above the primary
dissipated through hydrogen. The heat dissipating water in the primary water tank for the following
capacity of hydrogen is eight times higher than that of reasons.
air. For more effective cooling, the hydrogen in the
generator is pressurized.
• 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.

1111E
Turbogenerators Gas System
General Simplified Diagram
1 H2 bottle 10 Gas drier fan

2 H2 pressure reducer 11 Gas drier chamber
3 N2 bottle 12 CO2/H2 purity transmitter
4 N2 pressure reducer 13 Dehydrating filter for measuring gas
5 Primary water tank 14 Pressure reducer for measuring gas
6 Pressure controller 15 Compressed air hose
7 Upper generator gas header 16 Compressed air filter
8 Lower generator gas header 17 CO2 flash evaporator
9 Gas drier heater 18 CO2 bottle
1111E
Operation Primary Water Supply
1 General
failure of one pump, the standby pump is immediately
Th e p r i m a r y w a t e r r e q u i r e d f o r c o o l i n g t h e l i v e
ready for service and cuts in automatically.
components is circulated in a closed system.
In order to prevent corrosion, only copper,
4 Coolers
stainless steels or simillar corrosion-resistant materials
The function of the primary water cooler is to
are used throughout the entire cooling system.
dissipate the heat absorbed from the water-cooled
The primary water system comprises of the
components to the secondary coolant (water).
following principal components:
5 Filters
Primary water tank
In order to prevent the narrow cooling ducts in the
Primary water pumps
stator winding from becoming blocked by foreign matter
Coolers
a filter is installed in the main primary water system and
Fiters
a fine filter is provided downstream from the primary
Primary water treatment system
water treatment system.
Alkalization unit
6 Primary W ater Treatment System

The primary water admitted to the pump from
Because the primary water makes direct
the primary water tank is first passed to the EE
contact with the high-voltage stator winding, the
cooling water manifold in the generator interior and
conductivity of primary water must be very low. During
then to the neutral point of the terminal bushings via
operation, the electrical conductivity is maintained below
the cooler and fine filter. After having absorbed the
a value of 2μS/cm. In order to maintain such a low
heat losses in the stator winding, phase connectors
conductivity, it is necessary to provide for continuous
and main bushings, the water is returned to the
treatment of the primary water. For this purpose, a small
primary water tank from the TE cooling water manifold
quantity of the water flow is continuously passed
or the phase connectors. The gas pressure above the
through an ion exchanger arranged in a bypass to the
water level in the primary water tank is maintained
primary water main cooling system. The ion-exchanger
constant by a pressure controller.
resin material requires replacement at certain intervals.
The resins can be replaced during operation of the
turbine generator, since even with the water treatment
2 Primary Water Tank
system is out of service, the conductivity will deteriorate
The primary water tank is arranged in an easily
only very slowly.
accessible location on the stator frame on an elastic
The primary water system can be filed during
support, thus forming the highest point of the entire
commissioning and topped up from the condensate
primary water system in terms of static head.
system.
3 Primary Water Pumps

7 Alkalization Unit
The primary water is permanently circulated in a
The low-oxygen primary water is alkalized to prevent
closed system. To ensure uninterrupted generator
flow blockage due to copper corrosion in the water-
operation, two full-capacity pumps are provided. Each
cooled winding. The pH of the primary water is kept
pump is driven by a separate motor. In the event of
constant at 8.5 to 9 by continuous dosing of diluted
sodium hydroxide solution.

1111E
Turbogenerators Primary Water System
General (Simplified Diagram)
Primary water circuit, general

Coolant flow : stator winding
Coolant flow : main bushings and phase connectors
Water treatment
Waste gas
Hydrogen
1 Primary water tank 7 Bypass line

2 Pressure regulator 8 Cooling water for stator winding
3 Waste gas to atmosphere 9 Ion exchanger
4 Pump 10 Cooling water for main bushings and phase connectors
5 Cooler 11 Teflon hose
6 Filter 12 Cooling water manifold
13 Alkaliser unit
1111E
Turbogenerators Technical Data
Description General and Electrical Data
General
Project name 2X600MW TPP AT DERANG, ANGUL, ORISSA
Generator Type THDF 115/67
Main Exciter Type ELR 70/90-30/6-20
Pilot exciter Type ELP 50/42-30/16
Year of manufacture 2010
Rated Data and Outputs Turbogenerator Main Exciter Pilot Excitor

Apparent power 705.9 MVA - 65 kVA
Active power 600 MW 3840 kW -
Current 19407 A 5192 A 195 A
Voltage 21 kV + 1.05 kV 413 V 220 V + 22 V
Speed 50s-1 50s-1 50 s-1
Frequency 50 Hz 150 Hz 400 Hz
Power factor 0.85 (lag) - -
Inner connection of stator winding YY - -
H2 pressure 5 bar (g) - -
Cont. perm. unbalanced Load 8% - -
Rated field current for rated output 5192 A - -
Rated field voltage 413 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 20°C Turbogenerator Main Excitor Pilot Excitor

U-X 0.0009394 ohms U-0 0.00270 ohms
Stator Winding V-Y 0.0009394ohms F1-F2 0.58 ohms V-0 0.00270 ohms
W-Z0.0009394 ohms W-0 0.00270 ohms
U-V 0.000452 ohms
Rotor Winding F1-F2 0.06439 ohms U-W 0.000452 ohms
V-W 0.000452 ohms
Rectifier Wheel
Number of fuses 30
-
per rectifier wheel (800 V, 800 A)
Fuse, resistance approx. 150 μ 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.
1111E
Description Mechanical Data
Torques, Critical Speed etc. Torques and Units

Speeds
Maximum short-circuit torque of stator at

16428 kpm
line-to-line single-phase short-circuit
Moment of inertia of generator rotor shaft 10966 kgm2

nk1 672
Critical speed (calculated) nk2 1295 RPM
(Generator + Exciter coupled) nk3 2060
Generator Volume and Filling Quantities Volume Units

Generator volume (gas volume) 85 m3
CO2 filling quantity*** 340 m3 (s.t.p.)*
H2 filling quantity (to 3.5 bar)** 850 m3 (s.t.p.)*
Weights Weight units

Stator including end shields, coolers and Terminal box 369000 kg
Shipping weight of stator 312000 kg
Stator end shield, upper part TE 7505 kg
Stator end shield, upper part EE 7270 kg
Stator end shield, lower part, TE 8450 kg
Stator end shield, lower part, EE 8230 kg
Rotor 75000 kg
H2 cooler section, including water channels 2 X 3235 kg
Gas dryer 1010 kg
One seal oil cooler (air side) 1000 kg
One primary water cooler 1000 kg
Exciter rotor 7550 kg
Component Material Component Material

Rotor shaft 26NiCrMoV145 Electrical sheet-steel V270-50A
Rotor copper CuAg0.1PF25 / CuAg0.1PF20 Stator copper E-Cu58F20
Rotor wedges CuNi2Si Bearing babbitt Babbitt V 738
Retaining rings X8CrMnN1818K Seal rings babbitt Babbitt V 738
Damper wedges CuAg0.1F25
o
* s.t.p. = Standard temperature and pressure, 0 C 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.
1111 E
Description Seal Oil System
Design Data
AC Seal oil pumps -1,2 (MKW 11 AP 001 and MKW
12 AP 001)
Kind of pump Three Screw pump
Type T3ST - 70146
Capacity 420 LPM
Discharge pressure 12Kg/Cm2
Pump motor ND132M
Rating 15 KW
Voltage/ frequency 415V, 3 Ph AC 50Hz
Current 13.6 A
Speed 1450 RPM
Type of enclosure TEFC, IP55
Nos. 2x100% capacity
DC Seal oil pump (MKW 13 AP 001)

Kind of pump Three Screw pump
Type T3S - 52/54
Capacity 420 LPM
Discharge pressure 12 Kg/cm2
Pump motor AFS 225L
Rating 15 KW
Voltage 220 V DC
Current Armature 67 A
Speed 1450 RPM
Type of enclosure TEFC , IP55
Vacuum Pump (MKW10 AN001 and MKW10 AN002)
Capacity 162 LPM

Rating 0.37 KW
Voltage/ frequency 415V, 3 Ph AC 50Hz
Seal oil filters MKW21 AT 001, MKW22 AT 001,
Kind of filter Strainer-type filter

Type DUPLEX Filter NB 80 NP 4
Volumetric flow rate 24.6 m 3/hr
Degree of filtration 40 microns
Pressure drop across filter 0.3 bar with clean filter *
* 1.2 bar with 100% blockage
1111E
Description Gas System
Design Data
CO 2 vapouriser MKG51 AH 001

Rating 18 kW
Voltage 415V, 3 Ph AC 50Hz
Heat transfer liquid HYTHERM 500 (M/s HPCL)
Volume of heat transfer liquid 25 dm 3
Hole in orifice 2.8 mm
Relief valve on high-pressure side 175 bar
Relief valve on low-pressure side 8 bar
Refrigeration type gas drier

Rating and parameters As per sub-supplier’s manual
Compressed air filter MKG25 BT001
3
Volume of activated carbon 3 dm
Service hours approx. 1500 h to 2000 h
3
Throughput 80 m /hr at 8 bar
1111E
Description Primary Water System
Design Data
Primary water pumps MKF11AP001 and MKF12AP001

Kind of pump Centrifugal pump
Type CZ 65-250
Speed 2950 RPM
3
Capacity 100 m /Hr
Discharge head 50 m
Pump motor ND200 L
Rating 22KW
Voltage 415V, 3 Ph AC 50Hz
Frequency 50 Hz
Speed 2950 RPM
Type of enclosure TEFC,IP55
Main filter MKF27 AT001

Type INLINE
Volumetric flow rate 100 m3/hr
Degree of filtration 5 micron
Pressure drop across filter 0.1 bar with clean filter
1.2 bar with 100% fouling
Y Strainer MKF27 AT002

Type INLINE
Volumetric flow rate 120 m3/hr
Degree of filtration 100 micron
Fine filter MKF35 AT011

Kind of filter 1 plug. 1 cartridge
Type 1.55.1 (M/s Boll & Kirch)
3
Volumetric flow rate 0.42 dm /s max.
Ion exchanger MKF35 AT001

Volume 83 litres
Resin Lewatit
Resin volume 56 litres (45 kg)
1111E
Description Waste Gas System
Design Data
Bearing vapor exhausters MKQ81 AN001 and

MKQ82 AN001
Type AHSH-10-A-L1 (M/s Airlink)
Moter Rating 0.75kW
Voltage/frequency 415V, 3 Ph AC 50Hz
Current 1.8A
Speed 2780 RPM
Type of enclosure IP 55
Type of exhausters Radial-flow
1111E
Description Excitation System
Design Data
A-wheel (negative polarity)

No./Type of diodes 60 Nos./BHdL 1220 (BHEL EDN,Bangalore make)
No./Type of fuses 30 Nos./3NC 9 538
Resistance/voltage/current per fuse approx. 150 μΩ, 800 V, 800 A
No. of RC networks 6 Nos.
B-wheel (positive polarity)

No./Type of diodes 60 Nos./BHdL 1320(BHEL EDN,Bangalore make)
No./Type of fuses 30 Nos./3NC 9 538
Resistance/voltage/current per fuse approx. 150 μΩ, 800 V, 800 A
No. of RC networks 6 Nos.
Stroboscope
Type LX5-30/36-2
Voltage 240 V
Frequency 50/60 Hz
No. of stroboscope 1 No.
Exciter air dryer

Type BA-1.5 A (M/S BRYAIR MAKE)
Rating 4,6 kW
Voltage 230 V
Frequency 50 Hz
Adsorption air flow rate 120 m3/h
Regeneration air flow rate 35 m3/h
No. of dryer 1 No.
1111 E
Description Cooler Data
Design Data for the H2 Cooler,

Drg. No. 0-166-01-70006C Units Materials and Pressures
(4 x 25% each)
Hydrogen pressure 5.0 Bar (g) Materials

Fins Copper
Gas flow (Total) 24 m /s
3
Tubes 90/10 Cu-Ni
Heat dissipating capacity (Rated) 5090 kW Tubesheets Carbon steel
Cold gas temperature 46 °C Water channels Carbon steel
Hot gas temperature (max.) 81.7 °C
Pressures (Tube Side)
Gas pressure drop (approx.) 86 MMWC
Design pressure 10 kg/cm2
Cooling water flow (Total for 4 sections) 550 m3/hr Test pressure 15 kg/cm2
Cooling water inlet temperature (design) 39 °C
Water outlet temperature 47.9 °C
Water pressure drop 8.1 MWC
Design Data for One Seal Oil Cooler,

Units Materials and Pressures
(2 x 100% each)
Oil flow 15.9 m 3/hr Materials

Heat Transfer Plates SS316
Oil inlet temperature 66 °C Gaskets Neoprene
Oil Outlet temperature 41 °C
Cooling water Pressures
Oil pressure drop (approximate) 0.2 Bar Operating pressure 16 kg/cm2
Cooling water flow 59.4 m 3/hr Test pressure 24 kg/cm2
Cooling water inlet temperature (design) 39 °C Oil Side Pressures
Water outlet temperature 42 °C Operating pressure 16 kg/cm2
Water pressure drop (approximate)* Test pressure 24 kg/cm2
0.35 Bar
Note: The specified cooler data refer to max. cooling water inlet temperatures. During operation the operating
values of the coolers may deviate from above design data.
1111E
Design Data for the Primary Water
Units Materials and Pressures
Cooler, (2 x 100% each)
Oil flow 100 m 3/hr Materials
Oil inlet temperature Heat Transfer Plates SS316
75 °C
Gaskets Neoprene
Oil Outlet temperature 50 °C
Oil pressure drop (approximate) Cooling water Pressures
0.6 Bar
Operating pressure 16 kg/cm2
Cooling water flow 120 m 3/hr Test pressure 24 kg/cm2
Oil Side Pressures
Water outlet temperature 60 °C Operating pressure 16 kg/cm2
Water pressure drop (approximate)* 0.7 Bar Test pressure 24 kg/cm2
Design Data for the Exciter Air Cooler,

Drg. No. 0-166-05-70003C Units Materials and Pressures
(2 x 50% each)
Air pressure 1 Bar (g) Materials
Air flow (Total) 15.5 m /s
3 Fins Copper
Tubes 90/10 Cu-Ni
Heat dissipating capacity (Rated) 500 kW
Tubesheets Carbon steel
Cold air temperature 45 °C Water channels Carbon steel
Hot air temperature (max.) 74 °C
Air pressure drop (approx.) 700 Pa Pressures (Tube Side)
Design pressure 10 kg/cm2
Cooling water flow 200 m3/hr
Test pressure 15 kg/cm2
Water outlet temperature 40.2 °C
Water pressure drop* 3.0 mWC
* Flange-to-flange of equipment only
2.1-1830-0600/2
Description Reactive Capability Curve
2.1-1850-0600/1
BHEL,Haridwar 1111E
Description Load Characteristic of Pilot Exciter
PMG Pilot Exciter Characteristic
240
235
230
225
PMG Voltage(volts)
220
215
210
205
200
0 50 100 150 200 250
PMG field current (amps)
BHEL,Haridwar 2.1-1860-0 6 0 0 /1
1111 E
Turbogenerators
Description
Gas Specification
1. Compressed Air Q If obtained from a central bulk supply, the gas shall be
made available at the following conditions:
Q The compressed air shall be free of-
Gauge pressure : 1 to 2.5 bar
corrosive contaminants and
Temperature : 20 to 30 0C
hazardous gases, flammable or toxic.
Volumetric flow rate : 144 to 216 m3/h.
Q The maximum total oil or hydrocarbon content,
exclusive of non-condensables, shall be as close 3 Hydrogen (H2)
to zero (0) w/w or v/v as possible, and under no
circumstances shall it exceed one (1) ppm w/w or Q The hydrogen gas shall be made available with a purity
v/v under normal operating conditions. 99.9% v/v. The remaining 0.1 % v/v shall be free of
Q The compressed air shall be practically free of dust. corrosive contaminants: traces of ammonia (NH3) and
The maximum particle size in the air stream shall be sulphur dioxide (SO 2) shall not be detectable by
five (5) micrometers. analysis.
Q The oxygen content of the expanded air shall be Q If obtained from a central bulk supply, the hydrogen
between 20 and 21% v/v. gas shall be made available at the following conditions:
Q The dew point at line pressure shall be at least 15 K
below the minimum possible generator temperature. Gauge pressure : 8 to 9 bar
In no case should the dew point at line pressure Volumetric flow rate : 144 to 216 m3/h.
exceed 10 °C.
Q The compressed air shall be available at a gauge 4 Nitrogen (N2)
pressure between 6 and 9 bar.
Q Volumetric flow rate: 144 to 216 m3/h. Q The nitrogen gas shall be made available with a purity
of 99.99 % v/v.
2. Carbon Dioxide (CO2)
Contaminants (O2, H2O): not applicable
Q Carbon dioxide shall be made available with a purity ≥
99.9 % v/v. The remaining 0.1 % v/v shall be free of The remaining 0.01% v/v shall be free of corrosive
corrosive contaminants: traces of ammonia (NH3) and contaminants; traces of ammonia (NH3) and sulphur
sulphur dioxide (SO2) shall not be detectable by dioxide (SO2) shall not be detectable by analysis.
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.
BHEL,Haridwar 2.1-1883-0 6 0 0 /1
1111E
Turbogenerators
Description Primary Water Specification
The water used must not contain any contaminants Cu, dissolved/
that might have a harmful effect on the materials used in undissolved : Less than 20 ppb
the primary water circuit. For this reason, the water must
have the following quality criteria : Fe, dissolved/
Undissolved : Less than 20 ppb
Conductivity : < 10 μ mho/cm. preferably
0.5 μ mho/cm Dissolved solids : The water shall not contain chemicals
pH : 6-8 from treatment processes, such as
Dissolved O2 : Minimum, preferably less than 100 ppb hydrazine, morpholine, levoxine, phos-
Dissolved CO2 : Minimum, permissible conductivity phate, etc.
Chlorides and after a strongly acidic cation
other anions exchanger < 0.2 μ mho/cm If the water to be used does not meet these quality
Ammonia : Minimum, test with Nessler’s solution criteria, BHEL Haridwar must be informed for their evalua-
as a reagent shall not cause a change tion and approval.
in color.
BHEL,Haridwar 2.1-1885-0 6 0 0 /1
1111E
Turbogenerators
Description Specification for

Ion Exchange Resins
1. General
The primary water must have a low condictivity since it substances having a detrimental effect on the materials
comes into direct contact with the high-voltage winding. used in the primary water circuit and thus on the availability
To maintain a low conductivity the primary water requires of the generator.
continuous treatment. This is achieved by continuously Our recommendation to use Lewatit ion exchange
passing a small primary water volume flow through a mixed resins is based on many years of service experience and
bed ion exchanger arranged in the bypass of the main the close cooperation between the resin supplier and many
cooling circuit. The ion exchange resins must be replaced power plant operators as well as the high quality standard
at certain intervals. The resins may be replaced while the of the resins.
generator is in operation, since with the water treatment The initial charge of the mixed-bed ion exchanger
system out of service the conductivity will continue to rise consists of the following types of resins.
only very slowly. Q Lewatit S 100 KR/H/chloride-free
Q Lewatit M 500 KR/OH/chloride-free
2. Resin Specification
When replacing the resins, use either the above types
The resins should contain no impurities or soluble or resins available from other manufacturers which must
comply with the specification below.
Cation exchanger Anion exchanger

(Lewatit S100KR/H/chloride-free) (Lewatit M500 KR/OH/chloride-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 years
at temperatures of +1oC to +40oC
BHEL,Haridwar 2.1-1887-0 6 0 0 /1
1111 E
Turbogenerators
Description Additive Specificaiton

for Alkalizer Unit
Despite the use of oxygen-poor water, corrosion of concentration of 10 to 20 g of NaOH per dm3.
copper in the primary water circuits of water-cooled
windings, cannot be completely avoided, and in isolated Sodium hydroxide solution should be prepared from :
cases the corrosion products can reduce the cross-
sectional flow area of the water distribution system. Q Caustic Soda [NaOH] of P.A. quality, containing.
The severity of the corrosion attack can be NaOH : > 98%
substantially reduced by alkalizing the oxygen-poor water. Carbonates [Na2CO3] : < 1%
In addition, the system becomes less susceptible to Q Water in conformity with the primary water
disturbances resulting from air in-leakage. specification [2].
Operating the generator with alkaline water at pH 8 to
9 will improve the reliability and availability of the turbine 2 Lime
generator. A lime filter to be provided in the NaOH tank vent serves
For operation of the alkalizer unit [1], dilute sodium to bind the carbon dioxide (CO2) contained in the inlet air in
hydroxide for continuous injection into the primary water order to prevent the formation of carbonates in the sodium
circuit and lime are required. hydroxide solution.
The lime filter consists of equal parts of sodium
1 Sodium Hydroxide Solution hydroxide (NaOH) and calcium hydroxide (Ca(OH)2 ). This
The sodium hydroxide solution should have a mixture is commercially available and known as soda lime.
Also refer to the following information

[1] 2.1-7341 Alkalizer Unit for Primary Water Circuit
[2] 2.1-1885 Primary Water Specification
1111 E
Turbogenerators Stator Frame
Operation
To facilitate manufacture, erection and transport, Two lateral supports for the spring mounted core
the stator consists of the following main components: support in the frame are located directly adjacent to the
points where the frame is supported on the foundation.
Stator frame Due to the rigid design of the supports and foot portion
Cooler housing the forces due to the weight and short-circuits will not
End shields result in any over stressing of the frame.
Terminal box Manifolds are arranged inside the stator frame at
the bottom and top for filling the generator with CO2
The stator frame with spring mounted core support and H2.The connections of the manifolds are located
,core and stator winding is the heaviest component of side by side in the lower part of the frame housing.
the entire generator.A rigid frame is required due to the Additional openings in the casing which are sealed
forces and torques arising during operation.In,addition gastight by pressure resistant covers allow access to
the use of hydrogen for the generator cooling requires the core press rings of the spring mounted core support
the frame to be pressure resistant upto an internal and also permit the lower portion of the core to be
pressure of aprrox 10 bar (130 psig). inspected . Access to the end winding compartments is
The welded stator frame consists of the cyllindrical possible via manholes in the TE cooler housing and EE
frame housing, two flanged rings and axial and radial end shield.
ribs.The cooler housing at the turbine end encloses In the lower part of the frame at the exciter end an
the entire end-winding portion of the stator up to the opening is provided for bringing out the winding
end wall of the slot portion.The cooler housing is used ends.The terminal box is flanged to this opening .The
for routing the cold gas into the cooling gas ducts at the terminal box is made of non-magnetic steel
exciter end.The header is made of magnetis steel. The cooler housing is located at the Turbine end of
The arrangement and dimensioning of the ribs are the stator frame.It accomodates the baffle ring, the baffle
determined by the cooling gas passages and the required ring carrier and the hydrogen cooler sections.The cooler
mechanical strength and stiffness.Dimensioning is also sections are installed in vertical cooler wells.Ribs in the
dictated by vibrational considerations, resulting partly cooler assembly interior serve for improved cooling gas
in greater wall thickness than required from the point of passage and contribute towards mechanical strength
view of mechanical strength. and stiffness.

1111E
Turbogenerators Stator End Shields
Operation
, Pressure-resistant end shields are provided to seal The bearing oil is supplied to the libricating gap via
the cooler housing at the turbine end and the stator ducts in the bearing shell support and in the lower
frame at the exciter end. The end shields contain the bearing sleeve.
generator bearings and shaft seal. The bearing compartment is sealed on the air side
with labyrinth rings.On the hydrogen side the bearing
All bearings and seal oil inlet and outlet pipes are compartment is closed by shaft seal and labyrinth rings.
permanently installed in the end shield . The oil for the shaft seal is admitted via integrally welded
The horizontally split end shields are of hollow box pipes.The seal oil drained towards the air side is drained
type construction.Radial and axial ribs together with together with the bearing oil.The seal oil is drained
the end walls provide for the necessary stiffness of towards the hydrogen side is first collected in a gas
the end shields. and outlight prechamber below the bearing compartment
The lower half end shields accomodate the insulated for defoaming and then passed to the seal oil supply
bearing shell supports.The insulation prevents any short system.
circuiting of shaft currents across the bearings .The The EE end shield is covered with a tapered copper
bearing shell supports accomodate the spherica bearing shield to prevent stray fields between stator winding
shell and due to their shape ensure self-alignment of and frame.
the bearing with respect to the rotor axis.
.
.

1111E
Turbogenerators
Generator Terminal Box
Description
The phase and neutral leads of the three-phase magnetic steel plate. This material reduces stray
stator windings are brought out of the generator losses due to eddy currents.
through six bushings located in the generator Welded ribs are provided for the rigidity of the
terminal box at the exciter end of the generator. terminal box. Six manholes in the terminal box provide
The terminal box is a welded construction of non- access to the bushings during assembly and
overhauling.
1 2 3
1 Generator terminal box

2 Manhole
3 Flange for bushing
Fig.2 Terminal Box
1111 E
Turbogenerators Hydraullic Testing of Stator Frame
Operation
1 Hydraullic Testing of Stator Frame 2 Sealing the Bolted flange Joints

Following manufacturing , the empty stator frame The bolted flange joints which must be gastight (e.g.,
with attached cooler housing , end shields and terminal end shields) are sealed with a plastic sealing
box is subjected to a hydraulic test at 10 bar to ensure compound.On completion of the assembly of each
that it will be capable of withstanding maximum explosion component , the sealing compound is injected into the
pressures.The water pressure is increased in steps , respective grooves.
with the pressure being reduced to atmospheric Round flanges(e.g., manhole covers ,
pressure after each step to allow for measurement of bushings,terminal box) are sealed with O-ring packings.
any permanent deformation
The test also checks for leakage at the weld seams.
In addition , the welded structure is subjected to an air
pressure test to check its gastightness.

1111E
Turbogenerators
Anchoring of Generator to Foundation
Description
The Stator frame is anchored to the foundation with The different thermal expansion of the stator frame
steel plates and anchor bolts, the steel plates being and the steel plates is compensated for by fixing the
solidly bolted to the foundation through the anchor bolts. stator frame to the foundation by means of wedges
The Stator frame is placed on the steel plates, located at the axial centerpoint of the frame.This allows
aligned with shims and then firmly connected to the the frame to expand axially towards the exciter and
sole plates by means of the bolts turbine ends without affecting rotor performance.
1 Steel beam
2 Bolt
3 Compensating shims
4 Stator foot
5 Foundation
6 Gravel
7 Anchor bolt
8 Nut
9 Bracket

1111E
Turbogenerators Stator Core
Operation
1 Stator Core
The core is built up by stacking the lamination in layers
In order to minimize the hysteresis and eddy current
on the core press ring with its welded clamping fingers.
losses induced by the rotating magnetic flux traversing
The individual layers are staggered to ensure a uniform
the core,this is built up of successive layers of thin ,
permeability to the magnetic flux.Stacking mandrels and
segmented laminations
bolts inserted into the slots and bores during the stacking
process make for smooth slot walls.
The segments are punched from 0.5-mm thick electrical
To ensure maximum compression and to prevent
steel laminations with a high silicon content , carefully
undue compaction of the core during operation , the
deburred and then coated with insulating varnish on
laminations are hydraulically compressed at frequent
both sides
intervals during the stacking process, and at specified
stages, the core is also heated to ensure further
consolidation.The complete stack is kept under pressure
my means of tension bolts and core press ring.
.
The tension bolts running through the core are made
of non magnetic steel, and are insulated from the core
and core press ring.
Clamping fingers are used to transmit the pressure
from the core press ring to the core.The clamping fingers
extend up to the ends of the teeth and thus ensure a
firm compression even in this area.
The stepped and glued arrangement of the
laminations at the core end provides for an efficient
support of the tooth portions and also contibutes to a
reduction in eddy current losses and local heating in
this area.The clamping fingers are made of non magnetic
steel to prevent eddy current losses.

1111E
Turbogenerators Mounting of Stator Core in Stator
Frame
Description
1 Stator frame 5 Insulated through bolt

2 Flat spring 6 Pressure plate
3 Cage 7 Clamping finger
4 Flux shied 8 Core
1111E
Turbogenerators Spring-mounted Core Support
Operation
The revolving magnetic field exerts a pull on the core,

each set comprising a top and a bottom section.Each
resulting in a revolving and nearly elliptical deformation section , in turn , comprises two ring halves linked by
of the core which sets up a stator vibration at twice the means of steel tubes.
system frequency.To reduce the transmission of these The two sections of the spring baskets are arranged
dynamic vibrations to the foundation, the generator core
around the core , bolted firmly together and then welded
is spring mounted in the stator frame.To this end , the
to the core bars.
core is supported by several sets of spring baskets,
After lowering the core into the (outer) stator frame,
each set is conneted to the frame by flat springs.The
flat springs are tangentially arranged over the
. circumference of the core in sets of three springs per
ring set i.e. a vertical spring on either side of the core
and a single horizontal spring below the core.As an
alternative , the horizontal springs can be omitted.
The core is supported in the frame via two vertical
springs in the vicinity of the generator feet.The lower
spring prevents a lateral deflection of the core.The flat
springs are resilient to radial movements of the core
suspension points and will largely resist transmission
of double frequency vibration to the frame.In the
tangential direction they are, however sufficiently rigid
to take up the short circuit torque of the unit.The entire
vibration system is tuned so as to avoid resonance with
vibrations at system frequency or twice the system
frequency.

1111E
Turbogenerators
Stator Winding
Description
1. General, Connection properties and resistance to magnetically induced forces.

The bars afford maximum operating reliability, since each
The three-phase stator winding is a fractional-pitch two- coil consists of only main insulation identical.
layer type consisting of individual bars. Each stator slot
accommodates two bars. 2. Conductor Construction
The bar consists of a large number of separately

insulated strands which are transposed to reduce the skin
effect losses.
The strands of small rectangular cross-section are

provided with a braided glass insulation and arranged side
by side over the slot width. The individual layers are insulated
from each other by a vertical separator. In the straight slot
portion the strands are transposed by 5400.
The transposition provides for a mutual neutralization

of the voltages induced in the individual strands due to the
slot cross-field and end winding flux leakage and ensures
that minimum circulation currents exist. The current flowing
through the conductor is thus uniformly distributed over the
entire bar cross-section so that the current-dependent losses
will be reduced.
The alternate arrangement of one hollow strand and two

solid strand ensure optimum heat removal capacity and
minimum losses.
At the Roebel crossover points the insulation is

τp=pole pitch reinforced with insulating strip inserts.
Fig.1 Lap type Winding To ensure that the strands are firmly bonded together
are to give dimensional stability in the slot portion, the bars
The slot bottom bar and top bars are displaced from
are cured in an electrically heated press. Prior to applying
each other by one winding pitch and connected at their ends
the bar insulation, The bar ends are bent with a special care
to from coil groups.
to ensure a uniform spacing of the bars over the entire length
The coil groups are connected together with phase of the end turns after installation.
connectors inside the stator frame shown in the connection
Contacts sleeves for electrical connection of the bars
diagram.
and the water boxes with cooling water connections are
This arrangement and the shape of the bars at the ends brazed to the bar ends.
result in a cone shaped winding having particularly
In the course of manufacture, the bars are subjected to
favourable characteristics both in respect of its electrical
numerous electrical and leakage tests for quality control.
BHEL,Haridwar 2.1-2300-0 6 0 0 1
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Turbogenerators
Connection Diagram of Stator Winding
Operation

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Turbogenerators Stator Slot
Operation

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Turbogenerators Transposition of Stator Bars
Description
In slot portion: 540 o transposition of strands

In end winding portion: transposition, bar ends short circuit
At the bar end all strands are

brazed into a contact sleeve
and thus short-circuited.
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Turbogenerators
Micalastic High Voltage Insulation
Description
High-quality mica, selected epoxy resins and a epoxy resin to give it the mechanical strength required
matching vacuum pressure impregnation (VPI) for further processing.
process are the characteristic features of the Following this, several layers of mica t ape are
Micalastic insulation for large turbogenerators. A applied continuously, half-overlapped, upto the end
consistent development has led to a high-quality portions of the bar . The mica t ape consists of a thin
insulation system, the reliability of which is ensured high-strength backing material to which the mica is
by continuous quality control. Method of Insulation bonded by synthetic resin. The number of layers, i.e.,
and Impregnation the thickness of insulation, is determined by the
For insulation with Micalastic, the conductor voltage of the machine.The taped bars are then dried
strands as well as the ventilating ducts are arranged under vacuum and impregnated with epoxy resin
together to form a comp act assembly and set to the which, by reason of it s low viscosity penetrates the
required shape. This assembly is then baked with insulation thoroughly and eliminates all voids.After
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Fig. 2 Impregnating and Curing Mould for 20 stator Bars in Front of Impregnating Tank
impegnatioin under vacuum, the bars are subjected 30

to pressure, with nitrogen being used as pressurizing ×10 –3
medium (VPI process). 20
For direct cooled windings, the individual
tan δ
impregnated bars are brought to the required 10

dimensions in processing moulds and cured in an
oven at high temperature. With indirectly cooled 5
windings, up to 20 stator bars are placed in molds 0.2 0.4 0.6 0.8 1.0 1.2 1.4
with by insulation for impregnation and curing. Fig.2 Rated Voltage
shows a mold loaded with bars ready for impregnation Fig.3 Dielectric Dissipation Factor of a Stator Bar with
prior to insertion into the impregnating plant. Micalastic Insulation for 21 KV as a Function of the
To minimize corona discharges between the Voltage
insulation and the wall of the slot, the insulation in
the slot section is then provided with a coat of
conductive varnish.
For end corona protection at voltages above 6
kV, a semiconductive coating is also added on the
slot-end sections to control the electric field and
prevent the formation of creepage sparks during high-
voltage tests.
The bars are now ready for insertion into the slots.
In case of indirectly or direct gas-cooled stator bars,
Σ in %
the connecting bus bars and phase connectors are

a lso p rovided w ith an insulation bonded wi t h a
thermosetting synthetic resin. Dependent on their
geometrical configuration and dimensions, the
connections are provided with mica tapes and
insulating caps.
Tests
After insulation and curing, the insulation of each

stator bar is subjected to a high- voltage test at 150%
of the winding test voltage (U P= 2 ×U N + 1 kV) for
quality control. For assessment of the quality of the
slot insulation, the dielectic dissipatin factor tan δ is
measured as a function of the voltage. The dielectric Fig. 4 Cumulative frequency of Maximum increase in
dissipation factor/test voltage curve of a typical stator Dielectric Dissipation Factor of Bars in a 21 KV
winding with Micalastic insulation
2.1-2320-0600/2
Turbogenerators
Description
bar with Micalastic insulation is shown in Fig. 3. Mcalastic is a good conductor of heat by reason
of the high mica content and the void free synthetic
Fig.4 shows the fluctuations due to manufacturing of
resin. Efficient heat transfer is particularly important
the maximum increase in the dielectric dissipation
in machines that require a thick insulation because
factor up to rated voltage for the bars of a 21 kV
of the high voltages, especially if these machines are
winding. The method of impregnation, which is exactly
not designed with direct conductor cooling.
matched to the insulation, and the use of a special
Micalastic is highly resistant to high temperatures
impregnating resin enable the maximum increase in
and temperature chages. The composition of the
dielectric dissipation factor to be reduced considerably
insulation and synthetic resin impregnation permits
below the limits specified in section 33 of VDE 0530.
the machine to be operated continuously under
During insertion of the stator bars, high-voltage conditions corresponding to those for insulation class
tests of one minute duration are performed as follows F.
:
115% U P after installation and blocking of bottom bars
110% U P after installation and blocking of top bars
105% U P after completion of winding,
100% U P after run of generator.
The Properties of Micalastic

Micalstic is an extremely dependable winding
i n s u l a t i o n s y s t e m d e v e l o p e d f o r h i g h - v o l t age
turbogenerators. The insulation is applied from end Fig.6 Dielectric Dissipation Factor of 27 kV Micalastic
to ened on the st ator gbars providing effedtive Insulation as a Function of the Temperature
peotection against over voltages arising during normal
operation and against the high stresses that may Micalastic insulation shows only an insignificant
occur at the slot ends when high test voltages are increase in the dielectric dissipation factor with
applied. In this manner is is possible to isulate inceasing temperature.(Fig.6)
windings for voltages of over 30 kV efficiently and
reliably. The elasticity of Micalastic enables it to
Micalastic has a long electerical life as accomodate thermo-mechanical stesses. Studies on
determined on hunndreds of experimental bars and models have provided information on the on the
substantiated on numerous full-size bars (Fig. 5). performance of Micalastic insulation under the effect
of alternating thermal stresses. Heat cycles with large
differences in temperature are generated by the
alternate application of heating and colling. The result;
there is no displacement between the Micalstic
insulationand the copper conductor, even after 5000
heat cycles, with 1000 cycles between 40 o C and
160 o C.
Micalastic owes its insesitivity to high temperature

and temperature changes to the cured synthetic resin.
This favourable performance under thermal stress is
particularly advantageous for machines subject to
frequent load changes, e.g., generators driven by gas
turbines or peak-load generators in steam power
plants.
Fig.5 Dielectric Dissipation Factor of 27 kV Micalastic
Micalastic does not burn. The flammability is so
Insulation as a Function of the Temperature
low that even on arcing it does not continue to burn
once the arc is extinguished. Fire extinguishing
1111E
systems, such as CO 2 systems, are therefore not Micalastic retains its outstanding properties, even
necessaryfor machines insulated with Micalastic. after years of operation. Evidence of its unchanging
Micalastic provides protection against moisture quality has been provided by repeated test carried
due to its impregnation with synthetic resin which seal out on machines over an operating period of several
the winding completely. years.
Micalastic is highly resistant to chemical action. Micalastic owes its insesitivity to high temperature
Corrosive gases, vapours, lubrication oil and weak and temperature changes to the cured synthetic resin.
acids or alkalies, to which the windings of air-cooled This favourable performance under thermal stress is
machines may be exposed under unfavourable particularly advantageous for machines subject to
conditions, do not attack the insulation; the frequent load changes, e.g., generators driven by gas
impersonating resin behaves neutrally towards turbines or peak-load generators in steam power
chemicals. plants.
2.1-2320-0600/4
Turbogenerators
Construction of High Voltage Insulation
Description
Item No. Component Insulant, semiconductive material

1 Strand insulation Braided glass fiber insulation
2 Strand bonding Epoxy resin
3 Crossover insulation Micanite
4 Profiled strip Profiled micanite
5 Internal potential grading wrapper Semiconductive wrapping
6 Insulation Mica tape, vacuum impergnated with epoxy resin
7 Outer corona protection Semiconductive varnish
Note: The number of conductors shown does not necessarily correspond to the number of conductors of the generator .
1111E
Turbogenerators
Stator Winding
Description Corona Protection
To prevent potential differences and possible corona and prevents the formation of corona discharge during
discharges between the insulation and the slot wall, the operation and during performance of high voltage tests.
slot sections of the bars are provided will an outer
corona protection. This protection consist of a wear-
resistant, highly flexible coating of conductive alkyd A final wrapping of glass fabric tapes impregnated
varnish containing graphite. with epoxy resin serves as surface protection.
1 2 3 4 5 6 7
1 Stator bar (slot end)

2 High-voltage insulation
3 Outer corona protection
4 Transition coating
5 End corona protection
6 Glass tape-epoxy protective layer
7 Stator bar (end winding)
Fig.1 Typical Buildup of Corona Protection
At the transition from the slot to the end winding

portion of the stator bars a semi-conductive coating is
applied. On top of this, several layers of semi conductive
and corona protection coating are applied in varying
length. This ensures uniform control of the electric field Fig.2 Application of Graded End Corona
Protection
1111E
Turbogenerators
Coil and End Winding Support System
Description
The stator windings are placed in rectangular slots used to keep the stray losses at a minimum. The design
which are uniformly distributed around the and construction of the end windings are illustrated in a
circumference of the stator core. The location of the separate drawing [2].
bars in the slots is illustrated in a separate drawing [1]. Any gaps in the end winding due to the design or
The bars are protected by a cemented graphitize manufacturing are filled with curable plastic fillers,
paper wrapper over the slot portion of the bar. The bars ensuring solid support of the cone-shaped top and
fit tightly in the slots. Manufacturing tolerances are bottom layers.
compensated with semi-conducting filler strips along The two bar layers are braced with clamping bolts of
the bar sides which ensure good contact between the high-strength fibre glass fabric against a rigid, tapered
outer corona protection and the slot wall. supporting ring of insulating material. Tight seating is
Radial positioning of the bar is done with slot ensured by plastic filters on both sides of the bars which
wedges. Below the longitudinally divided slot wedges are cured on completion of winding assembly.
a top ripple spring of high-strength, fiber glass fabric is Each end winding thus forms compact, self-
arranged between the filler and slide strip which presses supporting arches of high rigidity which prevents bar
the bar against the slot bottom with a specific vibrations during operation and can withstand short-
preloading. An equalizing strip is inserted at the slot circuit forces.
bottom to compensate any unevenness in the bar shape In addition, the end turn covering provides good
and slot bottom surface during bar insertion. The strip protection against external damage. The supporting rings
is cured after insertion of the bars. These measures rest on supporting brackets which are capable of moving
prevent vibrations. The specified preloading is checked in the axial direction. This allows for a differential
at each slot wedge. movement between the end winding and the core as a
With the windings placed in the slots, the bar ends result of different thermal expansions.
form a cone-shaped end winding. A small cone taper is
1 2
1 2
1 Slot wedge
1 End turn covering
2 End turn covering
2 Clamping bolt
Fig.1 Stator with Complete Stator Winding

Fig.2 Covering and Locating the End Winding

[1]. 2.1-2303 Stator slot
[2]. 2.1- 2341 Stator End Winding
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Turbogenerators Stator End Winding
Operation

1111 E
Turbogenerators Electrical Connection of Bars
Water Supply and Phase Connectors
Description
1 Electrical Connection of Bars boxes. The cooling water is then discharged from the
generator via the hoses and the ring header.
The electrical connection between the top and bottom During manufacturing of the stator bars, various checks
bars is by a bolted contact surface. are performed to ensure water tightness and unobstructed
At their ends the strands are brazed into a connecting water passages.
sleeve, the strand rows being separated from each other The flow check ensures that no reduction in the cross
by spaces. The contact surfaces of the connecting sectional area of the strand ducts has occurred, and that
sleeves for the top and bottom bars are pressed against all strands are passed by identical water flows. After
each other brazing of the upper part of the water box, all brazed joints
are subjected to a helium leakage test followed by a
thermal shock treatment.
The tangential air clearance between the water boxes
and bar connections within a coil group and the axial
clearance relative to the inner shield, which is at ground
potential, is so dimensioned that additional insulation is
not required. For the spaces between the individual phases
insulating caps, which enclose both the connecting sleeves
and the water boxes, are connected to the stator bars.
3 Phase Connectors
The phase connector interconnect the coil groups and

link the beginning and ends of the winding to the bushings.
They consist of thick-walled copper tubes. The stator bar
Fig.1 Electrical Bar Connections and Water ends coupled to the phase connectors are provided with
Supply connecting fittings which are joined to the cylindrical
contact surface with Belleville washers on the bolts to
by non-magnetic clamping bolts. Special care is taken maintain a uniform and constant contact pressure.
to obtain flat and parallel contact surfaces. In order to The phase connectors are provided with a Micalastic
prevent an any reduction in contact pressure or any insulation. In addition, a grounded outer corona protection
plastic deformations due to excessive contact pressure, consisting of a semiconducting coating is applied over the
Belleville washers are arranged on the clamping bolts entire length. At the beginnings and ends of the phase
which ensure a uniform and constant contact pressure. connectors several layers of semi-conductive and corona
2 Water Supply protection is applied in varying lengths.
The phase connectors are mounted on end winding
The water connection at the stator bar is separate supporting ring over supporting brackets. Neighbouring
from the electrical connection. As a result no electrical phase connectors are separated with spacers and tied
forces can act on the water connection. securely in position. This ensures a high short-circuit
While the solid strands of the stator bars terminate strength and differential movements between phase
at the connecting sleeve, the hollow strands are brazed connectors and end windings are thus precluded.
into water boxes, with solid spencers inserted to
compensate for the solid strands. Each water box consist
of two parts, i.e. the sleeve-shaped lower part enclosing
the hollow strands and the cover-type upper part. The
strand rows are separated from each other by splicers.
Each water box is provided with a pipe connection
of non-magnetic stainless steel for connection of the
hose.
The exciter-end water boxes serve for water
admission and distribute the cooling water uniformly to
the hollow strands of the bar. The hot water is collected
on leaving the hollow strands in the turbine-end water Fig.2 Phase Connector Ends
1111E
Turbogenerators Electrical Bar Connection
and Water Supply
Description
1 2 3 4 5 6 7 9 10 11 12
14
15
1 Teflon Hose 6 Clamping bolt 11 Bottom bar

2 Crimping sleeve 7 Connecting sleeve 12 Top bar
3 Cap nut 8 Clamping plate with through bore 13 Belleville washer
4 Pipe connection 9 Intermediate member 14 Spring washer
5 Water box 10 Clamping plate with threaded bore 15 O-ring
Contact surface
*
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Turbogenerators Terminal Bushings
Operation

1111E
Turbogenerators Terminal Bushings
THDF,THFF series
Operation

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Turbogenerators Water Cooling System
Operation Stator Winding
1 General
Two seperate water cooling systems are used for The hoses in the terminal box are grounded at one end
the stator winding as well as the phase connectors and , and are furthermore provided with a metallic section
the Terminal bushings [1], [2]. for applying the volatge for measuring the insulation
The interconnections between live components as resistance of the water filled stator winding.
well as the connections between live components and The primary water is admitted to three terminal
the grounded cooling system manifolds are designed bushings via a water manifold , flows through the
as insulated and pressure resistant PTFE hoses.The connected phse connectors and is then discharged
locknuts are secured by means of O-rings made of Viton to the outlet manifold via the opposite terminal bushings.
and Bellevile washers.The fittings are made of non- The water flow through the two cooling systems
magnetic stainless steel. is moinitored by metering the flow rate through the three
phases.
2 Winding Cooling System
The primary water manifolds are arranged around

the end windings , and are connected to the stator bar
by means of hoses.The primary water manifolds are
insulated from the frame , and connected to the primary
water supply pipe by expansion joints which is located
outside of the stator frame and serves to accomodate
the thermal expansion of the Stator frame and the
primary water tank.
The primary water flows through the stator bars
from the exciter end to turbine end.The bars are
hydraulically connected in parallel in order to maximize
the cooling effect while minimizing the flow rate and
pressure loss.This design also ensures a unifrom
thermal expansion of all stator bars.
3 Phase Connector Cooling System
The primary water supply pipes for the phase

connectors and terminal bushings are arranged on the
outside of the stator frame near the terminal box.The
supply pipes are linked to the primary water inlets and
oulets by means of PTFE hoses which are also used to
route the primary water past the flexible connectors ,
and for linking series-connected sections of the phase
connectors.
[1] 2.1-1100 Design and Cooling System

[2] 2.1-7300 Primary Water supply

1111E
Turbogenerators Grounding of the Stator Cooling
Water Manifold
Description
Primary water Primary water

outlet inlet
2
6
8
4
4
1 Primary water inlet / outlet

2 Compensator 5
3 Insulation
4 Stator frame
5 Water manifold
6 Insulated ground connection
7 Water manifold ground connection
8 Stator frame ground connection
1111E
Turbogenerators Rotor Shaft
Description
The high mechanical stresses resulting from the that two solid poles are displaced by 1800.
centrifugal forces and short-circuit torques call for high- Due to the non-uniform slot distribution on the
quality heat-treated steel. Therefore, the rotor shaft is circumference, different moments of inertia are obtained
forged from a vacuum cast steel ingot. Comprehensive in the main axis of the rotor. This in turn causes
tests ensure adherence to the specified mechanical and oscillating shaft deflections at twice the system
magnetic properties as well as a homogeneous forging. frequency. To reduce these vibrations, the deflection in
The root shaft consists of an electrically active the direction of the pole axis and the neutral axis are
portion the so-called rotor body, and the two shaft compensated by transverse slotting of the pole.
journals. Integrally forged flange couplings to connect The solid poles are also provided with additional
the rotor to the turbine and exciter are located outboard longitudinal slots to hold the copper bars of the damper
of the bearings. Approximately two-thirds of the rotor winding. The rotor wedges act as a damper winding in
body circumference is provided with longitudinal slots the area of the winding slots.
which hold the field winding. Slot pitch is selected so
1 2 3 4 5 6
1 Shaft journal 4 Transverse slot in pole

2 Rotor slot 5 Retaining ring seat
3 Pole 6 Rotor tooth
Fig.1 Rotor Shaft
Note:Shaft and slots may vary from actual design.
1111E
Turbogenerators Cooling of the Rotor Winding
Operation
Each winding is divided imto eight cooling zones.The gap between the rotor body and stator through radial
first cooling zone incuded the slot portion from the end openings in the conductors and rotor slot wedges.The
to the center of the rotor body, and the second cooling cooling gas holes are arranged at different levels in the
zone extends across half of the end winding.These conductor assembly to give each hollow conductor its
two cooling zones are repeated four times in a own cooling gas outlet.
symmetrical arrangement around the rotor. The cooling gas for the end winding is admitted
The cooling gas for the slot area enters the hollow through the end face and flows through the conductors
conductors through openings in the end winding and upto approximately the pole center , where it passes
flows through these conductors to the centre of the into a collection compartment and is then discharged
rotor body.The hot gas is then discharged into the air into the air gap via slots in the end of the rotor body.

1111E
Turbogenerators
Cooling system for Rotor
Operation

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Turbogenerators Rotor winding
Operation

1111E
Turbogenerators Rotor slot
Operation

1111E
Turbogenerators Rotor End Winding
Operation

1111E
Turbogenerators
Rotor Retaining Ring
Description
The rotor retaining rings contain the centrifugal against axial displacement of the retaining ring.
forces due to the end windings. One end of each ring To reduce the stray losses and retain strength, the
is shrunk on the rotor body, while the other end of the rings are made of non-magnetic, cold-worked
ring overhangs the end windings without contacting material.
the shaft. This ensures an unobstructed shaft Comprehensive tests, such as ultrasonic
deflection at the end windings. examination and liquid penetrant examination, ensure
The shrunk on end ring at the free end of the adherence to the specified mechanical properties.
retaining ring serves to reinforce the retaining ring The retaining ring shrink-fit areas act as short-
and secures the end winding in the axial direction at circuit rings to induce currents in the damper system.
the same time. To ensure low contact resistance, the shrink seats of
A snap ring is provided for additional protection the retaining rings are coated with nickel, aluminium
and silver by a three-step flame spraying process.
1111E
Turbogenerators Field Connections
Operation

1111E
Turbogenerators Mechanical and Electrical
Connection of EE coupling
Operation

1111E
Turbogenerators Rotor Fan
Operation
The generator cooling gas is circulated by one axial- The moving blades of the fan are inserted into T-
flow fan located on the turbine-end shaft journal.To shaped grooves in the fan hubs.The fan hubs are shrink
augment the cooling of the rotor winding , the pressure -fitted to the shaft journal spider.
established by the fan works in conjunction with the
gas expelled from the discharge ports along the rotor.

1111E
Turbogenerators Hydrogen Coolers
Operation
The hydrogen cooler is a surface-type heat

exchanger. The heat removed from the hydrogen is dissipated
through the cooling water. The water flows through the finned
tubes while the hydrogen flows around them.
The vertical arrangement enables the heat
exchanger to be installed without having to increase the
overall axial length of the generator or the cross-sectional
area of the stator frame.
The cooler comprises a pair of separate cooling
elements each of which consists of two tube bundles, the
two tubesheets, two return water channels as well as the
inlet and outlet water channels. The water inlet and outlet
lines which route the colling water to and from the cooler are
connected to inlet and outlet channels which are situated
above the cooler elements. The tube bundles are
interconnected by the shared upper tubesheet. The end
compartment is located below the cooling elements. The gaps
between the stator frame and the end compartment as well
as between the stator frame and the upper tubesheet are
sealed with O-rings.
The side walls of the cooling elements are made of
structural steel and serve to brace the cooler and direct the
hydrogen flow. Close the rubber profiles attached to the
generator body to prevent uncooled hydrogen from flowing
past the cooler.
The upper tubesheets are bolted to the stator frame.
Fiberboard strips at the lower tubesheets guide the cooler
elements, thus allowing the tube bundies to vertically expand
and contract freely inside of the cooler well.
The hydrogen flows horizontally through the cooler,
while the cold water flows downward to the return water
channel where and flows upward again the water outlet
channel.
The water sides of the cooler elements are
connected in parallel. Shoutoff valves are installed in the
lines upstream and downstream of the cooler elements. The
requisite flow of cooling water depends on the generator
output and is regulated by a water-side control valve. Outlet-
side regulation of the flow of cooling water effectively ensures
uninterrupted cooling water flow through the cooler elements
and thus proper cooler performance.

1111E
Turbogenerators
Hydrogen Cooler
Description
1 Return water channel 4 Cooling water connection

2 End shield 5 Protective chamber
3 Finned tube bundle 6 Hydrogen seal
1111E
Turbogenerators Generator Bearings
Description
The rotor shaft is supported in sleeve bearings The tangential locator is supported on the bearing
having forced-oil lubrication. The bearings are located saddleover a piece of insulating material.
in the stator end shields. The oil required for bearing The inner surface of the cast bearing sleeve body
lubrication and cooling is obtained from the turbine oil is provided with spiral dovetail grooves which firmly hold
supply system and supplied to the lubricating gap via the babbitt liner to the bearing sleeve body. The lower
pipes permanently installed inside the lower half of the bearing sleeve has a groove to admit the bearing oil to
stator end shield and via grooves in the bearing saddle the bearing surface. The upper sleeve has a wide
and lower bearing sleeve. overflow groove through which the oil is distributed over
The lower bearing sleeve rests on the bearing the shaft journal and fed to the lubricating gap. The oil is
saddle via three brackets with spherical support seat for drained laterally from the lubricating gap, caught by
self-alignment of the bearing. The bearing saddle is baffles and returned to the turbine oil tank.
insulated from the stator end shield and the bearing All generator bearings are provided with a hydraulic
brackets are insulated from the bearing sleeve to prevent shaft lift oil system to reduce bearing friction during
the flow of shaft currents and to provide for double startup. High pressure oil is forced between the bearing
insulation of the generator bearing from ground. A radial surface and the shaft journal, lifting the rotor shaft to
locator serves to locate the bearing in the vertical allow the formation of a lubricating oil film.
direction and is bolted to the upper half of the stator end The bearing temperature is monitored with one
shield. The locator is adjusted to maintain the required double element thermocouple located approximately in
clearance between the bearing sleeve and the insulation the plane of maximum oil film pressure. The
of the radial locator. thermocouples are screwed in position on both sides of
A tangential locator is located at the bearing sleeve the lower bearing sleeve from outside with the detectors
joint to prevent the bearing from turning in the saddle. extending to the babbitt liner.
1 2 3 4 5 6 7
1 Stator End shield 4 Pressurised oil inlet for Hydraulic shaft lift oil system
2 Shaft Seal 5 OIl Baffle
3 Lower Bearing sleeve 6 Bearing oil inlet
7 Outer labyrinth ring
Fig.1 Generator Bearing
2.1-5000-0600/1
BHEL, Haridwar 1111E
Turbogenerators Generator End Shield
Operation

1111E
Turbogenerators Measuring of Bearing T emperature
Operation
1 End shield
2 Thermocouple lead
3 Insulation
4 Spacer ring
5 Bearing Saddle
6 Bearing Shell
7 Thermocoule
8 Babbitt

1111E
Turbogenerators Generator Bearing Insulation
Operation

1111E
Turbogenerators Generator Bearing
Operation Oil system

1111E
Turbogenerators Shaft Seal
Description Description of Shaft Seal
The rotor shaft ends are brought out of the gastight annular groove of the seal ring via passages in the seal
enclosure through shaft seals as shown on the attached ring carrier and seal ring. A continuous film of oil is
drawing. (See also 2.1.4-10610, Shaft Seal- Drawing.) maintained between the shaft and the seal ring. The
With this type of shaft seal, the escape of hydrogen clearance between shaft and seal ring is such that friction
between the rotating shaft and the housing is prevented losses are minimized and an oil film of sufficient
by maintaining a continuous film of oil between the shaft thickness is maintained without an unnecessarily large
and a non-rotating floating seal ring. To accomplish this, oil flow. Temperature rise of the seal oil is therefore small
seal oil is fed to the seal ring in a closed circuit at a which contributes to reliable sealing. The babbitt lining
pressure which is slightly higher than the hydrogen of the seal ring ensures high reliability even in the event
pressure. In addition, the air side seal ring is supplied of mixed friction.
with jacking oil to assure free axial movement. The seal oil pump delivers the oil at a pressure
The shaft seal is characterized by its short axial maintained 0.7 to 1.0 bar above the generator hydrogen
length, its independence from the-respective axial and gas pressure at the shaft seal by means of a differential
radial position of the shaft and an oil supply circuit with pressure valve.
facilities for continuous vacuum treatment of the oil. More Higher pressure oil for ring relief is fed to the annular
details are given in a separate description. (See also groove in the air side seal ring carrier and forced between
2.1.4-44000, Description of Seal Oil System.) the seal ring and the seal ring carrier. In this way the oil
The two halves of the babbitted seal ring float on the and gas pressures acting on the seal ring are balanced,
shaft journal with a small clearance and are guided in and the friction between seal ring and seal ring carrier is
axial direction by a divided seal ring carrier resistant to reduced. The seal ring is thus free to adjust its radial
distortion and bending. The seal ring is relatively free to position, which is important during the starting period.
move in the radial direction, but is restrained from rotating The seal ring will adjust its position according to the
by use of a pin. The seal ring carrier, bolted to the end shaft position as dictated by the oil film thickness and
shield, is insulated to prevent the flow of shaft currents. the vibratory condition.
The oil is supplied to the shaft seal at two different The seal ring need not follow the axial movement of
pressures (seal oil pressure and higher pressure oil for the generator shaft, which is primarily caused by the
ring relief) through the mounting flange of the seal ring turbine expansion. The design permits the shaft to slide
carrier at the end shield. The seal oil is admitted into the through the seal ring without impairing the sealing effect.
Fig. 1 Solid model of Shaft seal assembly

1111E
Turbogenerators Shaft Seal
Description Insulation and Sealing of Seal Ring Carrier
1. End shield bearing (top section) 6. Thrust bolt for seal

2. Shaft seal insultion 7. Seal ring carrier (bottom section)
3. Seal ring 8. Rotor shaft
4. Antirotation device 9. Bearing shell support
5. Joint

1111E
Turbogenerators Seal Oil System
Description
1. General to the seal oil tank, so that an approximately constant

seal oil pressure is established downstream of the seal
The rotor shaft ends are brought out of the gastight oil pumps.
and pressure-resistant enclosure through shaft seals. The
shaft seals are supplied with pressurized seal oil to 3.2 Seal Oil Pressure Regulation Upstream
prevent hydrogen losses at the shaft and air entry into of the Shaft Seals
the hydrogen-cooled generator. The required seal oil pressure (0.8 to 1.5 bar above
Details of the shaft seal are given in a separate hydrogen casing pressure) is controlled by a pressure
description. regulating valve. In order to ensure greater availability,
As long as the seal oil pressure in the annular gap two pressure regulating valves with graded settings are
exceeds the gas pressure in the generator, no hydrogen provided.
escapes from the generator housing. The shaft seal is Depending on the differential pressure setting, a
supplied with seal oil from a separate system. The oil in larger or smaller quantity of oil flows to the shaft seals,
the seal oil system is the same as that used in the turbine- so that the required seal oil pressure is established at
generator journal bearings. the shaft seals.
The seal oil system consists of the seal oil unit and The function of the pressure regulating valves can
the connecting pipework to and from the generator. The be seen in the attached drawing. Since the gas and signal
arrangement chosen provides for easy and simple oil pressures act in opposite directions, the valve stem is
supervision of the seal oil system. moved upwards or downwards when the pressures
become unbalanced. The valve cone is arranged so that
2. Seal Oil Circuit the valve opens further for a downward movement of the
During normal operation, the main seal oil pump 1 valve stem (occurs at rising gas pressure or falling seal
draws the seal oil from the seal oil tank and feeds it to oil pressure). The increased oil flow results in a rise of
the shaft seals via coolers and filters. The seal oil supplied the seal oil pressure at the shaft seals. Setting of the
to the shaft seals is drained towards the hydrogen side desired differential pressure (set value) to be maintained
and the air side through the annular gaps between the by the valve is done by a corresponding preloading of
shaft and the seal rings. The seal oil which drains towards the working diaphragm. The preloading is adjusted with
the air is returned directly to the seal oil tank via a float a compression spring, the upper end of which is rigidly
valve. The seal oil which drains towards the hydrogen connected to the valve yoke, while its lower end is linked
side is first collected in the generator prechambers and to the valve stem by means of an adjusting nut.
then passed to the intermediate oil tank.
Three seal oil pumps are provided for oil circulation. 4. Seal Oil Drains
In the event of a failure of the main seal oil pump due to
a mechnical or electrical fault, the main seal oil pump 2 The oil drained from the hydrogen side of the shaft
automatically takes over. seals is discharged into the generator prechambers. The
If both pumps fail, the seal oil supply is taken over by prechambers reduce the oil flow and permit the escape
the standby seal oil pump without any interruption. The of entrained gas bubbles and defoaming of the oil.
seal oil supply is thus designed as a self-contained system. Downstream of the prechambers. the oil flows are
combined and returned into the intermediate seal oil tank.
A float valve keeps the oil level in this tank at a
3. Seal Oil Pressure Regulation predetermined level and prevents the ingress of hydrogen
Oil pressures which exceed the generator gas into the vacuum. The oil from the intermediate oil tank is
pressure are required to ensure proper functioning of the returned into the vaccum tank together with the seal oil
shaft seals. The seal oil pressure is controlled in two drained from the air side of the shaft seals via a fIot
stages. valve. It excessive amount of oil is supplied to the vaccum
tank an over-flow upstream of the regulating valve allows
3.1 Seal Oil Pressure Regulation Downstream of the
some oil to return to the seal oil storage tank.
Seal Oil Pumps
The small amount of hydrogen escaping from the
The seal Oil pressure downstream of each pump is
generator together with the oil does not present a danger
separately maintained constant by a self-operated
to the generator surroundings since the seal oil storage
pressure regulating valve working on the relief-valve
tank is connected to the bearing vapour exhausters to
principle.
ensure continuous venting.
Depending on the valve setting and the pressure
signal prevailing (seal oil pressure downstream of the
pump), a large or smaller quantity of seal oil is returned 5. Seal Ring Relief .
To ensure free movement of the seal ring even at
higher casing pressures the shaft seals are provided with

1111E
pressure oil for seal ring relief. This system must be in 6. Vacuum Treatment System
operation when the generator is operated at gas pressures
of more than 1 bar. The seal oil in the Vacuum tank is subjected to a
vacuum treatment. A vacuum pump establishes a
The oil supply for ring relief is obtained upstream of vacuum in the vaccum-tank which removes entrained
the differential pressure regulating valve. The required air bubbles from the seal oil. The seal oil supplied to the
pressure setting for each shaft seal is done separately shaft seals by the seal oil pumps is thus largely free of
by means of a flow control valve. gas which prevents a deterloration of the hydrogen purity
in the generator.

1111E
Description Constant Pressure Controller
Fig. 1 Constant Pressure Controller
1. Valve disc 6. Compression springs

2. Valve seat 7. Actuating rod
3. Valve steam 8. Working diaphragm
4. Spring retainer for set-point adjustment 9. Vent
5. Relief bellows 10. Signal line

1111E
Description Differential Pressure Control Valve
Fig. 1 Differential Pressure Control Valve

1. Valve housing 7. Impulse connection (-), housing pressure
2. Valve cone 8. Working diaphragm
3. Relief bellows 9. Impulse connection (+), seal oil pressure
4. Interseal 10. Adjusting spring
5. Union nut 11. Adjusting nut for limit reference value
6. Diaphragm housing

1111E
Description Regulator for Seal Ring Relief Oil
Mode of Operation
The oil flows through the regulator in the direction of the actuating diaphragm via a bore in the cone. The
the arrow. The flow rate depends on the cross-sectional actuating diaghragm converts the differential pressure
areas adjusted by the orifice and the cone. For flow produced by the orifice into an actuating force which in
regulation, the pressure before the orifice is transmitted turn adjusts the cone. The pressure drop across the
to the high-pressure side of the actuating diaphragm and regulator is constant and nearly independent of the
the pressure after the orifice to the low-pressure side of pressure before the orifice. This ensures a constant
volumetric flow rate for seal ring relief under all conditions
of operation.
1. Setpolnt adjuster 5. Cone

Fig. 2 Regulator for Constant Flow Rate
2. Protective cover 6. Impulse line
3. Orifice (shown displaced)
4. Seat 7. Actuating diaphragm
Fig. 2 Regulator, Sectional View

1111E
Turbogenerators
List of Valves for Seal oil System
Description
SL VALVE TYPE OF VALVE NB mm BODY mat FUNCTION LOCATION

NO. DESIG NP MPA END conn
1 MKW01 GATE VALVE 65 CS DRAIN OIL BYPASS OF VACUUM TANK TO SOST PIPE LINE
AA286 4 FL
2M KW01 GLOBE VALVE 15 C S S.O.S.T. DRAIN PIPE LINE

AA471 2.5 B W
3M KW01 GLOBE VALVE 15 C S S.O.S.T. OUTLET U-LOOP DRAIN PIPE LINE

AA481 2.5 B W
4M KW06 FLOAT VALVE 50 C S OUTLET OF I.O.T. SEAL OIL UNIT

AA001 1.6 FL
5 MKW06 REGULATING GLOBE VALVE 50 C S I.O.T. OUTLET BYPASS SEAL OIL UNIT
AA 273 1.6 FL
6 MKW06 G ATE VALVE 50 C S INTERMEDIATE OIL TANK OUTLET BYPASS SEAL OIL UNIT
AA151 4 FL
7 MKW06 GLOBE VALVE 15 C S PRE-CHAMBER OUTLET U-LOOP DRAIN PIPE LINE

AA201 2.5 B W
8 MKW06 GLOBE VALVE 20 C S SHUTOFF TO LEVEL GAUGE OF I.O.T. SEAL OIL UNIT
AA381 2.5 FL
9 MKW06 GLOBE VALVE FOR H2 20 C S SHUTOFF TO LEVEL GAUGE OF I.O.T. SEAL OIL UNIT
AA331 1.6 FL
10 MKW10 F LOAT VALVE 50 C S INLET TO VACUUM TANK SEAL OIL UNIT

AA001 1.6 FL
11 M KW10 GLOBE VALVE 25 C S BYPSS OF VACUUM PUMPS

AA011 2.5 B W SEAL OIL UNIT
12 MKW10 G ATE VALVE 50 C S INLET TO VACUUM TANK
AA101 4 FL SEAL OIL UNIT
13 M KW10 GLOBE VALVE 20 C S SHUTOFF TO LEVEL GAUGE AT VACUUM TANK SEAL OIL UNIT
AA301 2.5 FL
14 MKW10 GL OBE VALVE 20 C S SHUTOFF TO LEVEL GAUGE AT VACUUM TANK SEAL OIL UNIT
AA331 2.5 FL
15 MKW10 GL OBE VALVE 25 C S OUTLET OF VACUUM PUMP-1 SEAL OIL UNIT

AA011 2.5 S C
16 M KW10 GLOBE VALVE 25 C S INLET OF VACUUM PUMP-1 SEAL OIL UNIT

AA121 2.5 S C
17 MKW10 GL OBE VALVE CS OUTLET OF VACUUM PUMP-2 SEAL OIL UNIT

AA021 2.5 S C
18 MK W10 GLOBE VALVE 25 C S INLET OF VACUUM PUMP-2 SEAL OIL UNIT

AA131 2.5 S C
19 MKW11 C ONSTANT PR.REGUL. 25 C S RECIRCULATION AT AC SEAL OIL PUMP MKW11/AP001 SEAL OIL UNIT
AA173 4F L
20 MKW11 R ELIFE VALVE 20 C S BLOW OFF OF OIL FOR AC SOP MKW11/AP001 SEAL OIL UNIT
AA031 0S C
21 M KW11 NON -RETURN VALVE 65 CS N. R. S.O. TO COOLERS AFTER AC SOP MKW11/AP001 SEAL OIL UNIT
AA051 2.5 F L
22 MKW11 GA TE VALVE 100 C S INLET TO AC SEAL OIL PUMP MKW11/AP001 SEAL OIL UNIT
AA261 4F L
23 MKW11 GA TE VALVE 50 CS RETURN TO VACUUM TANK AFTER ACSOP MKW11/AP001 SEAL OIL UNIT
AA181 4 FL
RETURN TO VACUUM TANK AFTER AC SEAL OIL PUMP 2.1-7112-0600/1

BHEL, Haridwar 1111 E
Turbogenerators List of Valves for Seal oil System
Description

24 MKW11 GATE VALVE 65 CS SYSTEM BYPASS SHUTOFF FROM PUMPS O/L SEAL OIL UNIT
AA185 4 FL
RECIRCULATION / RETURN TO VACUUM
25 MKW12 CONSTANT PR REGUL. 25 C S PUMPMKW12/AP001 SEAL OIL UNIT
AA173 4 FL
26 M KW12 RELIFE VALVE 20 CS BLOW OFF OF OIL FOR ACSOP MKW12/AP001 SEAL OIL UNIT
AA031 4 SC
27 M KW12 NON -RETURN VALVE 65 C S NR SHUTOFF TO COOLERS AFTER AC SOP MKW12/AP001 SEAL OIL UNIT
AA051 2.5 FL
100 C S INLET TO AC SEAL OIL PUMP MKW12/AP001 SEAL OIL UNIT

28 MKW12 GA TE VALVE
AA 261 4F L
29 MKW12 GATE VALVE 50 CS RETURN TO VACUUM TANK AFTER ACSOP MKW12/AP001 SEAL OIL UNIT
AA181 4 FL
CONSTANT PR REGUL. 25 CS RECIRCULATION AT ACSOP MKW13/AP001 SEAL OIL UNIT
30 MKW13
AA173 4 FL
BLOW OFF OF OIL FOR AC SOP SEAL OIL UNIT
31 MKW13 RELIFE VALVE 20 CS
AA031 0S C
32 MKW13 N ON -RETURN VALVE 65 C S NR SHUTOFF TO COOLER AFTER DC SOP MKW13/AP001 SEAL OIL UNIT
AA051 2.5 F L
33 MKW13 GATE VALVE 100 C S INLET TO DC SEAL OIL PUMP MKW13/AP001 SEAL OIL UNIT
AA261 4 FL
34 MKW13 GATE VALVE 50 C S RETURN TO VACUUM TANK AFTER DCSOP MKW13/AP001 SEAL OIL UNIT
AA181 4 FL
MKW14 AUTOMATIC PRESSURE 50 C S OIL SUPPLY FROM GOVERNING OIL SYSTEM SEAL OIL UNIT
35
REGULATING VALVE
AA001 2.5 F L
36 MKW14 GLOBE VALVE 50 C S OIL SUPPLY FROM GOVERNING OIL SYSTEM SEAL OIL UNIT
AA051 2.5 F L
37 MKW14 NR VALVE 50 C S OIL SUPPLY FROM GOVERNING OIL SYSTEM SEAL OIL UNIT
AA101 2.5 F L
38 MKW14 GLOBE VALVE 50 C S CONNECTION FROM LUBE OIL SYSTEM PIPE LINE
AA201 2.5 F L
39 SEAL OIL UNIT
MKW21 D OUBLE CHG OVER 65 C S INTERCHANGE OF COOLERS
AA151 VALVE 1.6 F L
SEAL OIL UNIT
40 MKW21 DOUBLE CHG OVER 65 C S TEMP. CONTROL VALVE AFTER S.O. COOLER
AA173 VALVE 1.6 F L
SEAL OIL UNIT
41 M KW21 DOUBLE CHG OVER 65 C S INTERCHANGE OF FILTERS
AA157 VALVE 1.6 F L
SEAL OIL UNIT
42 MKW21 DOUBLE CHG OVER 65 C S INTERCHANGE OF FILTERS
AA158 1.6 F L
8C S SEAL OIL UNIT

43 MKW21 GLOBE VALVE OIL DRAIN FROM COOLER MKW21/AC001
AA201 25 B W
8C S SEAL OIL UNIT

44 M KW21 GLOBE VALVE DRAIN FROM FILTER MKW21/AT001
AA211 25 B W
8C S OIL VENT FROM COOLER MKW21/AC001 SEAL OIL UNIT

45 MKW21 GLOBE VALVE
AA251 25 B W
8C S VENT FROM FILTER MKW21/AT001 SEAL OIL UNIT

AA261 25 B W
2.1-7112-0600/1
1111 E
BHEL, Haridwar
Turbogenerators
Description

8C S D.P. SWITCH MKW21/CP021 ISOLATION SEAL OIL UNIT

AA321 25 B W
8C S D.P.SWITCH MKW21/CP021 ISOLATION SEAL OIL UNIT

AA381 25 B W
SEAL OIL UNIT
49 MKW21 NON-RETURN VALVE 65 SS NON-RETURN SHUTOFF AT COOLER-1 OUTLET
AA241 16 F L
8C S FILLING VALVE UP STREAM OF SEAL OIL SEAL OIL UNIT

COOLER
AA421 25 B W
8C S FILLING VALVE UP STREAM OF SEAL OIL

51 MKW21 GLOBE VALVE SEAL OIL UNIT
FILTER
AA131 25 B W
52 MKW22 GLOBE VALVE 8C S DRAIN FROM COOLER MKW22/AC001 SEAL OIL UNIT
AA201 25 B W
53 MKW22 GLOBE VALVE 8C S DRAIN FROM FILTER MKW22/AT001 SEAL OIL UNIT
AA211 25 BW
54 8C S OIL VENT FROM COOLER MKW22/AC001
MKW22 GLOBE VALVE SEAL OIL UNIT
AA251 25 BW
55 8C S
MKW22 GLOBE VALVE VENT FROM FILTER-2 MKW22/AT001 SEAL OIL UNIT
AA261 25 B W
56 MKW22 N ON-RETURN VALVE 65 S S NON-RETURN SHUTOFF AT COOLER-2 OUTLET
SEAL OIL UNIT
AA241 16 F L
57 MKW31 DI FF. PR.REG. VALVE 50 C S FOR MAINTAINING CONSTT.PRESSURE DIFF. SEAL OIL UNIT
AA001 0F L
58 MKW31 50 C S INLET ISOLATION OF DPRV MKW31/AA001 SEAL OIL UNIT
GLOBE VALVE
AA101 4 FL
59 50 C S OUTLET ISOLATION OF DPRV MKW31/AA001 SEAL OIL UNIT
MKW31 GLOBE VALVE
AA111 25 BW
60 8C S SEAL OIL UNIT
MKW31 GLOBE VALVE SEAL OIL FEEDBACK TO DPRV MKW31/AA001
AA311 4B W
61 MKW31 8C S TO DPT MKW31/CP001 PIPE LINE
GLOBE VALVE
AA321 4B W
62 MKW32 DIFF. PR.REG. VALVE 50 C S FOR MAINTAINING CONST PRESSURE DIFF. SEAL OIL UNIT
AA001 0F L
63 MKW32 50 C S INLET ISOLATION OF DPRV MKW32/AA001 SEAL OIL UNIT
GLOBE VALVE
AA101 4 FL
64 MKW32 50 C S OUTLET ISOLATION OF DPRV MKW32/AA001 SEAL OIL UNIT
GLOBE VALVE
AA111 4 FL
65 MKW32 8C S SEAL OIL UNIT
GLOBE VALVE SEAL OIL FEEDBACK TO DPRV MKW32/AA001
AA311 25 B W
66 MKW32 8C S TO DPT MKW32/CP001 PIPE LINE
GLOBE VALVE
AA321 4 BW
67 MKW35 F LOW REGUL. 15 C S RING RELIEF OIL SUPPLY TO TURBINE SIDE SEAL OIL UNIT
AA001 1.6 F L
68 MKW35 20 CS BYPASS TO FLOW REGULATOR MKW35/AA001 SEAL OIL UNIT
GLOBE VALVE
AA011 2.5 SC
69 MKW35 20 C S INLET TO FLOW REGULATOR MKW35/AA001 SEAL OIL UNIT
GLOBE VALVE
AA101 2.5 B W
2.1-7112-0600/1
Turbogenerators
Description

70 MKW35 OUTLET TO FLOW REGULATOR MKW35/AA001 SEAL OIL UNIT

GLOBE VALVE 15 C S
AA111 2.5 BW
71 MKW36 15 C S RING RELIFE OIL SUPPLY TO EXCITER SIDE SEAL OIL UNIT
FLOW REGULATOR
AA001 1.6 F L
72 MKW36 15 C S BYPASS TO FLOW METER MKW36/AA001 SEAL OIL UNIT
GLOBE VALVE
AA011 2.5 SC
73 MKW36 INLET TO FLOW REGULATOR MKW36/AA001 SEAL OIL UNIT
GLOBE VALVE 15 C S
AA101 2.5 BW
74 MKW36 OUTLET TO FLOW REGULATOR MKW36/AA001SEAL OIL UNIT
GLOBE VALVE 15 C S
AA111 2.5 B W
75 MKW39 8C S HYDROGEN FEED-BACK TO DPR VALVES SEAL OIL UNIT
GLOBE VALVE
AA301 25 BW
76 MKW39 8C S HYDROGEN FEED-BACK TO DPRV MKW31/AA001 SEAL OIL UNIT
FLOW REGUL.
AA311 25 B W
77 MKW39 8C S HYDROGEN FEED-BACK TO DPRV MKW32/AA173 SEAL OIL UNIT
GLOBE VALVE
AA321 25 BW
78 15 C S SEAL OIL UNIT
PGB61 GLOBE VALVE WATER VENT FROM COOLER MKW21/AA001
AA551 25 B W
79 15 C S WATER VENT FROM COOLER MKW22/AC001 SEAL OIL UNIT
PGB61 GLOBE VALVE
AA552 25 B W
PGB61 GLOBE VALVE WATER DRAIN FROM COOLER MKW21/AC001
AA571 25 B W
PGB61 GL OBE VALVE WATER DRAIN FROM COOLER MKW22/AC001
AA572 25 B W
Legend
FL = Flanged
SC = Screwed
CS = Carbon Steel
CR = Cromium Steel
GM = Gun Metal
RT=Room Temperature
2.1-7112-0600/1
Description Bearing Vapor Exhauster
The bearing vapor exhauster In the waste gas system

establishes a slight vacuum condition. The generator
bearing compartments, the seal oil tank, the gas dryer
and in case of single-flow seal oil units, the vacuum
pump, join the vapor exhauster.
The vapor exhauster establishes a vacuum in the
generator bearing compartments which prevents the
escape of oil vapor from the bearing compartments along
the shaft. In addition, the vapor exhauster draws off any
hydrogen gas which may be admitted into the bearing
compartments in the event of a shaft seal failure.
The vapor exhauster embodies optimum safeguards
permitting it to be used for extracting hydrogen gas from
the bearing compartments.
The exhauster is driven by a three-phase motor
attached perpendicular to the exhauster housing. Flanged
connections are provided for the suction and delivery
pipes.
The fan impeller is directly mounted on the motor
shaft. The shaft is sealed with a double-acting grease-
lubricated axial seal which works via a packing washer
which is forced in the axial direction against the seal collar.
A spring provides for a highly flexible seal.
For safety reasons, two exhausters have been
arranged. If, due to an electric or mechanical failure, the
exhauster in operation fails, the second ready-for-
operation exhauster takes over.
Fig. 2 Vapor Exhauster -Drawing
1. Packing washer 5. Regreasing device

2. Seal collar 6. Exhauster housing
3. Motor shaft 7. Fan impeller
4. Motor flange
Note: The photograph shows a typical equipment which
may not correspond in all details to the specific equipment
described.
Fig. 1 Vapor Exhauster
1. Drive motor 3. Suction branch

2. Regreasing device 4. Delivery branch

1111E
Description Seal Oil Pumps
1. General
Oil lubricated radial seals at the rotor shaft ends 2. Construction and Mode of Operation
prevent the hydrogen gas from escaping from the The seal oil pumps are three-screw pumps. One
generator to the atmosphere. double-thread driving rotor and two driven idler screws
Seal oil pumps are used to supply the seal oil to are closely, meshed and run with a close clearance in
the shaft seals in a closed circuit. the casing insert. The pump casing accommodates the
casing insert and is closed off by covers at the drive end
and non drive end.
The screw pump is suitable for rigorous service and,
due to the absence of control parts sensitive to dirt, allows
for relatively large variations of seal oil viscosity.
High speeds are readily attainable because all
moving parts perform rotary movements only.
The main components of the pump are illustrated
in the sectional view of a screw pump.
By intermeshing, the helical passages in the rotors
are divided into compartments completely sealed which,
while rotating progress completely uniformly and without
undue stressing from the suction to the discharge end,
thus acting like a piston. Dummy pistons compensate
for the axial thrust on the thread flank faces at the
discharge end. Axial thrust on the deep-groove ball
bearing is thus eliminated.
1. Idler screw The idler screws are hydraulically driven due to
2 Driving rotor suitable screw dimensioning. The thread flanks transmit
3. Dummy piston only the torque resulting from fluid friction. which ensures
4. Shaft seal (sliding ring gland)
very quiet running.
The screw pumps are driven by electric motors
Fig.1 Screw Pump With Relief Valve through a coupling. The motor speed and rating are
matched to the expected delivery flow and heads.

1111E
Description Vacuum Pump
1. General 3. Technical Data

A vacuum pump establishes a vacuum in the Displacement - 162 Litrs/Min
Vacuum tank and draws off the air released from the oil. Ultimate vacuum - 0.2 mm/Hg
When the alarm High Oil level is given, a level transmitter Oil temp. - 850C (max.)
in vacuum tank switches off the vacuum pump. Motor rating - 0.37 KW
Power supply - 415 volt,3∅,50 HZ
2. Construction and Mode of Operation
The vacuum pump is of oil-sealed rotary sliding vane
type. 4. Oil Seperator
The pump consists of an eccentrically mounted rotor The oil seperator is combined with a float-operated
(4) in a stator (3). The rotor is fitted with two sliding vanes valve, resulting in considerably longer maintenance
(5) which follow the casing bore, thereby dividing the intervals for the vacuum pump. The oil consumption is
pump chamber into several spaces. The volume in each negligibly small, and a daily check of the oil level is not
space varies periodically as the rotor revolves. required. The oil separated from the exhaust air is
The gas drawn in via the intake port into the pump collected automatically and returned to the pump
chamber. After the sliding vane has closed the inlet port, chamber whenever a predetermined oil level is reached.
the air in the pump chamber is pushed forward and Benefits of oil Seperator with oil return :
compressed. Oil injected into the pump chamber serves
for lubrication and sealing between the pump chamber Remove of entrained tube oil particles by filtration.
wall and the vane tips as well as for lubricating and sealing Return of lube oil into the intake channel
the vanes (5) In the rotor (4). downstream of the intake port valve by means of a
The gas compressed in the pump chamber is float-operated valve.
discharged into the waste gas pipe via the discharge port. No operating costs due to loss of lube oil.
The oil entrained in the compressed gas is separated Standard filter element
from the gas in the oil separator which provides for both Built-in relief valve
fiitlation of the oil and removal of mechanical impurities.
To avoid the condensation of vapours in the pump The filter is installed at the exhaust port of the
chamber, a pre-determined quantity of air (gas ballast) Vacuum pump, and lube oil return pipe is connected to
is admitted at the beginning of the compression cycle. the intermediate flange beneath the intake. An effective
The gas ballast valve is opened and screwed by means filter element separates the entrained oil from the exhaust
of sowed handle. air.
A very small quantity of secondary air which is The oil collects in the housing of the vapours filter.
additionally admitted into the pump chamber has a Whenever a predetermined oil level is reached the rising
silencing effect and prevents the knocking noise (oil float opens an outlet port. The lube oil is drawn through
hammer) normally occurring when the ultimate pressure the pipe connecting the outlet port to the intake and
is reached. returned to the tube connecting the outlet port to the intake
When the vacuum pump is stopped, the main return and returned to the lube oil circuit of the vacuum pump.
valve provided in the exhaust side gets closed and seals
the vacuum in the tank.
The built-in oil sight glass allows easy checking
of the oil level in the pump.

1111E
Description Seal Oil Coolers and Seal Oil Filters
1. Seal Oil Coolers 2. Seal Oil Filters

The seal oil coolers are plate type heat exchangers.
The seal oil and cooling water flow through the The seal oil filters are of magnetic strainer type, the
alternate plates, thus transferring the heat of oil to magnetic strainer consists of the filter housing with a
cooling water efficiently. filtering cage and the filter cover.
The seal oil cooler consists of The filtering cage consists of fine-mesh wire cloth
stainless steel plates,which is held at both sides with support strainers on both sides and the magnet bars.
by pressing plates.The seal oil and cooling water The seal oil entering the filter must first passes through
are forced into their respective plates by gaskets the magnetic field set up by the magnet bars so that aII
iron particles contained in the seal oil are attracted by
placed between the plates. The seal oil inlet/outlet
the magnet bars. The seal oil then flows through the fine-
flanges and cooling water inlet/outlet flanges are mesh wire cloth which retains all dirt particles containing
on the same side.These inlet /outlet flanges are no iron.
diagonaly opposite to each other.Venting plugs
are provided on each inlet/outlet.

1111E
Description Seal Oil Filter
1. Changeover Lever 4. Drain

2. Vent 5. Pressure Equalising Valve
3. Filter housing with strainer wit magnetic 6. Differential Pressure Indicator
bars

1111E
Description Vacuum Regulating Valve
General
time constant and so precisely that the preselected
The MR 16 diaphragm pressure regulator is an
control pressure is kept constant with an inaccuracy of
absolute pressure controller by means of which the
only approximately 2%.
pumping speed of vacuum pumps can be matched
automatically and without input of energy to the gas
The instrument is equipped with all valves and
accumulation in the vacuum system.
Connections required to enable easy adjustment and
control of reference pressure and system pressure under
This regulation is achieved with an extremely low
varying operating conditions.
time constant and so precisely that the preselected control

1111E
Operation
1 General 3 Carbon Dioxide Supply (CO2)
The gas system consists of the following components: As a precaution against explosion, air must never be
directly replaced with hydrogen during generator filling nor
• H2 bottle rack the hydrogen replaced directly with air during the emptying
• CO2 bottle rack procedure. In both cases, the generator must be scavenged
• N2 bottle rack or purged with an inert gas, carbon dioxide (CO2) being used
• Gas unit for this purpose.
• Gas dryer
3.1 CO2 Bottle Rack
The design of the gas system complies with the safety The carbon dioxide is supplied in steel bottles in the
regulations according to VDE 0530, Part 3 / IEC 842 and with liquid state. The bottles must be provided with risers to ensure
the German pressure vessel code, considering the special complete emptying. The liquid CO2, which is stored under
properties of H2. pressure, is fed to the CO2 flash evaporator via a shutoff
valve for being evaporated and expanded.
2 Hydrogen Supply (H2)
3.2 CO2 Flash Evaporator
The hydrogen should have a minimum purity of > 99.9% The CO2 flash evaporator is a compact system with
[1]. The hydrogen gas for the generator is obtained from the two parallel heat exchangers being operated alternatively.
H2 bottle rack. The liquid CO2 is evaporated and expanded by
Pressure reduction takes place in two stages. The ambient air in a CO2 flash evaporator. A relief valve on the
first stage, pressure reduction to intermediate pressure will high-pressure side protects the pipe system aganist
be in the the H2 bottle rack. The second stage, pressure inadmissible high pressure.
reduction to the generator housing pressure is arranged in
the Gas unit. 4 Compressed Air Supply
The vent connections at the pressure reducers and
possible safety vents are connected to the waste gas system, To remove the CO2 from the generator, a compressed
routing the H2 to the outdoors. air supply with compressed air filter is connected to the
The advantage of a dual stage regulator is its ability general air system of the power plant.
to deliver a constant pressure, even with a decrease in inlet Under all operating conditions, except for CO2
pressure purging, the compressed air hose in the gas unit must be
disconnected. This visible break, which must be provided
according to VDE 0530/IEC 842, is to ensure that no air can
be admitted into a hydrogen-filled generator.
2.1 H2 Bottle Rack
The H2 bottles are connected to a header on the bottles 5 Gas Unit and Gas Monitoring
rack with high-pressure hoses. Valves on the bottles and Equipment
valves on the header allow replacement of individual bottles
during operation. The hydrogen gas avilable in the header at 5.1 Gas Unit
bottles pressure is passed to one of two parallel-connected
pressure reducers for expansion to the required intermediate To facilitate valve operation, the gas unit is fumished
pressure and is then passed to the gas unit. with a mimic diagram on the face of the panel.
The valves and fittings used in the gas system are
of an approved type for gas as per DIN/ISO specifications.

1111E
5.2 H 2 Pressure Reduction . Now the gas passes through the Moisture
Separator, where the water is separated from the gas and
The hydrogen gas avilable from the r H2 bottle rack at discharged regularly through the Drain Valves. The cold gas
an intermediate pressure is passed to one of two parallel- then exits at outlet, after it has passed through the other side
connected pressure reducers for expansion to the pressure of the gas-to-gas Heat Exchanger, where it is warmed by the
required for generator operation incoming hot gas. This re-heating increases the gas’s effective
volume and prevents pipe sweating downstream. Gas stream
5.3 Casing Pressure Measurement does not fall below the temperature to which it was chilled in
the gas-to-refrigerant heat exchanger (referred to as dew
For measuring and checking the gas pressure in the point temperature) and hence no more water vapour will
generator, the gas unit is provided with pressure transmitters condense into trouble-some liquid. Removing the water keeps
and a pressure gauges for local measurement. For safety, the inside of generator along with pipe lines, valves etc clean
the pressure transmitters are of an explosion proof design. and dry.
5.4 Thermal Gas Analyzer System

.
The two thermal gas analyzer in the H2 unit are of an • Removal of the air above the water level in the
explosion proof design. The analyzers operate on the thermal primary water tank during initial operation of the primary
conductivity method and measure the purity of the H2 gas in water system
the generator as well as the composition of gas mixtures • Removal of oxygen dissolved in the primary water
(CO2/air and H2/CO2) during filling, emptying, and operation of when filling the primary water system
the generator. • Removal of the H2 above the water level in the
primary water tank when shutting down the primary water
5.5 Gas Analysis system
• Removal of any hydrogen dissolved in the primary
In addition, facilities are provided for gas water when shutting down the primary water system.
sampling for chemical analysis of the gas in the The objective of the purging process performed
generator.
during initial operation is to ensure that any oxygen is removed
from the primary water system in order to minimized the risk
6 Gas Dryer
of corrosion.
During operation at rated speed, a small amount of the The objective of the purging process performed
hydrogen circulating in the generator for cooling is passed when shutting down the primary water system is to prevent
through a gas dryer. The gas inlet and gas outlet pipes of the the formation of explosive hydrogen-air mixtures since
gas dryer are connected at points of the generator with during normal generator opertaion, hydrogen can enter the
different static heads (differential fan pressure), so that the primary water tank by duffusion via the insulating hoses.
gas is forced through the dryer by the differential pressure The nitrogen is contained in steel bottles from
only. where it is routed through a pressure reducer for expansion
For gas drying , 2 nos Refrigeration type gas
driers ( 2 X 100 % each) are provided.Hydrogen Gas,
saturated with water vapour, enters Dryer inlet and is pre-
cooled by outgoing Refrigerated gas . Pre-cooling removes
some of the heat load from the incoming gas allowing the use
of a more efficient refrigeration condensing section. The
precooled gas then passes through a gas-to-refrigerant Heat
Exchanger , where it is cooled to 2 Deg. C by giving up heat
to the refrigeration system
2.1-7200-0600/1
0810E
Turbogenerators
List of Valves for Gas System
Description

1 MKG11 MANIFOLD VALVE 8 CS H2 DISTRUBUTOR MANIFOLD H2 DISTRIBUTOR

AA501 25 SC
2M KG11 MANIFOLD VALVE 8C S H2 DISTRUBUTOR MANIFOLD H2 DISTRIBUTOR

AA502 25 SC

AA503 25 SC

AA504 25 SC

AA505 25 SC

AA 506 25 SC

AA507 25 SC

AA508 25 SC
9M KG11 GLOBE VALVE 8C S SHUTOFF AT INLET TO MKG11/AA001 H2 DISTRIBUTOR

AA561 25 SC
10 M KG15 GLOBE VALVE 25 C S SHUTOFF AT OUTLET FROM MKG11/AA001 H2 DISTRIBUTOR

AA501 2.5 SC
11 M KG15 GLOBE VALVE 25 C S FOR CONNECTING H2 DISTRIBUTOR TO GAS UNIT GAS UNIT
AA504 2.5 SC
12 M KG15 GLOBE VALVE 8C S SHUTOFF AT INLET TO MKG12/BY001 H2 DISTRIBUTOR

AA501 25 SC
13 MK G16 GLOBE VALVE 25 C S SHUTOFF AT OUTLET FROM MKG12/AA001 H2 DISTRIBUTOR

AA501 2.5 SC
14 MK G15 GLOBE VALVE 25 C S SHUTOFF AT INLET TO MKG19/AA001 GAS UNIT

AA502 2.5 SC
15 MK G15 WAY VALVE 50 C S SHUTOFF AT OUTLET FROM MKG15, MKG16/BY001 GAS UNIT
AA151 1.6 F L
16 MK G17 GLOBE VALVE 25 C S SHUTOFF AT INLET TO MKG19/AA002 GAS UNIT

AA505 2.5 SC
THREE WAY VALVE 50 C S GAS UNIT

17 MK G25 SHUTOFF TO H2 SUPPLY TO TG
AA519 1.6 F L
GLOBE VALVE 50 C S GAS UNIT
18 MK G25 TO EXHAUST
AA502 2.5 FL
25 C S GAS UNIT
19 M KG17 GLOBE VALVE FOR CONNECTING GAS UNIT TO STATION H2 PLANT
AA504 2.5 SC
GAS UNIT
20 M KG25 GLOBE VALVE 8C S FOR TAKING SAMPLE OF GAS FOR PURITY ANALYSIS
AA512 2.5 B W
GAS UNIT
21 M KG25 THREE WAY VALVE 50 C S FOR CALIBRATION OF GAS ANALYSER
AA507 1.6 F L
GAS UNIT
22 M KG25 GLOBE VALVE 8C S SHUTOFF AT INLET TO GAS ANALYSER CABINET
AA511 25 BW
PIPE LINE
23 M KG25 GLOBE VALVE 8C S SHUTOFF AT INLET TO GAS ANALYSER CABINET-1
AA022 25 BW
BHEL, Haridwar
2.1-7212-0600/1
1111 E
SL VALVE TYPE OF VALVE NB mm BODY mat FUNCTION LOCATIOIN
24 M KG25 PIPE LINE

GLOBE VALVE 8C S SHUTOFF AT INLET TO GAS ANALYSER CABINET-2
AA024 25 BW
PIPE LINE
25 M KG25 GLOBE VALVE 8C S SHUTOFF AT OUTLET TO GAS ANALYSER CABINET-1
AA021 25 BW
26 M KG25 PIPE LINE

GLOBE VALVE 8C S SHUTOFF AT OUTLET TO GAS ANALYSER CABINET-2
AA023 25 BW
PIPE LINE
27 M KG05 GLOBE VALVE 12 C S ISOLATION VALVE AFTER GAC
AA501 1.6 S C
ISOLATION VALVE AFTER REFRIGERATION GAS PIPE LINE
28 MKG69 GLOBE VALVE 50 C S
DRYER
AA504 1.6 F L
PIPE LINE
29 MKG69 GAS VALVE 50 CS SHUTOFF AT INLET OF OIL TRAP
AA501 1.6 FL
PIPE LINE
30 MKG 69 GAS VALVE 50 C S SHUTOFF AT INLET OF REFRIGERATION GAS DRIRE-1
AA502 1.6 FL
PIPE LINE
31 MKG69 GAS VALVE 50 C S SHUTOFF AT INLET OF REFRIGERATION GAS DRIRE-2
AA509 1.6 FL
PIPE LINE
32 MKG69 GAS VALVE 50 C S SHUTOFF AT OUTLET OF REFRIGERATION GAS DRIER-1
AA503 1.6 FL
33 MKG 69 GAS VALVE 50 C S SHUTOFF AT OUTLET OF REFRIGERATION GAS DRIRE-2 PIPE LINE
AA510 1.6 FL
34 MKG69 NEEDLE VALVE 8 CS ISOLATION OF MOISTURE MONITOR PIPE LINE

AA105 25 SCRD
35 M KG69 NEEDLE VALVE 8 CS ISOLATION OF MOISTURE MONITOR PIPE LINE

AA106 25 SCRD
36 MKG69 GLOBE VALVE 15 CS SHUTOFF AT DRAIN AT OIL TRAP OIL TRAP

AA108 2.5 B W
37 M KG51 MANIFOLD VALVE 8 CS CO2 DISTRIBUTOR MANIFOLD VALVE CO2 DISTRIBUTOR

AA501 25 S C

AA502 25 S C

AA503 25 S C

AA504 25 S C

AA505 25 S C
42 MKG51 MANIFOLD VALVE 8 CS CO2 DISTRIBUTOR MANIFOLD VALVE CO2 DISTRIBUTOR

AA506 25 S C

AA507 25 S C

AA508 25 S C
45 MKG51 SAFETY VALVE 6 CS TO RELEASE EXCESS CO2 PRESSURE AT INLET TO CO2CO2 DISTRIBUTOR
AA001 17.5 S C VAPORISER SET 80 BAR
46 MKG51 GLOBE VALVE 8 CS SHUTOFF AT INLET TO H2 DISTRUBUTOR H2 DISTRIBUTOR

AA531 25 S C
47 MKG51 GLOBE VALVE 8 CS SHUTOFF AT INLET TO CO2 VAPORISER CO2 DISTRIBUTOR

AA561 1.6 F L
MKG71
48 GLOBE VALVE 8 CS SHUTOFF AT INLET TO CO2 VAPORISER CO2 DISTRIBUTOR
AA131 25 S C MKG 51/AH001
2.1-7212-0600/2
1111 E
Turbogenerators
Description

49 M KG59 SAFETY RELF. VALVE 32 CS TO RELEASE EXCESS CO2 PRESSURE AT CO2 DISTRIBUTOR
AA001 0.6 F L SET 8 BAR
50 M KG59 GLOBE VALVE 50 C S SHUTOFF AT INLET OF GAS UNIT FROM CO2 PIPE LINE
AA507 1.6 F L S O
51 MKG 25 3WAY VALVE 50 C S SHUTOFF CO2 SUPPLY TO TG/ EXHAUST FROM GAS UNIT
AA518 1.6 F L G
52 MKG25 GLOBE VALVE 25 C S SHUTOFF AT INLET TO MKG25/BT001 GAS UNIT

AA501 2.5 S C
53 MKG25 GLOBE VALVE 25 C S SHUTOFF AT OUTLET TO MKG25/BT001 GAS UNIT

AA509 2.5 S C
54 M KG19 GLOBE VALVE 50 C S SHUTOFF AT OUTLET TO MKG19/AA001 GAS UNIT

AA501 2.5 F L
55 M KG19 GLOBE VALVE 50 C S SHUTOFF AT OUTLET TO MKG19/AA002 GAS UNIT

AA502 2.5 F L
56 M KG35 GLOBE VALVE 8C S SHUTOFF AT OUTLET OF PRESSURE REGULATOR N2 DISTRIBUTOR

AA501 2.5 S C
57 M KG31 GLOBE VALVE 8C S SHUTOFF AT INLET OF PRESSURE REGULATOR N2 DISTRIBUTOR

AA503 2.5 S C
58 M KG31 GLOBE VALVE 8C S N2 DISTRIBUTOR MANIFOLD N2 DISTRIBUTOR

AA501 2.5 S C
59 M KG31 GLOBE VALVE 8C S INLET TO THE PRESSURE GAUGE MKG31/CP502 N2 DISTRIBUTOR

AA502 2.5 S C
Legend
FL = Flanged
SC = Screwed
CS = Carbon Steel
CR = Cromium Steel
GM = Gun Metal
RT=Room Temperature

1111 E
Turbogenerators
CO 2 Vaporiser
Description
1 General outlet to the cooled copper pipe of the evaporator.

CO 2 is used to displace air from the generator The horizontally arranged housing is
before hydrogen filling and to displace hydrogen from filled with heat transmitting liquid to ensure a better
the generator before filling the generator with air. heat transfer to the copper pipe coil and thus to the
Since the CO 2 is available in the liquid state, it CO 2 flowing through the pipe coil.
must be expanded into a gas before use. The CO 2 is The heat transfer liquid is filled into the CO 2
expanded in a CO 2 vaporiser located on the gas valve vaporiser through the expansion vessel mounted on
rack.To prevent icing of the vaporiser it is electrically top of the housing. For protection against excessive
heated. pressures in the CO 2 line, one relief valve is arranged
before and after the CO 2 flash evaporator.
2 Design features and mode of operation
The orifice at the CO 2 out let of the expansion
The CO 2 vaporiser consists of a tubular housing vessel provides for an expansion of the CO 2 obtained
closed by flanges at both ends. One flange carries from the bottles to a pressure of 25 to 7 psig. Heating
electrical heating elements which are connected to of the CO 2 in the copper pipe coil is sufficient to
terminals in the terminal box mounted external to the prevent icing of the expansion device at the prevailing
flange. The opposite flange contains the inlet and flow velocities.
1 2 3 4 5 6
12 11 10 9 8 7
1 Vent for heat transmitting liquid 7 CO2 inlet

2 Copper pipe coil 8 CO2 outlet
3 Insulation 9 Housing
4 Expansion vessel 10 Heating element
5 Relief valve before CO 2 vaporiser 11 Drain for heat transfer liquid
6 Shutoff valve before CO 2 vaporiser 12 Terminal box
Fig.1 CO 2 Vaporiser

1111E
Turbogenerators Gas Dryer (RefrigerationT ype)
Description
For hydrogen gas drying, 2 nos. Refrigeration gas driers After the operation of the Refrigeration drier, the
are available. Either of these two can be selected for the condensate gets collected in the condensate chamber,
gas drying operation, by suitably operating the following which can be observed through the glass window.
valves, to bring in circuit either drier-1 or drier-2: Drain the condensate chamber once every 24 hours.
For draining, first open the upper valve and let the
MKG69 AA502 At inlet of Refrigeration gas drier-1 condensate flow from the condensate chamber and
MKG69 AA503 At outlet of Refrigeration gas drier-1 collect in the pipe. Then close this upper valve and
open the lower valve to drain the condensate. This is
MKG69 AA 509 At inlet of Refrigeration gas drier-2 done to ensure that no hydrogen leakage takes place
MKG69 AA510 At outlet of Refrigeration gas drier-2 from the generator system.
The Refrigeration gas drier is to be operated for a total For further details, refer O&M manual for the
period of 8 hours in 24 hours duration. This can be Refrigeration gas drier
suitably selected on the timer available on the drier.
BHEL, Haridwar 2.1-7270-0 6 0 0 /1

1111E
Description
1 General free, mechanically clean

The losses occurring in the stator windings, -distilled water
terminal bushings and phase connectors are -fully de-mineralised water from boiler feed water
dissipated through direct water cooling. Since the treatment plant
cooling water is the primary coolant to dissipate the -condensate
losses, it is designated as primary water. Since the primary water comes into direct contact
The primary water system basically consists of the with the high-voltage stator winding, it must have an
following components: electrical conductivity below a value of 2 µmho/cm. The
-Primary water supply unit water in the primary water circuit is therefore treated in a
-Primary water coolers water treatment system. Fully de-mineralised water from
-Primary water valve rack the boiler feed water treatment plant and condensate may
-Primary water tank only be used if no chemicals, such as ammonia,
hydrazine, phosphate, etc. were added to the water or
The primary water supply unit combines the condensate.
following components for primary water supply to the
generator: 3 Primary Water Circuit
Primary water pumps Fig. 1 shows a simplified schematic of the primary
Primary water filters water system. Note that the diagram shows that the
Conductivity transmitter external portion of the system may be operated through
Water treatment system a bypass line, with no primary water flowing through the
Flow, pressure and temperature transmitters. water-cooled generator components.
The primary water is circulated by one of the two
2 Primary Water Quality pumps on the primary water supply unit. Both primary
The primary water system may be filled with oxygen- water pumps are of full-capacity type. The electric control
12 1 2 3
1 Primary water tank

2 Pressure regulator
3 Waste gas to atmosphere
4 Pump
5 Cooler
9 6 Filter
11 7 Bypass line
8 Cooling water for stator
winding
8 9 Ion exchanger
10 Cooling water for main
4 bushings
12
and phase connector
5
11 Teflon hose
12 Cooling water
manifold
Primary water circuit-General

Coolant flow: Stator winding
11 7 2 10 Coolant flow: Main bushings
and phase connectors
Water treatment
Fig.1 Simplified schematic of the primary water system Waste gas

1111E
circuit of the pumps is arranged so that either pump may leaves the stator winding. The hydrogen occurs in the
be selected for normal service. primary water due to diffusion through the teflon hoses
The primary water is drawn from the primary water which connect the stator winding to inlet and outlet
tank and passes to a primary water manifold (inlet) via manifolds.
coolers and filters and from there to the stator bars via Since the primary water tank is the lowest pressure
teflon hoses. The primary water leaving the stator point in the system, has a relatively high water
winding is passed through similar teflon hoses to another temperature, a large water surface and sufficient
primary water manifold (outlet) and is then returned to retention time, intensive de-gassing of the primary water
the primary water tank. A separate flow path from a point is ensured. The hydrogen gas in the primary water tank
before the stator winding inlet cools the bushings and is vented to atmosphere via the primary water valve rack
phase connectors. and a pressure regulator. The pressure regulator can be
adjusted to set the gas pressure in the primary water
4 Primary Water Tank tank.
The primary water tank is mounted on the stator The water level in the primary water tank can be read
frame on anti-vibration pads and is covered by the at a water level gauge. Additionally, a capacitance type
generator lagging. The purpose of primary water tank is measuring system is provide for activating an alarm at
to remove the hydrogen in the primary water after it minimum and maximum water level.
2.1-7300-0 6 0 0 2
1111E
Turbogenerators
List of Valves for Primary Water System
Description

1M KF12 N-R VALVE 125 SS NON RETURN AT OUTLET OF STATOR WATER PUMP-2 P&F UNIT
AA231 1.6 FL
2 MKF12 GL OBE VALVE 125 SS INLET TO STATOR WATER PUMP-2 MKF12/AP001 P&F UNIT
AA251 2.5 FL
3 MKF12 N EEDLE VALVE 10 SS DRAIN VALVE BEFORE PUMP-2 P&F UNIT

AA411 2.5 FL
4 MKF12 GL OBE VALVE 125 SS OUTLET OF STATOR WATER PUMP-2 P&F UNIT
AA281 2.5 FL
5M KF11 N-R VALVE 125 SS NON RETURN AT OUTLET OF STATOR WATER PUMP-1 P&F UNIT
AA231 1.6 FL
6M KF11 GLOBE VALVE 125 SS INLET TO STATOR WATER PUMP-1 MKF11/AP001 P&F UNIT
AA 251 2.5 FL
7M KF11 NEEDLE VALVE 10 SS DRAIN VALVE BEFORE PUMP-1 P&F UNIT

AA411 2.5 FL
8M KF11 GLOBE VALVE 125 SS OUTLET OF STATOR WATER PUMP-1 P&F UNIT
AA281 2.5 FL
9M KF36 DOZING VALVE 25 S S FEED VALVE AFTER DOSING PUMP ALK. UNIT
AA211 1.6 FL
10 MKF36 GLOBE VALVE 25 S S SHUTOFF VALVE FOR ALKALISER UNIT PIPE LINE
AA051 1.6 FL
11 MKF36 NEEDLE VALVE 15 S S VENT VALVE AT ALKALISER UNIT PIPE LINE

AA511 2.5 SC
12 M KF21 GLOBE VALVE 125 S S PRIMARY WATER SHUTOFF VALVE BEFORE COOLER-1 PIPE LINE
AA251 2.5 FL
13 M KF22 GLOBE VALVE 125 S S PRIMARY WATER SHUTOFF VALVE BEFORE COOLER-2 PIPE LINE
AA251 2.5 FL
14 M KF21 GLOBE VALVE 125 S S PRIMARY WATER SHUTOFF VALVE AFTER COOLER-1 PIPE LINE
AA281 2.5 FL
15 M KF22 GLOBE VALVE 125 S S PRIMARY WATER SHUTOFF VALVE AFTER COOLER-2 PIPE LINE
AA281 2.5 FL
16 M KF21 NEEDLE VALVE 15 SS PRIMARY WATER SHUTOFF VALVE FOR COOLER-1 PIPE LINE
AA282 2.5 SC
17 M KF22 NEEDLE VALVE 15 SS PRIMARY WATER SHUTOFF VALVE FOR COOLER-2 PIPE LINE
AA282 2.5 SC
18 M KF21 NEEDLE VALVE 10 SS PRIMARY WATER VENT VALVE FOR COOLER-1 PIPE LINE
AA571 2.5 SC
19 M KF22 NEEDLE VALVE 10 SS PRIMARY WATER VENT VALVE FOR COOLER-2 PIPE LINE
AA571 2.5 SC
20 M KF21 NEEDLE VALVE 15 SS PRIMARY WATER VENT VALVE BEFORE COOLER-1 PIPE LINE
AA511 2.5 SC
21 M KF22 NEEDLE VALVE 15 SS PRIMARY WATER VENT VALVE BEFORE COOLER-2 PIPE LINE
AA511 2.5 SC
22 M KF21 NEEDLE VALVE 15 SS COOLING WATER DRAIN VALVE AT COOLER-1 PIPE LINE
AA552 2.5 SC
23 M KF22 NEEDLE VALVE 15 S S COOLING WATER DRAIN VALVE AT COOLER-2 PIPE LINE
AA411 2.5 SC

1111 E
24 MK F27 GLOBE VALVE 125 SS INLET TO WATER FILTER P&F UNIT

AA251 2.5 F L
25 MKF27 NEEDLE VALVE 15 S S DRAIN VALVE AT FITER P&F UNIT

AA411 2.5 S C
26 MKF27 NEEDLE VALVE 10 SS VENT VALVE AT FILTER P&F UNIT

AA511 2.5 S C
27 MKF27 GLOBE VALVE 125 S S INLET TO Y-STRAINER PW UNIT

AA256 2.5 F L
28 MKF27 GLOBE VALVE 125 S S OUTLET TO Y-STRAINER PW UNIT

AA286 2.5 F L
25 SS RELIEF VALVE IN MAKE UP LINE P&F UNIT

29 MKF37 RELIEF VALVE
AA191 2.5 FL
30 MKF29 GLOBE VALVE 125 S S OUTLET TO PW FILTER PW UNIT
AA251 2.5 F L
31 MKF29 BALL VALVE 8S S SHUTOFF VALVE AT CONDUCTIVE TRANSMITTER PW UNIT

AA301 1.6 S C
32 MKF29 BALL VALVE 8S S SHUTOFF VALVE AT CONDUCTIVE TRANSMITTER PW UNIT

AA311 1.6 S C
33 MK F29 BALL VALVE 8S S DRAIN VALVE AFTER PW FILTER PW UNIT

AA611 1.6 S C
34 MKF37 N-R VALVE 25 S S CHECK VALVE IN MARK UP LINE P&F UNIT

AA231 1.6 FL
35 MK F35 REG. VALVE 25 S S CONTROL VALVE FOR WATER TREATMENT SYSTEM P&F UNIT
AA251 1.6 FL
36 MK F35 NEEDLE VALVE 10 S S VENT VALVE BEFORE ION-EXCHANGER P&F UNIT

AA511 2.5 SC
37 MKF37 GLOBE VALVE
25 SS SHUTOFF VALVE IN MARK UP LINE P&F UNIT
AA261 2.5 FL
38 MKF35 GLOBE VALVE 25 S S SHUTOFF VALVE AFTER ION-EXCHANGER P&F UNIT

AA261 1.6 FL
39 MK F35 NEEDLE VALVE 10 S S DRAIN VALVE AT FINE FILTER P&F UNIT

AA421 2.5 SC
40 MKF35 NEEDLE VALVE 10 S S VENT VALVE AT FINE FILTER P&F UNIT

AA521 2.5 SC
41 MKF35 GLOBE VALVE 25 S S SHUTOFF VALVE AFTER FINE FILTER P&F UNIT
AA281 1.6 FL
42 MKF35 NEEDLE VALVE 8 SS DRAIN VALVE FOR WATER TREATMENT SYSTEM P&F UNIT
AA431 1.6 SC
43 MKF35 GLOBE VALVE 25 S S SHUTOFF VALVE AFTER WATER TREATMENT SYSTEM P&F UNIT
AA291 1.6 F L
DRAIN PRIMARY WATER MAKE UP LINE
44 MKF37 NEEDLE VALVE 10 S S P&F UNIT
AA401 2.5 SC
SHUTOFF AT INLET TO GEN.
45 MKF41 GLOBE VALVE 125 S S PW TANK
AA261 2.5 F L
SHUTOFF VALVE FOR GEN. BY PASS
46 MKF40 GLOBE VALVE 125 S S PW TANK
AA271 2.5 F L
SHUTOFF VALVE BEFORE WATER LEVEL
47 MKF01 WATER VALVE 20 S S PW TANK
GAUGE TOP
AA321 1.6 F L
SHUTOFF VALVE BEFORE WATER LEVEL
48 MKF01 WATER VALVE 20 S S PW TANK
AA311 1.6 F L
WATER VALVE SHUTOFF VALVE BEFORE LEVEL TRANSMITTER,
49 MKF01 20 S S PW TANK
TOP
AA326 1.6 F L
2.1-7312-0600/2
Turbogenerators
List of Valves for Primary Water System
Description

50 M KF01 WATER VALVE S.O. VALVE BEFORE LEVEL TRANSMITTER

20 SS PW TANK
AA316 1.6 F L
51 M KF01 GLOBE VALVE DRAIN VALVE AT LEVEL TRANSMITTER

10 S S PW TANK
AA411 2.5 S C
52 M KF01 WATER VALVE 20 SS VENT VALVE AT LEVEL TRANSMITTER PW TANK

AA511 1.6 F L
53 M KF01 WATER VALVE 20 S S S.O. VALVE FOR INLET TO LEVEL TRANSMITTER PW TANK
AA306 1.6 F L
54 M KF01 WATER VALVE 20 S S SHUTOFF FOR OUTLET FROM LEVEL TRANSMITTER PW TANK
AA301 1.6 F L
55 M KF01 REG. VALVE 20 SS FOR NITROGEN FILLING PW TANK

AA251 1.6 F L
56 M KF41 GLOBE VALVE 8 S S SHUTOFF VALVE IN PRIMARY WATER OUTLET OF PW TANK

AA281 1.6 S C
57 M KF41 REG. VALVE 8 S S STATOR WINDING PIPE LINE

AA251 1.6 S C
58 M KA20 NEEDLE VALVE 8 S S ISOLATION VALVE FOR D.P. GAUGE GEN.

AA301 1.6 S C
59 M KA20 NEEDLE VALVE 8 S S ISOLATION VALVE FOR D.P. GAUGE GEN.

AA361 1.6 S C
60 M KF51 REG. VALVE 8 S S REGULATING VALVE BEFORE BUSHING PIPE LINE

AA251 1.6 S C
61 M KF51 BALL VALVE 8 S S SHUTOFF VALVE AFTER BUSHING PIPE LINE

AA281 1.6 S C
62 P GB21 GLOBE VALVE 8 S S COOLING WATER INLET OF COOLER-1 PIPE LINE

AA501 1.6 F L
63 P GB22 GATE VALVE 8 S S COOLING WATER INLET OF COOLER-2 PIPE LINE

AA501 1.6 F L
64 PGB21 G ATE VALVE 8 S S COOLING WATER OUTLET OF COOLER-1 PIPE LINE

AA502 1.6 S C
65 PGB22 G ATE VALVE 25 S S COOLING WATER OUTLET OF COOLER-1 PIPE LINE

AA502 2.5 F L
Legend
FL = Flanged
SC = Screwed
CS = Carbon Steel
CR = Cromium Steel
GM = Gun Metal
RT=Room Temperature
2.1-7312-0600/3
1111 E
BHEL, Haridwar
Turbogenerators Primary Water Pumps
Description
Design Features of Primary Water Pumps discharge is directed radially upwards. The spiral casing
is flanged to the bearing housing. The pump impeller is
The primary water for cooling the stator winding, provided with relief holes close to the hub so that no axial
phase connectors and terminal bushings is circulated in a thrust is carried by the bearings. The point where the pump
closed system. To insure uninterrupted generator shaft passes through the pump casing is sealed by means
operation, two full-capacity primary water pump sets of a water-cooler sliding-ring gland. The cooling water is
are provided. Either pump can be in service with other supplied to the sliding-ring gland through a bypass line
acting as the stand-by. The standby pump is ready for from the pump discharge. The pump shaft is supported in
service and is automatically started without interrupting oil-lubricated anti-friction bearings. The oil level in the
the primary water circulation if the operating pump fails. bearing housing can be checked at an oil sight glass. The
The primary water pumps are of a single-stage pump is connected to the three-phase AC motor by a flexible
centrifugal type with spiral casing and overhung impeller. coupling covered by a coupling guard.
The pump suction is arranged axially, while the
BHEL, Haridwar 2.1-7320-0 6 0 0 /1

1111E
Primary Water Cooler
Turbogenerators
Description
Primary water Coolers

The primary water coolers are plate type heat
exchangers. The Primary water and cooling water flow
through the alternate plates, thus transferring the heat
of Primary water to cooling water efficiently.
The Primary water cooler consists
of stainless steel plates,which is held at both sides by
pressing plates.The Primary water and cooling water
are forced into their respective plates by gaskets
placed between the plates. The Primary water inlet/
outlet flanges and cooling water inlet/outlet flanges
are on the same side.These inlet /outlet flanges are
diagonaly opposite to each other.Venting plugs are
provided on each inlet/outlet.
BHEL, Haridwar 2.1-7330-0 6 0 0 /1

1111E
Turbogenerators Primary Water Treatment System
Operation
The function of the water treatment system is to 2 Ion Exchanger Resins

maintain the electrical conductivity of the primary water at a
low level. The water treatment system is connected in parallel Due to their chemical composition and porous structure,
to the main system and comprises a mixed-bed ion exchanger the ion exchange resins are not only durable but also highly
with series-connected fine filter, a flow meter and a reactive.
conductivity transmitter. The base substances of the resins are
polymerisation products containing highly active groups of
1 Mixed-Bed Ion Exchanger different types. The polymer in the cation exchanger contains
highly acid groups, while the polymer in the anion exchanger
The mixed-bed ion exchanger comprises of a tank filled is composed of highly basic groups.
with anion and cation exchanger resins. Nozzle trays in the The exchanger resins are thus capable of accepting
upper and lower part of the exchanger tank prevent the ions from the primary water, while simultaneously releasing
escape of the resins into the piping system. equivalent amounts of the other ions (hydrogen ions from the
A fine filter downstream of the exchanger retains cation exchanger and hydroxyl ions from the anion
any resins particles. An alarm is intiated when the filter is exchanger) to the primary water.
contaminated.
The primary water flow through the ion exchanger 3 Adding Makeup Water to the Primary
is controlled by the specific loading of the resins and the rate Water System
at which the primary water can flow through the ion
exchanger. The water flow passing through the ion exchanger Any loss of primary water in the system can be
is measured by means of a flow meter downstream of the compensated for by introducing makeup water upstream of
filter. After the ion exchanger , part of the flow is passed the mmixed-bed ion exchanger. The quantity of makeup water
through a conductivity transmitter for checking the resin is totaled by a flow meter and indicates the leaktightness of
activity. the primary water system.

1111E
Turbogenerators Alkalizer Unit
for Primary Water Circuit
Description
1 General
carbon dioxide ions, etc. from the water, However, it
Even with the use of oxygen-poor water, copper also removes the Na + ions from the sodium hydroxide
corrosion in the primary water circuit of water-cooled solution. This elimination of sodium, which is
windings cannot be completely avoided; in isolated proportional both to the volumetric flow rate through
cases the corrosion product s reduce the cross- the ion exchanger and the NaOH concentration, must
sectional flow area of the water distribution system. be compensated by continuous feeding of dilute
Besides, the formation of conductive deposits can sodium hydroxide solution.
occur in the rotating water inlet and outlet hoses of The alkalizer unit is arranged in the treatment
water-cooled rotor windings. circuit Sodium hydroxide solution is injected into the
The severity of the corrosion attack can be largely treatment circuit where it is mixed with the water in
reduced by alkalizing the oxygen-poor water. Also, the the treatment circuit and raises its conductivity. The
system becomes less susceptible to disturbances water has the highest purity at the feed point
resulting from air in-leakage. downstream of the ion exchangers. The conductivity
Operating the generator with alkaline water at pH of the mixed water is only determined by the
8 to 9 improves its reliability land availability. concentration of the sodium hydroxide solution and
Operation at alkaline pH is ensured by a self- provides a reference quantity for the pH valve. The
regulating alkalizer unit for feeding dilute sodium relationship between pH and conductivity under ideal
hydroxide solution (NaOH). conditions is illustrated in Fig.1
Following the admission on alkaline water, the
2 Mode of Operation conductivity in the treatment circuit is monitored.
Dilute sodium hydroxide solution is injected into Conductivity must be maintained constant as required
the low-conductivity primary water circuit where it for obtaining the specified alkalinity. Conductivity in
remains as dissolved, dissociated sodium hydroxide primary water circuit likewise approaches a constant
solution. OH – ion concentration determines the pH value after several hours.
value.
3 Hydraulic Circuit
The ion exchanger in the water treatment system,
i.e. mixed bed filters with H + cation exchangers and The hydraulic circuit of the alkalizer units is
OH – a n i o n e x c h a n g e r s , r e m a i n s i n s e r v i c e illustrated in Fig.2
continuously. It removes all copper, iron, chlorine, The diaphragm pump extracts the NaOH solution
1 Diaphragm pump 4 Level detector

2 NaOH tank 5 Soda lime filter in tank vent
3 Feed valve 6 Vent
(check valve) 7 Treatment circuit
Fig. 1 Conductivity as a function of pH in water at 18oC Fig.2 Schematic Diagram of Alkalizer Unit

1111E
from the NaOH tank and delivers it to the treatment circuit and venting of the unit for activation. Low NaOH level in
via a spring-loaded feed valve. The treatment circuit and the tank is sensed with a level detector to activate an
especially the fine filter down steam of the treatment alarm. A soda lime filter in the tank vent binds the carbon
circuit homogenize the concentration of the solution dioxide contained in the inlet air and prevents the
injected into the circuit by shot feeding. The volume flow formation of carbonates in the NaOH solution.
meter in the treatment circuit stops the diaphragm pump The tank has a capacity to store the sodium hydroxide
via a limit switch when the volumetric flow rate drops solution required for a service period of several months.
below a predetermined limit value. A vent on the
diaphragm pump enables starting without back pressure 4 Control and Monitoring
An interlock using the volumetric flow rate in the
treatment circuit as a criterion prevents starting of the
diaphragm pump and NaOH feeding into the treatment
5
circuit under no-flow or empty conditions. The feed rate
4
of the diaphragm pump is controlled by changing the
stroking rate dependent on the conductivity in the
3
treatment circuit using a controller and stroking rate
2 transducer.
The diaphragm pump is stopped as soon as the
conductivity in treatment circuit or conductivity in primary
water circuit exceeds a predetermined maximum valve,
or as soon as the conductivity in treatment circuit or
volumetric flow rate in treatment circuit drops below a
1 minimum valve.
This avoids over feeding due to faults or incorrect
operation of the alkalizer unit. After the pump has been
stopped the conductivity of the water is promptly
decreased by ion exchanger in the mixed-bed filter.
The alkalizer unit provides warning limits for
Q low conductivity in primary water circuit
Q low conductivity in leakage water circuit
Q low level in NaOH tank.
which are displayed in the control cabinet.
1. NaOH tank Via potential-isolated contacts the following alarm
2. NaOH tank cap conditions can be signalled to the control room either as
3. Diaphragm pump single alarm or as group alarm:
4. NaOH tank vent with lime filter Q low conductivity in leakage water circuit
5. Feed valve (check valve) Q low conductivity in primary water circuit
Q low NaOH level in tank
Fig. 3 Alkalyser Unit Q loss of supply voltage.
2.1-7341-0600/2
1111E
Turbogenerators
Primary Water Filters
Operation
1 Main Filters
The filter elements consist of polypropylene fibers shielded

The primary water system includes a strainer-type main
by polyethylene. The fibers are distributed in the element in
filter [1] with disposable filter elements. The filter cloth of the
such a way that their porosity is highest on the outer
filter elements gives a degree of filtration of 5μm.
circumference of the element and decreases continuously
On contamination of the strainer-type filter, which
towards the filter interior. Therfore, filtration takes place in
is indicated by an alarm initiated at excessive differential
depth, and the solid particles are retained in the entire volume
pressure, the elements must be removed by new ones.
of the element. The coarser particles are removed at the
highly porous outer surface, while the smaller particles are
2 Fine Filter
arrested in the element body at varying depth, depending on
their size. On contamination of the filter, which is indicated by
A fine filter with disposable filter elements giving a
an alarm initiated at excessive differential pressure, the filter
degree of filtration 5μm is installed in the primary water
elements must be removed and replaced with new ones.
treatment system.

1111E
Turbogenerators
Primary Water Main Filter
Description
2
3
Primary
water
inlet
Primary 8
water
outlet
9
10
13
1 Connection for vent pipe

2 Filter cover
3 O-ring
4 Compression spring
5 Clamping bolt (adjustablea0
6 Connections for differential
pressure indicator
7 Supporting cylinder (inner)
12
8 Filter screen
9 Supporting cylinder (outer)
10 Filter housing
11 Connection for drain pipe
12 Tension bolt
11 13 Magnet bar
Note: Internal details shown here are typical and may vary
from actual supply.

1111E
Turbogenerators
Primary Water Fine Filter
Description
5
6
Primary
water outlet
9
1 Connection for vent pipe
2 Differential pressure indicator
3 Filter cover
4 O-ring
5 Impulse pipe for differential
pressure indicator 10
6 Support plate
7 Upper seating ring
8 Filter housing
9 Filter element
10 Clamping bolt
11 Bottom seating ring
12 Connections for drain pipe
11
Primary
water inlet
Note: Internal details shown here are typical and may vary
from actual supply.
12

1111E
Turbogenerators Protective Screens at Primary Water Inlet
and Outlet
Description
Primary water Primary water

outlet inlet
Detail-X
Section A-B
Detail-Y

1111E
Turbogenerators Coolant Temperature Control
Description
Due to load variations during operation and the resulting should be opened only when the generator is carrying load,
thermal expansions and contractions, the generator is since only then current-dependent heat losses will have to
subjected to stresses. be dissipated.
In order to reduce these stresses, the hydrogen cooling The temperature control systems are cold coolant
circuit and the primary water cooling are each provided with temperature control schemes with variable set point as a
a temperature control system to control the cooling gas and function of the stator current. Set point adjustment is selectable
primary water temperatures so that the active generator between I and I2 or with an exponent between one and two.
components are maintained at the proper temperature level. With rising stator current, the set point is reduced, so that the
The requirements for the temperature control systems are mean value (ϑmean) of hot and cold coolant temperatures
described below : assumes a nearly constant value, as shown in Fig. 1.
The difference between the setting values of the two set
ϑcold = Cold gas temperature or cold primary water points corresponds to half the temperature rise of the
temperature hydrogen cooling gas at no-load, with 5-10 K (9-180F) to be
ϑhot = Hot gas temperature or hot primary water taken as a guiding value.
temperature In order to maintain a low temperature level in the
ϑmean = Mean temperature of hot and cold gas or of generator, the reference should be set at the lowest possible
hot and cold primary water value, ensuring that the cold coolant temperature will not drop
∆ϑ = ϑ - ϑcold with generator carrying full load. below the minimum level of 10 0 C (50 0F) even when the
hot
generator is carrying the full load.
The temperature rise ∆ϑ at full load is the temperature
Parallel shifting of the curves shown in Fig. 1 is possible
difference between the hot and cold hydrogen gas as given
by adjustment of the cold gas reference. The temperature of
in the hydrogen cooler design data or between the hot and
cold primary water must, however, always be higher than cold
cold primary water as given in the design data of the primary
hydrogen cooling gas over the entire load range of the
water cooler.
generator in order to avoid any condensation of moisture
After start-up and run-up to rated speed, the cooling water
contained in the gas on the generator components carrying
supply to the hydrogen coolers should be opened only when primary water.
the temperature of the hydrogen gas has reached the preset The control valve must be absolutely tight when in the
cold gas reference. The temperature difference between cold closed position to ensure that the cooling gas temperature
gas and hot gas is determined by the no-load losses. will not drop while the generator is being shut down.
The cooling water supply to the primary water coolers
t
(0F)
Room
temperature
Generator load l/lN (%)
Fig. 1 Coolant temperature as a Function of Generator load

1111E
Turbogenerators Safety Equipment
Description for Hydrogen Operation
The use of hydrogen as coolant in the generator separated from each other.
calls for special safety equipment to ensure that T h e s e a l o i l d r a i n e d f r o m t h e s e a l o i l t ank
hazardous operating conditions which might endanger (hydrogen side circuit) passes into the seal oil storage
personnel or the plant will not occur. tank. After remaining in this tank for a predetermined
The safety and protective measures provided for time, the degassed oil is admitted to the turbine oil
the generator are described in detail in this section. tank together with the bearing oil via a loop seal.
The required measuring and alarm equipment is The measures outlined above have the following
discussed elsewhere in this manual [1]. effects:
During normal operation, leaks may develop which
result in a continuous escape of hydrogen. Long time Q The bearing compartments and the oil drain pipes
experience has shown that no operational restrictions are ventilated continuously so that no explosive
are required as long as the hydrogen losses do not hazard will arise during normal operation.
3
exceed 12 m (s.t.p.) during any 24 hour period. The
surroundings of the generator and the hydrogen Q During normal operation, practically no hydrogen
supply system should not be endangered if will enter the turbine lube oil tank via the loop seal
engineering principles were followed in plant design together with the seal oil drained from the shaft
and provision is made for ample ventilation of these seals, since the hydrogen is already extracted in
areas so that the formation of localized hydrogen the seal oil storage tank.
pockets or explosive hydrogen-air mixtures is
precluded. Q The isolating action of the loop seal prevents the
Particular precautions are taken with respect to a hydrogen escaping due to small leakages from
failure of the seal oil system. A special vapor flowing into the turbine through the only partly filled
exhauster creates a slight vacuum in the generator oil drain pipe.
bearing compartments to prevent the escape of oil
vapor from the bearing compartments along the shaft. The seal oil storage tank is continuously vented
Any hydrogen collecting in the bearing compartment via the vapor exhauster provided for the bearing
will be drawn off by the exhauster and vented. compartments. The exhauster creates a slight vacuum
Operation of the exhauster is monitored by a flow in the seal oil storage tank so that the oil saturated
transmitter with limit switch. If the exhauster fails, the with hydrogen is degassed. After remaining in this tank
second exhauster on standby is automatically started. for a predetermined time, the degassed oil is admitted
To prevent the hydrogen which enters the bearing to the turbine oil tank together with the bearing oil via
compartment from escaping via the oil drain pipes, a loop seal.
the drain oil is returned to the turbine oil tank via the This continuous ventilation of the seal oil storage
seal oil storage tank and a loop seal. This loop seal tank prevents the formation of any explosive
is permanently filled with oil to prevent the escape of hydrogen-air-mixture.
gas. The loop is designed to withstand momentary To avoid any danger to the unit to the hydrogen
pressure surges. supply, only two hydrogen bottles should be opened
The bearing oil circuit and the seal oil circuit are if the bottle supply is used.
Also refer to the following section

[1] 2.1-8400 Measuring devices and supervisory equipment

1111E
Turbogenerators
List of Valves for Waste Gas & Waste FluidSystem
Description

1 MKQ81 DIAPHRAGM VALVE 80 GM SHUT OFF AT INLET TO VAP.EXHAUSTER-1 PIPE LINE

AA551 2.5 F L
2M KQ82 DIAPHRAGM VALVE 80 G M SHUT OFF AT INLET TO VAP.EXHAUSTER-2 PIPE LINE

AA551 2.5 FL
3M KQ81 NON RETURN 80 C S SHUT OFF AT O/L OF VAP.EXHAUSTER-1 PIPE LINE

AA051 2.5 FL
4M KQ82 NON RETURN 80 C S SHUT OFF AT O/L OF VAP.EXHAUSTER-2 PIPE LINE

AA051 2.5 F L
5M KF80 SAFETY VALVE 6C S SHUT OFF AT PW TANK EXHAUST PIPE LINE

AA071 2.5 S C
6M KF80 GLOBE VALVE 20 C S PW TANK GAS EXHAUST PIPE LINE

AA 061 2.5 S C

AA411 2.5 S C

AA412 2.5 S C
9M KX81 GLOBE VALVE 25 C S OUTLET AT DRAIN OIL COLLECTOR DRAIN OIL COLL.
AA211 2.5 B W
Legend
FL = Flanged
SC = Screwed
CS = Carbon Steel
CR = Cromium Steel
GM = Gun Metal
RT=Room Temperature
2.1-8312-0600/1
Turbogenerators
Generator Waste Fluid System
Description
The Waste fluid system serves for controlled are discharged to the waste fluid system.
discharge of fluid to be drained from the Any waste fluid collected is discharged to the
waste fluid system either directly or via collecting
• seal oil system
vessels that are integrated in the respective systems.
• generator liquid level detection system
In the waste fluid system, the fluid is collected in
• waste gas system
a pipe section of large nominal size. This pipe section
as a result of venting or minor leaks. is fitted with a shutoff valve for fluid draining and a
level detector for activating a high level alarm. The
In addition, the fluids to be drained for carrying fluid drained should be transferred to the waste oil
out repair or maintenance work in the above areas tank of the power station for controlled waste disposal.
PIPE COLUMN /
DRAIN OIL COLLECTOR
Fig. 1 Generator Waste Fluid System

1111E
Turbogenerators Generator Mechanical Equipment
Description Protection
1 Tripping Criteria terminal bushing and phase connectors. Secondary

cooling water flows through the hydrogen coolers located
Turbogenerators require comprehensive safety and in the stator end shields. Generator operation will only
supervisory devices to prevent damage and long forced be endangered by these coolants in the event of large
outages. leakages. As a result of the high hydrogen pressure.
The protective equipment detects dangerous Little water will emerge from a small leak. Hydrogen will,
operation conditions at an early stage and prevents them however, enter into the water circuit. The hydrogen loss
from developing into damaging conditions. The can be derived from the hydrogen consumption of the
protection relieves the operating personnel from making generator.
the necessary fast decisions. Operation of the generator will be seriously
The following criteria are sensed by the generator endangered in the event of a major ingress of water which
mechanical equipment protection and processed by the will collect in the generator terminal box. Due to the
generator protection circuits: restricted volume of the compartment the liquid can rise
quickly, resulting in a terminal short-circuit or ground
1.1 High Cold Gas Temperature in Generator fault. In order to prevent such a failure, two level
detectors are connected to the generator terminal box
1.2 Liquid in Generator Terminal Box to activate the generator mechanical equipment
protection before a critical level is reached.
1.3 High Hot Air Temperature in Exciter Unit
2.3 Exciter Unit Protection Against Overheating
1.4 High Seal Oil Inlet Temperatures The protection circuit covering criterion 1.3 prevents
overheating of the exciter in case of insufficient cooling
1.5 High Primary Water Inlet Temperature (failure of exciter coolers).
1.6 Low Primary Water Flow Rate at Sector Outlet 2.4 Shaft Seal protection Against High Seal Oil Inlet
Temperature
1.7 Low Primary Water Flow Rate at Bushing Outlets High seal oil inlet temperature endangers proper
sealing performance of the shaft seals. High seal oil
Each of these criteria activates a turbine trip. The temperature, as may, for instance, be experienced on
generator is disconnected from the system and de- failure of the seal oil coolers, results in a reduction of oil
excited through the two-channel reverse power relay. viscosity. The gas may penetrate the seal oil film at the
shaft seal contact face and allow the hydrogen to enter
2 Protection Circuits the bearing compartment.
2.1 Generators Protection Against Overheating by 2.5 Protecting of Water-Cooled Components Against
High Cold Gas Temperature Overheating
The protection circuit covering criterion 1.1 prevents The protection circuit covering criteria 1.5 prevents
insufficient cooling and thus overheating of the hydrogen- insufficient cooling and thus overheating of the water-
cooled components in case of high cooling gas cooled components in case of high primary water inlet
temperature. temperature.
2.2 G enerator Protection Against Internal Ground 2.6/2.7 Protection of Water-Cooled Components
Fault or Terminal Short-Circuit Against Insufficient primary Water Supply
The generator may be damaged by leaks in The protection circuits covering criteria 1.6 to 1.7
components through which primary or secondary cooling prevent overheating and damage to the stator winding,
water or seal oil flows inside the generator. phase connectors and bushing in case of insufficient
Primary water flows through the stator winding, primary water supply.

1111E
Turbogenerators Tripping Scheme for Generator
Description Mechanical Equipment Protection
TT GCB FB A
Liquid in generator terminal box
High cold gas temperature
High hot air temperature

in main exciter
High seal oil temperature

downstream of cooler
High primary water flow rate

at stator outlet
High primary water flow rate

at stator outlet
Low primary water flow rate

at bushing outlet
Tripout without reverse power protection (Short time initiation)
TT = Turbine trip
GCB = Generator Circuit breaker
FB = Field breaker
A = Alarm
Alarm is initiated when the electrical generator protection system is tripped. Individual alarms for each criterion are provided.

1111E
Turbogenerators Generator Mechanical Equipemtn Protection
Two-out-of-Two Protection Circuit
Description With Functional Test
Plant
enable
CSA11 = non coincidence module GS = limit value monitor

CSF11 = functional test module K1 = relay
CSV11 = logic module MU = transducer
CSZ11 = pulse generator

1111E
Turbogenerators
Generator Electrical Protection
Description
Generators are high-quality machines for securing Rapid fault detection is required for the following
the best possible continuity of power supply. In reasons:
addition to a suitable technical design and responsible Q An interruption of the field circuit with arcing
mode of operation, provision must therefore be made releases high amounts of energy in the form of
for automatic protection facilities. This protection must heat which may cause severe burning.
ensure a fast and selective detection of any faults in Q A one-line-to-ground fault may develop to a double
order to minimize their dangerous effects. ground fault, resulting in dangerous magnetic
The protective equipment must be designed so unbalances, especially on four-pole generators.
that any serious fault will result in an immediate
disconnection and de-excitation of the generator. To minimize the consequential damage, it is
Faults which do not cause any direct damage must recommended to provide two pole and four-pole
be brought to the attention of the operating staff, generators with a protection circuit featuring a delayed
enabling them to operate the unit outside the critical response. In the core of four-pole generators, the rotor
range or to take precautionary measures for shutdown. ground fault protection must always operate of avoid
Generators may be endangered by short-circuits, the hazard of sudden, extremely high vibrations due
ground faults, overvoltages, under-excitation and to magnetic unbalances.
excessive thermal stresses.
The following protective equipment is Relay time: approximately 1 s
recommended:
4 Under-excitation Protection
1 Differential protection Failure of the voltage regulator, mal-operation of
Breakdown of insulation between different stator the generator or transformer control system and
phase windings results in an internal short-circuit. The generator operation in a system with capacitive load
fault is detected by a differential relay which initiates may result in a reduction of the excitation required to
immediate isolation and de-excitation of the generator. ensure system stability below a predetermined
In order to obtain a high sensitivity, the protected area minimum value. Short-circuits or interruptions in the
should include the generator only. field circuit result in a complete loss of field and thus
in instability of the generator. This causes higher
Operating value: 0.2-0.4/ N temperature rises in the rotor and core end portions,
Relay time: < 60 ms r o t o r o v e r v o l ta g e , s y s t e m s w i m s a n d t o r s i o n a l
vibrations of the shaft.
In cert ain cases, the generator may also be A momentary excursion beyond the steady-state
included in the differential protection for the main stability limit must not necessarily result in a loss of
transformer and station service feeder. Generator stability. Therefore it is advisable to design the under-
faults are then detected by two differential protection excitation protection so that a warning will be given
devices. when the steady-state stability limit is reached. The
generator will be shut down after a few seconds only.
2 Stator Ground Fault Protection The protection must operate instantaneously if a
Breakdown of insulation between the stator loss of field occurs when the steady-state stability limit
winding and frame results in a stator ground fault. If is reached.
possible, the stator ground fault protection should If the loss of field cannot be detected directly (e.g.
cover the complete winding, including the neutral point exciters with rotating diodes), it is recommended to
o f t h e g e n e r a t o r. T h e p r o t e c t i o n i s t o i n i t i a t e introduce a second stator criterion covering the range
immediate isolation and de-excitation of the generator. of the permeance values 1/ xd and 1/ x ’d and to provide
for instantaneous tripping when this criterion is
Relay time: <1 s exceeded.
The load resistance of a found transformer and 5 Over current Protection

any required boost to raise the neutral point potential System faults may result in inadmissible thermal
should be selected so that ground current due to a stressing of the generator. For this reason, an over
fault will amount to less than 15 A. current protection should be provided which operates
3 Rotor Ground Fault Protection

1111E
on failure of the system protection. Since the frequency deviation due to a system
A definite-time delay over current relay may be used disturbance is normally accompanied by a voltage
for this purpose, however, its relay time should longer deviation, the protection should be designed on the basis
than that of the system protection. of the permissible load characteristic of the generator
on frequency and voltage deviations.
Operating value: 1.3/N
Relay time: 6-8 s maximum 9 Reverse Power Protection
To avoid long relay times, it is recommended to equip A rise in system frequency for any reason whatsoever
large generators with an inverse-time-delay (impedance result in closing of the control valves, and the turbine is
relay. This relay is energized by over current and driven by the motoring generator. Since the turbine is
operates with long or short-time setting, dependent on then no longer supplied with cooling steam, the unit must
the location of the short-circuit. be disconnected from the system. The relay must be
If connected to the generator neutral point, the over- provided with a time delay of approximately 20s to
current protection serves as backup protection for the prevent undesired response to system swings (long time
differential protection. setting).
Specific faults in the turbine-generator interior initiate
6 Load Unbalance Protection emergency tripping. The steam supply to the turbine is
Generators operating in an interconnected system interrupted. A reliable criterion of perfectly tight closure
are normally subjected to small load unbalances only. of the emergency stop valves is the flow of power from
However, all one and two line-to-ground faults occurring the system back into the generator.
in the system, phase breakages or circuit breaker failures Disconnection of the unit from the system by the
are in fact load unbalances which may result in unduly generator circuit breaker with a time delay of 4s is only
high thermal stressing of the rotor. permissible after the reverse power has been drawn by
It is recommended to provide a two-stage load the generator (short-time setting).
unbalance protection. When the continuously permissible
load unbalance is reached, an alarm is given, whereas Operating value: about 50-80% of reverse power
a time-dependent isolation from the system occurs when Relay time: longtime setting: approximately 20 s
this value is exceeded. short-time setting: approximately 4s
In case of large units, it is recommended to provide
a protection with unbalanced load/time characteristic. 10 Overvoltage Protection
Operating value and relay time should be matched to The use of surge inverters on the high-voltage side
the load unbalanced/time characteristic applicable to the of the unit transformer is considered sufficient for
particular generator. protecting the generator against atmospheric over
voltage and switching surges in the system.
7 Rise-in-voltage Protection With a view to a possible flashover from the high-
Rejection of partial or complete system loads causes voltage winding to the low-voltage winding in the unit
a voltage rise, followed by an increase in the prime mover transformer, it is, however, advisable to provide surge
speed. This may result in the generator and the diverters for the generator too, which should be
apparatus connected to it being endangered by unduly connected between the phases and ground.
high voltages. Mal-operation during manual voltage Normally, the surge diverters are installed in the direct
regulation of the generator may also result in vicinity of the unit transformer. It is assumed that
inadmissible voltage stressing of these devices. Due to switching surges due to a load isolator or circuit breaker
the sudden voltage variations resulting from switching connected between the generator and transformer will
operations, it is advisable, at least in the case of large not endanger the generator.
units, to provide a two-stage rise-in voltage protection, Care should be taken to provide explosion-proof
i.e.: surge diverters or suitable constructional measures in
Q with high (1.45 × UN) operating value and order to avoid danger to persons or nearby components.
instantaneous tripping;
Q with low (1.2 × UN) operating value and delayed Design principle:
tripping. Reseal voltage: approximately 1.2-1.4 × UN
(allowing for power-frequency
8 Under-Frequency Protection overvoltage on load rejection)
Major disturbances in an interconnected system may Power-frequency
result in operation of the generator at under-frequency. spark-over voltage: approximately 2 × UN
At rated voltage, the generator can be continuously (<test voltage for stator winding,
operated at rated k VA up to 95% of rated frequency. e.g. VDE 0530,
To avoid excessive magnetic and thermal stressing, UP = 2 UN + 1 kV)
it is recommended to provide an under-frequency Impulse spark-over
protection. voltage <4 × UN
2.1-8330-0600/2
Turbogenerators Tripping Scheme for
Description Generator Electrical Protection
Initiation of
TT GCB FB
Differential protection
Stator ground fault protection
Rotor ground fault protection
Underexcitation protection
without loss of field
with loss of field
Over current protection
Unbalance load protection
Rise-in-voltage protection
Under-frequency protection
Reverse power
Long time
short time (operates uonly at TT) TT has been
activated
TT = Turbine trip
GCB = Generator circuit breaker
FB = Field breaker
Alarm is initiated when the electrical power protection system is tripped. Individual alarms for each criterion are provided.

1111E
Turbogenerators
Rotor Grounding System
Description
Grounding brushes are fitted to the turbine-end sta-

tor end shield to remove the static charges of the shafts.
The brush holders are arranged with 90 0 displace- 1

ment, which ensures that at least one brush will make
contact with the rotating shaft journal.
Fig.1 Arrangement of Brush Holders
1. Stator end shield 3. Rotor shaft

2. Brush holder 4. Turbine bearing

1111E
Turbogenerators Arrangement of Brush Holders
for Rotor Grounding System
Operation

1111E
Turbogenerators Measuring Devices and Supervisory
Equipment
Operation Introduction
The supervisory equipment consists of alarms and measuring and alarm devices are combined to form
measuring devices. The measuring devices give a one supervisory.
visual indication of the system parameters, the alarm Closely associated with the supervisory equipment
devices initiate visual or audible signals in the event are regulating systems, automatic controls and
of a controlled quantity falling below or exceeding the protective devices which provide for a reduction of
predetermined limit values. In many cases, the the manual supervisory work.

1111E
Temperature Tranducers
Turbogenerators
Resistance Temperature Detectors
Operation and Thermocouples
1 Resistance Temperature Detectors (RTD’s)
RTD’s are used for temperature measurements on the

generator, e.g. to measure the slot temperatures and the
cold gas and hot gas temperatures.
When making measurements with RTD’s the resistance
element is exposed to the temperature to be measured.
The RTD works on the change in electrical resistance of a
conductor by the following formula:
R = R0 (1+ α T)
where
R0 = reference resistance at 00C
α = temperature coefficient, and
T = temperature in 0C
Fig. 2: Four-wire Connection

Leads RL1 and RL2 form the pair of lead wires to the
RTD Pt 100, while the other set of lead wires RL3 and RL4
from the RTD are connected to amplifier V. Being a normal
differential amplifier, it amplifies only the voltage drop across
the RTD to the required output voltage level.
Due to the mostly very high input resistance of amplifier

V, the resistance of lead wires RL3 and RL4 from the RTD
to the amplifier is negligible, even if it would be substantially
increased be the provision of a safety barrier (explosion
protection).
Fig. 1: Resistance Characteristics of Platinum RTD’s 100 Ω
2 Thermocouples
The standard reference resistance of the platinum
resistance element is 100 ohms. The temperature Thermocouples are used for temperature
coefficient amounts to α =3.85×10-3 degC-1 this being the measurements on generator, e.g. to measure the generator
mean value for the range 0 -100 0C. and exciter bearing temperatures. Thermocouples are
mainly employed where small time constants require fast
1.1 Circuit Connections temperature indication.
The two-wire connections so far commonly used involves
errors in case of leads. Long leads are exposed to different 2.1 Principle
temperatures, and the lead resistances then reach values in Temperature measurement with thermocouples is
the order of the resistance of the RTD element. carried out as follows:
Two conductors of dissimilar materials, i.e. the
1.1.1 Three wire Connections positive and the negative conductor (thermoelectric
If a third lead is connected to the element in addition to elements) are joined at one end (hot junction) so as to
the two element leads, automatic compensation for lead produce an electromotive force (emf), i.e. a
wire resistance including its changes can be achieved by thermoelectric emf (in mV). The magnitude of the emf is
resistance of the two leads forming the pair to the element dependent upon the temperature difference between the
are always the same. temperature to be measured and that of the other two
ends of the conductors.
1.1.2 Four-Wire Connection To use the thermoelectric emf for temperature
If the two element leads are not alike or if the three- measurement, the free ends of the conductors are exposed
wire method of compensation would be too costly a four- to a constant temperature (cold junction temperature) and
wire circuit should be used. Fig.2 shows the circuit diagram connected to a milli-voltmeter calibrated in 0C.
of the four-wire method.

1111E
Temperature limits Max. continuous Colour codes
Thermocouple oC oC Parameter Indicator
Neg. pole Pos.pole
Cu - NiCu -200 - +600 400 ~4.3 mV/100 deg C Red Brown

Fe - NiCu -200 - +900 700 ~5.3 mV/100 deg C Red Blue Moving
Ni Cr - Ni ± 0 - +1200 1000 ~4.1 mV/100 deg C Red Green coil
Pt Rh - Pt ± 0 - +1600 1300 ~0.6 mV/100 deg C Red White
Ni Cr- Constantan ± 0 - +1000 400 ~6.3 mV/100 deg C Red Purple
thermocouple, the cold junction temperature must be

known. A cold junction at a temperature of 00C can be
very easily produced by melting ice. The use of
thermostats with reference junction temperature of 20
0
C and 500C is also possible. Note that in these cases
certain corrections must be added to the calibration figure
of the particular thermocouple which are referred to 00C.
1 Hot junction 4 Cold junction correction
2 Thermocouple 5 Connecting cables To do this, add the thermoelectric emf due to the cold
3 Compensating lead 6 Milli volt meter junction temperature to the measured thermoelectric emf
7 Compensating resister and read measuring point temperature to obtain the total
Fig. 3: Thermocouples thermoelectric emf .
60
Thermoelectric voltage Utherm in mV
50
NiCr-Const.
40
Cu-CuNi
30 Fe-CuNi
NiCr-Ni
20
10
PtRh-Pt
0
Fig.4: Voltage-temperature function for standardised

thermocouples
2.2 Compensating Leads

The compensating leads serve to extend the 1 Compensator
thermocouple up to the cold junction. When exposed to 2 Genenerator
a temperature up to 200 0C they produce the same 3 Double pole double throw switch
thermoelectric emf as the associated thermocouple. See Fig.: 5 Circuit arrangement for connection of several
DIN 43710 for calibration data and limits of error of thermocouples
compensating leads.
The compensating leads used for the different The cold junction can, however, also be implemented
thermocouples are identified by colors: by using a Pt100 RTD for determination of the actual
Cu-CuNi brown temperature. The temperature is referred to the
Fe-CuNi blue calibration figure for 0 o C by electronic means. The
NiCr-Ni green electronic cold junction also avoids the temperature error
PtRh-Pt white
due to the junction between the compensating leads and
NiCr-Constantan red
the copper leads.
The insulating sleeve of the positive lead is provided
To obtain a simpler circuit, the large number of
withe a red mark in addition to the color code.
thermocouples used on the generator can be connected
to a double pole measuring point selector switch enabling
2.3 Cold Junction
the respective thermocouple to be connected to a
For measuring a temperature by means of a
compensator for measurement.
2.1-8410-0600/2
1111E
Turbogenerators Supervision of Generator
Operation
The most essential measuring and supervisory devices 2 Stator Liquid Detection
at the generator serve for: Liquid (cooling water from hydrogen coolers, primary
-temperature monitoring water or seal oil) entering the generator housing is sensed
-detection of liquid in generator interior. by level detectors connected gastight to pipes from the
low level points of the generator.See Fig 3
1 Temperature Monitoring
1.1 Stator Slot Monitoring

The slot temperatures are measured with resistance
temperature detectors (RTD’S). This platinum measuring
wire is embedded in a molded plastic body which provides
for insulation and pressure relief.
The RTD’S are embedded directly in the stator slots
between the bottom and top bars at points where the
highest temperature are expected.
The RTD’S are characterized by a constant temperature
vs. resistance characteristic, high mechanical strength and
insensitivity to electrical and magnetic fields.
1 2 3 4
1
1 Neoprene Gasket
2 2 Flange of Stainless steel
3 3 Safety tube
4 Probe rod
4
Fig. 2 Level detector
5
Pipes from several low-level points of the generator are
1 Top bar connected to a common level detector.Sight glasses are
2 Resistance temperature detector
3 Separator provided in the inlet pipe to identify the source of the liquid.
4 Bottom bar The generator terminal box has two leakage detection
5 Stator core pipes . The two pipes extend several inches above the
bottom of the generator terminal box and are
Fig. 1 Stator slot resistance temperature detector interconnected so that both detectors will respond if the
box should be in an inclined position.
1.2 Cold and Hot Gas Temperatures These detectors are utilized as tripping criteria for the
The temperature of the hot and cold gases are generator mechanical equipment protection, whereas all
measured by RTD’S upstream and downstream of the other detectors initiate only alarms.
hydrogen coolers, The temperatures measured are
provided to be used with the hydrogen temperature control
system and the generator electronical equipment protection.
Temperature detectors located in the generator interior
are mounted in gas tight protective tubes welded to the
stator frame.
1.3 Primary Water Temperatures

The temperature of the hot primary water in the drain
water manifold of the stator winding is measured with
resistance temperature detectors. The temperature
detectors are welded to the drain water manifold in
protective tubes exposed to the primary water temperature.

1111E
Turbogenerators
Description
List of Valves for Gen. Instrumentation Scheme

1 MKA11 GLOBE VALVE 25 CS SHUT OFF AT INLET OF LEVEL SWITCH LDR

AA116 2.5 FL
2 MKA11 GLOBE VALVE 25 CS SHUT OFF AT OUTLET OF SIGHT GLASS LDR

AA118 2.5 B W
3 MKA12 GLOBE VALVE 25 CS SHUT OFF AT OUTLET OF SIGHT GLASS LDR

AA118 2.5 B W

AA115 2.5 F L

AA116 2.5 F L
6M KA16 GLOBE VALVE 25 CS SHUT OFF AT INLET OF LEVEL SWITCH LDR

AA 117 2.5 F L
7M KA16 GLOBE VALVE CS SHUT OFF AT OUTLET OF SIGHT GLASS LDR

25
AA118 2.5 B W
8M KA16 GLOBE VALVE 25 CS SHUT OFF AT INLET OF LEVEL SWITCH LDR

AA136 2.5 FL
9M KA16 GLOBE VALVE 25 CS SHUT OFF AT OUTLET OF SIGHT GLASS LDR

AA138 2.5 B W
10 PGB31 GATE VALVE 150 CS SHUT OFF AT INLET OF H2 COOLER ‘A’ PIPE LINE
AA501 4F L
11 P GB31 GATE VALVE 150 C S SHUT OFF AT INLET OF H2 COOLER ‘B’ PIPE LINE
AA502 4F L
12 P GB31 GATE VALVE 150 C S SHUT OFF AT INLET OF H2 COOLER ‘C’ PIPE LINE
AA503 4F L
13 P GB31 GATE VALVE 150 C S SHUT OFF AT INLET OF H2 COOLER ‘D’ PIPE LINE
AA504 4F L
14 PGB31 GLOBE VALVE 10 CS DRAIN FOR INLET OF H2 COOLER ‘A’ PIPE LINE
AA571 4B W
15 PGB31 GLOBE VALVE 10 CS DRAIN FOR INLET OF H2 COOLER ‘B’ PIPE LINE
AA572 4B W
16 PG B31 GLOBE VALVE 10 CS DRAIN FOR INLET OF H2 COOLER ‘C’ PIPE LINE
AA573 4B W
17 PG B31 GLOBE VALVE 10 CS DRAIN FOR INLET OF H2 COOLER ‘D’ PIPE LINE
AA574 4B W
18 PG B31 GLOBE VALVE 10 CS VENT OF H2 COOLER ‘A’ PIPE LINE

AA551 4B W
19 PG B31 GLOBE VALVE 10 CS VENT OF H2 COOLER ‘B’ PIPE LINE

AA552 4B W
20 PG B31 GLOBE VALVE 10 CS VENT OF H2 COOLER ‘C’ PIPE LINE

AA553 4B W
21 PG B31 GLOBE VALVE 10 CS VENT OF H2 COOLER ‘D’ PIPE LINE

AA554 4B W

1111 E
22 PGB32 REG GLOBE VALVE 150 CS SHUT OFF AT OUTLET OF H2 COOLER ‘A’ PIPE LINE
AA501 4 FL
23 PG B32 REG GLOBE VALVE 150 C S SHUT OFF AT OUTLET OF H2 COOLER ‘B’ PIPE LINE
AA502 4 FL
24 PG B32 REG GLOBE VALVE 150 C S SHUT OFF AT OUTLET OF H2 COOLER ‘C’ PIPE LINE
AA503 4 FL
25 P GB32 REG GLOBE VALVE 150 C S SHUT OFF AT OUTLET OF H2 COOLER ‘D’ PIPE LINE
AA504 4 FL
PIPE LINE
26 PGB32 GLOBE VALVE 10 CS DRAIN FOR OUTLET OF H2 COOLER ‘A’
AA571 4B W
27 P GB32 GLOBE VALVE 10 CS DRAIN FOR OUTLET OF H2 COOLER ‘B’ PIPE LINE
AA572 4 BW
28 P GB32 GLOBE VALVE 10 CS DRAIN FOR OUTLET OF H2 COOLER ‘C’ PIPE LINE
AA573 4 BW
29 PGB32 GLOBE VALVE 10 CS DRAIN FOR OUTLET OF H2 COOLER ‘D’ PIPE LINE
AA574 4 BW
30 PGB33 CONTROL. VALVE 300 CS COLD GAS TEMP. CONTROL VALVE PIPE LINE
AA001 4 BW
Legend
FL = Flanged
SC = Screwed
CS = Carbon Steel
CR = Cromium Steel
GM = Gun Metal
RT=Room Temperature

1111 E
Turbogenerators Supervision of Bearings
Operation
1 Generator Bearing Temperatures

1
The generator bearing temperatures are measured 2

3
with thermocouples located in the bearing lower
halves. The actual measuring point is located at the
babbitt/sleeve interface. Measurement and recording
of the temperatures are performed in conjunction with 4
the turbine supervision. The overall turbine protection
is tripped when the maximum permissible temperature
is exceeded.
2 Vibration Monitoring
The generator and exciter rotors are manufactured

with high precision and carefully balanced.
The unavoidable residual unbalance will, however,
result in vibrations during operation, which are
transmitted to the stator frame and foundation via the
bearings.
To permit a reliable assessment of the running 1 Rotor shaft
condition, vibration pickups are located at the 2 Babbitt
bearings. Measurement and recording of the 3 Thermocouple
vibrations are performed in conjunction with the 4 Bearing sleeve
turbine supervision. The overall turbine protection is
Fig. 1 Bearing temperature measurement
tripped when a predetermined amplitude is exceeded.

1111E
Turbogenerators Supervision of Seal Oil System
Description
The location of the transmitters of the measuring and Local indication is provided for setting the pressure
supervisory equipment in the seal oil system is shown in the regulator and for observation.
Seal Oil Diagram[1].
The most essential measuring and supervisory 2.4 Seal Oil Pressure Downstream of Filter
devices in the seal oil system are: At this pressure gauge the seal oil pressure
Level detectors downstream of the filter can be observed.
Pressure measuring devices The pressure switch activates the standby seal oil
Temperature measuring devices pump, if the set seal oil pressure is not reached.
Volumetric flow rate measuring devices
2.5 Seal Oil Pressures Upstream of TE and
1. Level Detectors EE Shaft Seals
The readings are required for manual adjustment
Within the seal oil system of the seal oil pressures. Pressure transmitters trigger
The oil levels in the TE and EE prechambers alarm signals if the seal oil pressure drops below a
The oil level in the seal oil tank specified low limit.
The oil level in the seal oil storage tank
The oil level in the intermediate oil tank are super- 2.6 Vacuum in Seal Oil Tank
vised. This pressure transmitter signals a loss of vacuum.
A high oil level in the generator prechambers, due to
2.7 Differential Pressure Across Seal Oil Filter
an Increase In the amount of seal oil on the hydrogen
This local indicator displays the degree of filter
side of the shaft seal, results in an alarm. The alarm is
contamination on a dial (red/white) and activates an
initiated when the probe is immersed in oil.
alarm at a preset pressure differential.
A low oil level in the intermediate oil tank and in the
seal oil storage tank is monitored such that an alarm is
activated when the probe is no longer immersed in oil. 3. Temperature Measuring Devices
At high oil level in the seal oil tank, the vacuum pump
is stopped to prevent it from drawing seal oil. The alarm The following temperatures are measured locally:
is activated when the probe is immersed in oil. Seal oil temperature upstream and downstream of
To prevent dry running of seal oil pumps 1 and 2 with seal oil coolers.
low oil level in the seal oil tank, a second probe is provided
to stop seal oil pumps 1 and 2 when the probe is no In addition, the following temperatures are
longer immersed in oil. measured by means of resistance temperature detectors
for remote indication:
2. Pressure Measuring Devices Seal oil temperature downstream of filter
The following pressure measuring points are Seal oil temperature in hydrogen side seal
provided: oil drain, TE and EE.
2.1 Pressure Downstream of Seal Oil Pump 1 4. Volumetric Flow Rate Measuring Devices
On failure of seal oil pump 1, a pressure transmitter
activates seal oil pump 2. If the latter is not ready for The following volumetric flow rate measuring points
operation, the standby seal oil pump is automatically started. are provided:
Local indication is provided for setting the pressure
regulator and for observation. 4.1 Volumetric Flow Rates for TE and EE Shaft Seals
The volumetric flow rate of the seal oil supplied to
2.2 Pressure Downstream of Seal Oil Pump 2 each shaft seal is indicated by a volumetric flow rate
On failure of seal oil pump 2, a pressure transmitter indicator upstream of the shaft seal.
activates seal oil pump 1. If the latter is not ready for
operation, the standby seal oil pump is automatically started. 4.2 Volumetric Flow Rates for TE and EE
Local indication is provided for setting the pressure
Seal Ring Relief
regulator and for observation.
The volumetric flow rate of the seal ring relief oil
supplied to each shaft seal is indicated by a volumetric
2.3 Pressure Downstream of Standby Seal 011 Pump
flow rate indicator upstream of the shaft sea.
A pressure transmitter signals the takeover of the
seal oil supply by the standby seal oil pump.
[1] 2.1-7111 Seal oil Diagram
BHEL, Haridwar 2.1-8450-0600

Turbogenerators Supervision of Gas System
Operation
The location of the transmitters of the measuring and 3 Pressure Gauges

supervisory equipment in the gas system is shown in the
Gas Diagram [1].
The following measuring points are provided :
The essential measuring and supervisory devices in
the gas system are : Q CO2 bottle pressure
The bottle pressure during CO2 filling can be observed

Q Purity meter systems at a local pressure gauge.
Q Volume flow meter system
Q Pressure gauge Q H2 bottle pressure
Q Temperature detectors
The bottle pressure can be read at the pressure gauge.
The pressure switch activates a signal at low H2 pressure.
1 Gas Purity Meter System In addition, the pressure is sensed with a pressure
transmitter, the electrical signal being used for remote
The gas purity meter system measures the purity of control and supervision.
the hydrogen gas in the generator as well as the
Q N2 bottle pressure
composition of the gas mixtures (CO2/ air and H2/ CO2)
during filling of the generator. The gas purity meter system The bottle pressure can be read at a local pressure
is also used when removing the hydrogen from the gauge.
generator, where the hydrogen is replaced with carbon
dioxide and the carbon dioxide in turn with air. The gas Q H2 pressure at pressure reducers.
required for the measurement is taken from the generator
For observation of the pressure settings.
or from the filling lines, respectively, and, on completion of
the measurement, is discharged to the atmosphere through Q H2 casing pressure
a vent line.
The pressure is sensed by pressure transmitters, the
For details on the gas purity meter system, refer
electrical signal of one pressure transmitter being used for
Operation and maintenance manual of the Gas analyser
remote control and supervision. The signals of the
cabinet [2].
remaining two transmitters are converted into alarm and
The gas purity meter system is equipped with a limit
control signals.
switch which provides a signal to initiate an alarm when
The H2 casing pressure can be read at a local pressure
the purity drops below a preset value.
gauge.
2 Volume Flow System 4 Temperature detectors
Within the gas system, temperature detectors are used

Q Measuring gas volume flow for supervision of CO2 flash evaporator.
The temperatures of the heat transfer liquid in CO2 flash
For comparison measurement, a precisely defined
evaporator is detected by means of RTD and used for
measuring gas flow must be admitted to the gas purity meter
control functions. In addition, the temperature of heat
system. The measuring gas volume flow can be read locally
transfer liquid in the CO2 flash evaporator is indicated locally
at the flow meter.
by a thermometer.
Als refer to the following sections

[1] 2.1-7211 Gas Diagram
[2] refer Operation and maintenance manual of the Gas
analyser cabinet

1111E
Turbogenerators
Operation Supervision of Primary Water System
The Primary water diagram [1] shows the location of

Pressure downstream of primary water pump 1
the transmitters of the measuring and supervisory
Pressure downstream of primary water pump 2
equipment for the primary water system.
The essential measuring and supervisory devices in
The two pressure measuring points are equipped with
the primary water system are:
pressure transmitters and are required for the automatic
control of the primary water pumps
Conductivity meter system
In addition, a pressure gauge is provided downstream
Level monitoring system
of each pump to allow the pressure to be monitored locally.
Volume flow meters
Pressure gauges
Temperature detectors
Gas pressure in primary water tank
1 Conductivity Meter System

A pressure switch activates an alarm at rising gas
pressure in the primary water tank.
The conductivity of the primary water is monitored:
In addition, a pressure gauge is provided for local
observation of the tank gas pressure.
Downstream of ion exchanger
Upstream of primary water inlet of generator
Differential pressure across main filter
Differential pressure across fine filter
The measuring point downstream of the ion exchanger
is used to monitor the functional capability of the ion
Differential pressure transmitters are provided
exchanger.
across both these filters for indication of differential
This measuring point upstream of the primary water
pressure and also for initiating alarm.
inlet allows the conductivity of the entire primary cooling
water to be monitored.
Differential pressure across the stator winding
The two metering systems are provided with indicating
The hydraulic resistance of the stator winding is
and alarm functions.
monitored with a differential pressure transmitter.
Differential pressure is a reliable parameter for
2 Level Monitoring System
monitoring the water cooling system.Any increase in
surface roughness in the cooling ducts of the stator
The coolant level in the primary water tank is measured
winding or blocking of the cooling ducts due to the buildup
by means of capacitive level detectors, and an alarm is
of corrosion products is indicated by a rise in differential
triggered to indicate high level or low level.
pressure.An increase in differential pressure of upto 10%
A local water level indicator is provided in parallel
is normal and can be neglected.
to the electrical level monitoring system .
5 Temperature Detectors
3 Volume Flow Meter System
The following temperatures are measured locally by
Temperature gauge
The primary water flow through the
Primary water temperature Upstream
Stator winding
and downstream of coolers.
Teminal Bushings
Primary water temperature downstream of
is measured and indicated using a vortex flowmeter
bushings.
measuring system.If the flow drops below a specified
minimum rate , an alarm is activated. If the flow rate
Resistance temperature detectors are used to
continues to drop, the mechanical protection equipment is
measure the followings temperatures for further
tripped.
processing according to different methods:
The amount of primary water flowing through the ion
exchanger is measured using a local flowmeter.If the flow
Primary water temperature upstream and
drops below a specified minimum rate , an alarm is
downstream of coolers
activated.
Primary water temperature upstream and
The amount of make up water added to the primary
downstream of stator winding
water system during operation is determined by means of
Primary water temperature downstream of
a water meter.
bushings
4 Pressure GaugesPressure levels and differential
pressure levels in the primary water system are measured
Also refer to the following section
at the following locations.
[1] 2.1-7311 Primary Water Diagram

1111E
Turbogenerators
Supervision of Exciter
Operation
The most essential measuring and supervisory wheels may be checked during operation with the built-
devices at the exciter are: in stroboscope.
Q Temperature monitoring system 3 Ground Fault Detection System

Q Fuse monitoring system
Q Ground fault detection system Two sliprings are installed on the shaft between the
Q Excitation current measuring device main exciter and bearing. One is connected to the star
point of the three-phase winding of the main exciter and
1 Temperature Monitoring System the other to the frame. These sliprings permit ground
fault detection.
The exciter is provided with devices for monitoring
the temperatures of the cold air after the exciter cooler 4 Excitation Current Measuring Device
and the hot air leaving the rectifier wheels and hot air
leaving the rectifier wheels and main exciter. The excitation current is measured indirectly
through a coil arranged between two poles of the main
2 Fuse Monitoring System exciter. The voltage induced in this coil is proportional
to the excitation current thus enabling a determination
The indicator flags of the fuses on the rectifier of the excitation current.

1111E
Turbogenerators Exciter
Description
permanent magnet poles. The three-phase AC generated

1 Design Feature
by the permanent-magnet pilot exciter is rectified and
The exciter consists of
controlled by the AVR to provide a variable DC current
-Rectifier wheels for exciting the main exciter. The three-phase AC is
-Three-phase pilot exciter induced in the rotor of the main exciter. This three-phase
-Cooler AC induced in the rotor of the main exciter is rectified by
-Metering and supervisory equipment the rotating rectifier bridge and fed to the field winding
of the generator rotor through the DC leads in the rotor
shaft.
5 4 3 2 1
2
4
5
1
1 Coupling
2 Rectifier wheel
3 Rotor of main exciter
7 4 Fan
5 Permanent magnet rotor
Fig. 2 Exciter Rotor
The exciter rotor shown in fig. 2 corresponds to the

basic arrangement described above. A common shaft
carries the rectifier wheels, the rotor of the main exciter
8 and the permanent-magnet rotor of the pilot exciter. The
shaft is rigidly coupled to the generator rotor. The exciter
shaft is supported on a bearing between the main and
9
pilot exciter. The generator and exciter rotors are thus
10 supported on total of three bearings.
Mechanical coupling of the two shaft assemblies
results in simultaneous coupling of the dc leads in the
1 Automatic voltage regulator central shaft bore through the Multicontact electrical
2 Permanent magnet pilot exciter contact system consisting of plug-in bolts and sockets.
3 Sliprings for field ground fault detection This contact system is also designed to compensate for
4 Quadrature-axis measuring coil length variations of the leads due to thermal expansion.
5 Three-phase main exciter
2 Rectifier Wheels
6 Diode rectifier set
7 Three-phase lead
The main-components of the rectifier wheels are the
8 Multicontact connector
silicon diodes which are arranged in the rectifier wheels
9 Rotor winding of turbogenerator
in a three-phase bridge circuit. The contact pressure for
10 Stator winding of tubogenerator
the silicon wafer is produced by a plate spring assembly.
The arrangement of the diodes is such that this contact
Fig. 1 Basic Arrangement of Brushless Excitation System pressure is increased by the centrifugal force during
With Rotating Diodes rotation.
Fig. 3 shows additional components contained in the
Fig. 1 shows the basic arrangement of the exciter.
rectifier wheels. Two diodes each are mounted in each
The three-phase pilot exciter has a revolving field with
aluminum alloy heat sink and thus connected in parallel.

1111E
1 2 3 6 5 3 4
1. Diode 2. Fuse 3. Diode Rectifier Wheel 4. Exciter armature
3. Diode Rectifier Wheel 5. Wound armature 6. Exciter main stator
Fig. 3 Rectifier Wheel
Associated with each heat sink is a fuse which serves to

switch off the two diodes if one diodes fails (loss of
reverse blocking capability).
For suppression of the momentary voltage peaks

arising from commutation, each wheel is provided with
six RC network consisting of a capacitor and a damping
resistor each, which are combined in a single resin-
encapsulated unit.
The insulated and shrunken rectifier wheels serve
as DC buses for the negative and positive side of the
rectifier bridge. This arrangement ensures good
accessibility to all components and a minimum of circuit
connections. The two wheels are identical in their 7 8 3 4
mechanical design and differ only in the forward
directions of the diodes. 3. Stator
The direct current from the rectifier wheels is fed to 4. Amature Rotor
7. Sliprings for ground fault detection
DC leads arranged in the center bore of the shaft via
8. Bearing housing
radial bolts.
The three-phase alternating currents is obtained via Fig. 4 Main Exciter
copper conductors arranged on the shaft circumference
between the rectifier wheels and the three-phase main compression rings. The three-phase winding is inserted
exciter. The conductors are attached by means of in the slots of the laminated armature rotor. The winding
banding clips and equipped with screw-on lugs for the conductors are transposed within the core length, and
internal diode connections. the end turns of the rotor winding are secured with steal
bands. The connections are made on the side facing the
3 Three-Phase Main Exciter rectifier wheels. The winding ends are run to a bus ring
system to which the three-phase leads to the rectifier
The three-phase main exciter is a six-pole revolving-
wheels are also connected. After full impregnation with
armature unit. Arranged in the stator frame are the poles
synthetic resin and curing, the complete armature rotor
with the field and damper winding. The field winding is
is shrunk onto the shaft. A journal bearing is arranged
arranged on the laminated magnetic poles. At the pole
between main exciter and pilot exciter and has forced
shoe bars are provided. Their ends being connected so
oil lubrication from the turbine oil supply.
as to form a damper winding Between two poles a
quadrature-axis coil is fitted for inductive measurement
4 Three-Phase Pilot Exciter
of the exciter current.
The armature rotor consists of stacked laminations,
The three-phase pilot exciter is a 16 pole
which are compressed by through bolts over
revolving-field unit. The frame accommodates the
2.1-9100-0600/2
Turbogenerators Exciter
Description
in a closed circuit and cooled in two cooler sections

arranged alongside the exciter.
The complete exciter is housed in an enclosure draw
the cool air in at both ends and expel the warned air to
the compartment beneath the base plate.
The main exciter enclosure receives cool air from
the fan after it passes over the pilot exciter. The air enters
the main exciter from both ends and is passed into ducts
below the rotor body and discharged through radial slots
in the rotor core to the lower compartment. The warm
air is then returned to the main enclosure via the cooler
sections.
6 Replacement of Air Inside Exciter Enclosure
When the generator is filled with hydrogen (operation

1 2 3 or standstill) an adequate replacement of the air inside
the exciter enclosure must be ensured. The air volume
1 Stator
2 Pilot exciter Stator winding inside the exciter enclosure requires an air change rate
3 Permanent magnet rotor of 125 m3/h.
While the generator is running, the air leaving the
Fig. 5 Permanent-Magnet Pilot Exciter
exciter enclosure via the bearing vapor exhaust system
laminated core with the three-phase winding. The and the leakage air outlet in the foundation provides for
rotor consists of a hub with mounted poles. Each pole a pull-through system. The volume of air extracted from
consists of 12 separate permanent magnets which are the cooling air circuit is replaced via the filters located
housed in a non-magnetic metallic enclosure. The at the top of the enclosure.
magnets are braced between the hub and the external When the generator is at rest, the air dryer of the
pole shoe with bolts. The magnet hub is shrunk onto exciter unit discharges dry air inside the exciter
the free shaft end. enclosure. The air leaves the exciter enclosure via the
leakage air filter and the leakage air outlet at the shaft
5 Cooling of Exciter as well as via the bearing vapor exhaust system if this
system is in service.
The exciter is air cooled. The cooling air is circulated

1111E
Turbogenerators Basic Arrangement of Brushless
Excitation System
Description
1 4
10
1 Automatic voltage regulator 6 Diode rectifier set

2 Permanent magnet pilot exciter 7 Three-phase lead
3 Sliprings for field ground fault detection 8 Multicontact connector
4 Quadrature-axis measuring coil 9 Rotor winding of turbogenerator
5 Three-phase main exciter 10 Stator winding of tubogenerator

1111E
Turbogenerators
Rectifier Wheels
Description
1
~
3
4
6 Current path
7 - +
8
4
3
10
+ _
1 AC lead 6 Hot air outlet

2 Fuse 7 Tension bolt
3 Heat sink 8 Terminal bolt
4 Diode 9 Rectifier wheel (-ve polarity)
5 Rectifier wheel (+ve polarity) 10 DC lead

1111E
Turbogenerators Rectifier Wheels and Coupling
Description
1 Balancing Weight
2 Fuse
4 3 Rectifier wheels
4 Diode
5 Multi Contact band
6 DC lead
7 Coupling
8 Contact pin
5 6 7 7 8
Exciter coupling without Contact pin Exciter coupling with Contact pin

1111E
Turbogenerators Permanent-Magnet
Description Pilot Exciter Rotor and Fan
4 5
1 2 3 4
1 Permanent magnet pole

2 Fan
3 Sliprings of field ground earth fault detection
4 Rotor of main exciter

1111E
Turbogenerators
Exciter Cross Section
General
1 2 3 4 5 6 7 8 9 10 11 12 13 14
20 19 18 17 16 15
1 Coupling with connector 6 Magnetic pole of main exciter 11 Radial flow fan 16 Cooler
2 Fuse 7 Main exciter rotor 12 Pilot exciter stator 17 Armature balancing ring
3 Heat sink 8 Main exciter stator 13 Pilot exciter rotor 18 Air housing
4 Rectifier wheels 9 Sliprings for ground fault detection 14 Exciter enclosure 19 Base frame
5 Diode 10 Bearing 15 Foundation 20 DC lead
0310E
Turbogenerators Exciter cooling Air circuit
Description During operation
to bearing vapour exhauster

Leakage air and makeup air
C
Cold air
Hot air
A
Section A-B
Section C-D

1111E
Turbogenerators Stroboscope for Fuse Monitoring
Description
The fuses on the rectifier wheels may be checked sequence of flashes can be interrupted at any time by
during operation with the stroboscope. A separate flash actuating the Feed or Return push-button. Following
tube is provided for each wheel (A and B). The tubes, this, a stationary image is obtained which ensures
which are supplied through a common control unit, are accurate checking of a single fuse. After approximately
permanently installed in the rectifier wheel enclosure. two minutes, the stroboscope is automatically switched
This permits easy monitoring without any adjustment off. If this period should not be sufficient for fuse
outside the exciter enclosure being required. checking, switching on the stroboscope for another two
Fig. 1 shows the basic arrangement of a fully minutes without delay can be repeated for any desired
transistorized stroboscope The electronics required for number of times by depressing the On push-button.
control of the light signals are contained in the control The stroboscope contains four plug-in printed circuit
unit and in the tubular lamps. The tubular lamps are boards which can be readily replaced in order to remedy
connected to the control unit by cables. any faults.
The stroboscope is located in the rectifier wheel and The capacitor and high-voltage transformer required
exciter enclosure so that the fuses may be observed from to produce the firing pulses for the flash tubes are located
outside the exciter enclosure while controlling the on a printed circuit board which is accommodated in the
stroboscope. handle of the flash lamp.
To synchronize the sequence of flashes with the The operating elements are located on the front panel
generator rotation, the system frequency is utilized to of the control unit for ease of operation. A depressed
activate the flashes. A double synchronous motor, push-button is indicated by an illuminated dot in the push-
controlled through two push-button and connected to two button head.
potentiometers and IC's, causes the flash to be timed The line connector, the two connectors for the flash
so that a slow-motion observation of the fuse becomes lamps and the fuse are located on the back of the control
possible. unit.
The Observation period for one full revolution of the All connectors have a mechanical lock and are
rectifier wheel (360 0) is approximately 25 seconds. At protected against dust and splash water. The cables are
approximately 4500, the flash is reset to its initial rate, run in flexible metal hoses for protection against
and the observation can be repeated. The continuous mechanical damage.
1 2 3 4 5 67 8 9 10
1 Flash tube 1 (A wheel) 5 Feed pushbutton 8 On pushbutton

2 Control unit 6 Pilot lamp for control voltage 9 Off pushbutton
3 Pushbutton for flash tube 1 7 Return pushbutton 10 Flash tube 2 (B wheel)
4 Pushbutton for flash tube 2
Fig.1 Components and Operating Elements of Stroboscope

1111E
Turbogenerators Exciter Drying System
Description
1 General adsorption section of the dryer wheel, with part of the

moisture contained in the air being removed by the
A dryer (dehumidifier) and an anti-condensation heating
adsorbent material, i.e. lithium chloride. The moisture is
system are provided to avoid the formation of moisture
condensate inside the exciter with the turbine-generator at
1 2 3 4 5
rest or on turning gear.
2 Mode of Operation
The dryer dehumidifies the air within the exciter

enclosure. The dryer wheel is made of a nonflammable
material. On its inlet side, the wheel is provided with a
system of tubular ducts, the surfaces of which are
impregnated with a highly hygroscopic material. 5 4 6 7
The tubular ducts are dimensioned so that a laminar
1 Regeneration air outlet
flow with low pressure loss is obtained even at high air
2 Dryer wheel
velocity. 3 Heater
The moisture absorbed by the dryer wheel is removed 4 Ventilator
5 Filter
in a regeneration section by a stream of hot air directed
6 Shutoff valve
through the wheel in the opposite direction of the inlet air 7 Dry air outlet
and then discharged to the atmosphere.
After regeneration, the dryer wheel material is again
capable of absorbing moisture. Fig. 1 Schematic Diagram of Dryer
The adsorption of moisture and regeneration of the
dryer wheel material take place simultaneously, using removed as a result of the partial pressure drop existing
separate air streams, which ensures a continuous drying between the air and the adsorbent material.
of the air.
2.1.2 Regeneration Section
In the regeneration section of the dryer wheel, the
2.1 Operating Principle of Adsorption Dryer
accumulated moisture is removed from the dryer wheel by
The dehumidification takes place in a slowly rotating
the heated regeneration air.
dryer wheel (approximately 7 revolutions per hour). The
Continuous rotation of the dryer wheel ensures
honeycomb dryer wheel consists of a magnesium silica
continuous dehumidification of the air within the exciter.
alloy containing crystalline lithium chloride. The inlet side
of the dryer wheel is subdivided so that 1/4 is available for 3 Anti-condensation Heating System
regeneration and 3/4 for the adsorption section. An Anti-condensation heating system to support the
dryer is installed in the exciter base frame. The heaters
2.1.1 Adsorption Section
are rated and arranged so that the temperature in the exciter
The air to be dehumidified passes through the
interior.

1111E
Turbogenerators
Ground Fault Detection System
Description for Exciter Field Circuit
The field ground fault detection system detects high- fault detection system consists of two stages and
resistance and low-resistance ground faults in the exciter operates continuously.
field circuit. It is very important for safe operation of a If the field ground fault detection system detects a
generator, because a double fault causes magnetic ground fault, an alarm is activated at RE < 80 kΩ (1st
unbalances with very high currents flowing through the stage). If the insulation resistance between the exciter
faulted part, resulting in its destruction within a very short field circuit and ground either suddenly or slowly drops
time. It is therefore an essential requirement that even to RE < 5 kΩ the generator electrical protection is tripped
simple ground faults should activate an alarm and (2nd stage).
protective measures be initiated, if possible, before the The generator is thus automatically disconected from
fault can fully develop. For this reason, the field ground the system and de-excited.

1111E
Turbogenerators Arrangement of Bursh Holders for
Description Ground Fault Detection System
A B
1 Measuring sliprings
2 Measuring brush
3 Mounting plate
4 Brush carrier segment
6
5 Plug-in brush holder
6 Measuring rod
7 Measuring leads
Section A-B

1111E
Turbogenerators Brush Holders for Ground Fault
Description Detection System
1 Handle
2 Bayonet sleeve
3 Brush contact pressure adjustment
4 Compression spring
5 5 Brush pigtail
6 Measuring brush

1111E
Turbogenerators Operating and Setting Values
Operation General
Strict observance of the operating and setting The operating and setting values initially
values is a prerequisite for reliable operation of the specified in this manual are based on experience
Turbogenerators. under due consideration of the specific site conditions,
Separate tables are provided for the various such as static head in case of pressure measuring
design groups of the generator and its auxiliaries. p o i n ts o r t h e r m a l c h a r a c t e r i s t i c s i n c a s e o f
They show the transmitters activating the controls and temperature measuring points. These calculated
alarms as well as the transmitters acting on the values are intended as guiding values for making the
generator protection circuits. preliminary settings during initial commissioning of the
The Remark column contains additional unit.
information on controls, temperatures and pressures. These settings require certain corrections to
All operating and setting values refer to rated account for the actual conditions. The final settings
output of generator and maximum cooling water obtained after startup and initial load operation are to
temperatures under steady-state conditions. be entered in the Operating Value column.

1111E
Turbogenerators
Gas Quantities
Operation
Gas Startup Shutdown Operation Recommended Stock
Replacement of air in Startup :

Replacement of H2 in Not permitted
Generator housing*: Generator housing*: 3. V1
CO 2
V1 = 2.V V1 = 2.V During operation :
2. V1
Replacement of CO2 in
Compensation for H2
generator housing*:
losses :
V1 = 2.5 V 2.( V1 + V2)
H2 Not required 0.5 m3/hr (s.t.p.)
Filling to operating
+ consumption**
pressure :
V2 = p e.V
Replacement of CO2 Supply of 40-60 dm3 /s

Not required Not permitted
(s.t.p.) compressed air
Air in generator housing* :
from air system must
V1 = 3.V be ensured
Reduction of O2 Reduction of O2
N2 Reduction of H2 content of Primary
content of Primary
content of Primary water introduced by 100 m3 (s.t.p.)
water:
water to be drained: makeup warer:
50 m3 (s.t.p.)
10 m3 (s.t.p.) 6 m3 (s.t.p.)/addition
* It is assumed that generator is at rest during gas filling and removal. Filling during turning gear operation will result
in a higher gas consumption. Due to the whirling motion between the medium to be displaced and medium admitted,
the purity deteriorates so that more gas is required for scavenging.
** Consumption: H2 purity measurement : 20 dm3/hr (s.t.p.)

Primary water leakage monitoring system : 120 dm3/hr (s.t.p.)
Primary water purging gas system : 100 - 300 dm3/hr (s.t.p.)
s.t.p. = Standard temperature and pressure, 0oC and 1.013 bar

1111E
In the following, an example is given to illustrate Amount of H2 required to fill generator to operating
the calculation of the amounts of CO2, H2 and air required pressure (operating pressure in bar x generator volume)
for filling. In the example one given generator volume
V2 = Pe . V = 4 . 80 m3 = 320 m3 (s.t.p.)
and one given operating pressure are assumed. The
values for other generator sizes, operating pressures and
V2 320 m 3 (s.t.p.)
gas bottle sizes will vary accordingly. Z = ---- = -------------------- ~ 53 H 2 bottles
V3 6 m3 (s.t.p.)
1 Example 1.2 Purging
Amount of CO 2 required for removing H 2 (2
Pe = Operating pressure, e.g. 4 bar generator volumes)
V = Generator volume, e.g. 80 m3
V1 = Amount of gas to fill or purge generator V1 = 2 . V = 2 . 80 m3 = 160 m3 (s.t.p.)
V2 = Amount of gas to fill generator to operating
pressure V1 160 m3 (s.t.p.)
Z = ---- = ----------------- ~ 11 CO2 bottles
V3 = H2 bottle volume, e.g. 6 M3 (s.t.p.) V4 15 m3 (s.t.p.)
V4 = CO2 bottle volume, e.g. 15 M 3 (s.t.p.)
Z = Number of bottles required
Amount of compressed air required for removing
CO2 (3 generator volumes)
1.1 Filling
V1 = 3 . V = 3 . 80 m3 = 240 m3 (s.t.p.)
Amount of CO 2 required for removing air from
1.3 Bottle Volume
generator (2 generator volumes)
H2 bottle 40 Liters at 150 bar = 6 m3 (s.t.p.)

V1 = 2 . 80 m3 = 160 m3 (s.t.p.)
H2 bottle 50 Liters at 200 bar = 10 m 3 (s.t.p.)
V 160 m 3 (s.t.p.) CO2 bottle : 40 Liters = 15 m 3 (s.t.p.)

Z = ----1 = -------------------- ~ 11 CO2 bottles
V4 15 m 3 (s.t.p.) 45 = 17
66.7 = 25.2
Amount of H 2 required for removing CO 2 from

It should be taken into consideration that the bottle
generator (2.5 generator volumes)
contents cannot be completely used up. For H2 bottles it
is assumed that the contents can be expanded to a
V1 = 2.5 . V = 2.5 . 80 m3 = 200 m3(s.t.p.)
pressure of approximately 1 bar above the operation
pressure. This means approximately 3% of the bottle
V1 200 m3 (s.t.p.) contents at a final pressure of 4 bar will remain following
Z = ---- = -------------------- ~ 33 H2 bottles
V3 6 m3 (s.t.p.) a fill to 3 bar.
* For reasons of safety, a sufficient number of full CO 2 bottles

must be available prior to starting with any generator filling
operations.
2.3-4010-0600/2
Operation Generator Supervision
Parameters Tag No. Minium Setting value Operating Max.Setting Value Unit Remarks

Value
Control Protection Alarm Control Protection Alarm
MKA20 CT001A,1B to
Stator Slot Temp. 50‐80 >80
MKA20 CT0012A,12B °C
TE‐MKA11 CT001 to
MKA11 CT006
Stator Core Temp. <90 >90 °C
EE‐MKA13 CT001 to
MKA13 CT006
(A/B)‐ MKA71 CT011A ,11B
>55 High
Cold Gas Temp. after H2 to MKA 71 CT013A,13B
<45 >60 °C
Cooler (C/D)‐MKA71 CT031A,31B
>60 High High
to MKA71 CT033A,33B
Hot Gas Temp. before H2 MKA72 CT011A,11B
40‐75 >80 °C
Cooler MKA72 CT012A,12B
Temp. Cold Gas (Left)‐EE MKA70 CT019A,19B <45 >55 °C
Temp. Cold Gas (Right)‐EE MKA70 CT039A,39B <45 >55 °C
PGB30 CT501
Cooling Water Temp.
PGB31 CT001A,1B 39 >39 °C
before H2 Cooler
PGB31 CT002A,2B
A‐PGB32 CT001A,1B
Cooling Water B‐PGB32 CT002A,2B
47 >67 °C
Temp.after H2 Cooler C‐PGB32 CT003A,3B
D‐PGB32 CT004A,4B
MKD11 CT013A,13B,13C >90 High
Gen.Bearing Temp. TE <90 >130 °C
MKD11 CT017A,17B,17C >130 High High
Gen.Bearing Temp. EE <90 >130 °C
>84 micron High
Gen.Bearing Vib‐ TE <84
>106 pk‐pk High High
Gen.Bearing Vib‐ EE <84 >84 micron High

>106 pk‐pk High High

Operation Seal Oil System
Parameters Tag No. Minium Setting value Operating Max.Setting Value Unit Remarks

Control Protection Alarm Value Control Protection Alarm
Temp. H2 Side Seal Oil
MKW04 CT010A,10B 50‐60 >70 °C
Drain‐TE
Temp. H2 Side Seal Oil
MKW05 CT010A,10B 50‐60 >70 °C
Drain‐EE
Vacuum in Seal Oil MKW10 CP001 Switch on/off
<‐0.65 ‐0.5 >‐0.4 bar
Tank MKW10 CP501 vacuum pump
Pressure After Pump MKW11 CP001 Auto C/O to
<8 <8 10 bar
MKW11AP001 MKW11 CP501 MKW12AP001
Pressure After Pump MKW12 CP001 Auto C/O to
<8 <8 10 bar
MKW12AP001 MKW12 CP501 MKW11AP001
Pressure after Stand by MKW13 CP001 <8 <8 10 bar

Pump MKW13AP001 MKW13 CP501
DP across seal oil Filter MKW21 CP021 <0.9 >0.9 bar
Temp. of Seal Oil
MKW11 CT001A,1B 66 °C
before cooler
MKW21 CT001A,1B >50 High
Temp. after Filter 45 °C
MKW21 CT501 >55 High High
Seal Oil Flow TE MKW31 CF551 <60
Seal Oil Flow EE MKW32 CF551 <60
Seal Oil Pressure to MKW31 CP051
6.5
Seals MKW31CP551 <4.5
Ring Relief oil Flow TE MKW35 CF551 <15
Ring Relief oil Flow EE MKW36 CF551 <15
Seal Oil/H2 DP <0.9 <0.9 1.5
BHEL, HarIdwar 2.3-4050-0600/1

Operating
Parameters Tag No. Minium Setting value Max.Setting Value Unit Remarks
Value
H2 Bottle MKG11CP501 <15 bar

Pressure MKG11CP001
MKG25 CP001 to
H2 Casing MKG25CP003 <0.2 <4.8 5 5.2 bar
Pressure MKG25CP503
<95
<90 >97
H2 Purity MKG25CQ001 <90 %H2
CO2 Bottle
100-150 bar
Pressure MKG51CP501
Temp. CO2 MKG51
On/Off
Flash CT001A,1B <145 120-130 >150 >150 °C
Evaporator
Evaporator MKG51 CT501
The operation and setting values refer to rated output of generator and maximum cooling water temperature.
All pressures indicated in bar are gauge pressures.

Turbogenerators Operating And Setting Values
Operation Primary Water System
Operating
Value
Temp. PW O/L Manifold MKA27 CT001A,1B to 76 >80 °C

MKA27 CT003A,3B
MKF01 CL001 <155 low low , low ,
PW Water Tank Level <100 225 >225 mm
MKF01 CL501 <195 High High
MKF11 CP001 Auto C/O to
Pr. After Pump-1 <5 5 >5 bar
MKF11 CP501 pump-2
MKF12 CP001 Auto C/O to
Pr. After Pump-2 <5 5 >5 bar
MKF12 CP501 pump-1
MKF41 CP001
Pr. At the inlet of Wdg <4.5 >4.8
MKF41 CP501
DP across Stator Wdg MKA20 CP021 0.7 bar
DP across main filter MKF27 CP021 <0.9 >0.9 bar
MKF21 CT001A,1B
Temp before PW Cooler 76 °C
MKF21 CT501
MKF21 CT506
Temp after PW Cooler 49 °C
MKF29 CT511
DP across the Fine Mesh
MKF35 CP021 <0.9 >0.9 bar
filter
Conductivity after Ion On/Off Dosing
MKF35 CQ001 <1 <1 1-3.0 >3
exchanger Pump
Conductivity after Main >2.5 >3
MKF29 CQ011 <1 <1 1-2.5 µS/cm
filter >4.0 >4 **
Temp of PW at inlet of MKF29 CT011A,11B to
51 >60 >55 °C
wdg MKF29 CT013A,13B
Temp of PW at Outlet of
MKF41 CT011A,11B 76 >80 °C
wdg
MKF80 CP011 Leakage of H2
Gas Pressure PW tank <0.3 >0.3 bar
MKF80 CP511 in PW circuit
Flow at outlet of Stator MKF41 CF011A ,11B
<64 <72 80 m3/hr
Wdg MKF41 CF012
Flow to bushings <2.38 <2.54 2.75 m3 /hr
** For Conductivity >2.5 Dosing pump of f

>4.0 Flush with fresh DM water
The operating and setting values refers to rated output of generator and maximum cooling water temperatures.

Operation Exciter Supervision
Operating
Value
Temp of cold air , Main MKC80 CT012A,12B on/off
<43 <45 >50 °C
exciter MKC80CT014A,14B drier
Temp of Hot air , Main MKC82 CT001A,1B to
<75 >75 °C
exciter MKC82 CT003A,3B >80
Temp of Hot air, Rectifier
MKC84 CT002A,2B <75 >75 °C
Wheels
Temp after Exciter cooler
PGB42 CT001A,1B <42 >42 °C
E
Temp after Exciter cooler
PGB42 CT002A,2B <42 >42 °C
F
>84 micron
Exciter brg Vibration <84
>106 pk-pk
>200 micron
Exciter Shaft Vibration <200
>320 pk-pk
Exciter Brg Temp <90 >130 °C
BHEL, Hardwar 2.3-4090-0600/1

Turbogenerators Running Routine
Operation General
1. Operating Log turbogenerators should be noted separately. Such notes

During initial startup and during normal operation, the may be useful in determining the cause of any subsequent
hydrogen-cooled Turbogenerators, auxiliaries and all trouble and speeding up corrections.
instruments and controls should be monitored to assure
continuous reliable operation. The observations and 2. Normal and Special Operating Conditions
readings should be recorded. A typical operating log is The Generator should be continuously monitored from
contained in these operating instructions. This table will, startup to shutdown. During initial startup, all checks should
of course, have to be adapted to the particular conditions be made at frequent intervals. Hourly readings may be
of the plant. The important requirement is that all checks taken after completion of the initial period.
and readings be made at certain predetermined intervals A generator at standstill is considered to have been
and preferably at the same load point. Any special taken into service and must be continuously monitored after
conditions regarding the operation of the hydrogen-cooled one supply system was placed in operation.

1111E
Turbogenerators Operating Log
Operation Generator Supervision
Job name ............................................................ Sl. No. ............................................ Remark .............................................
Operating values* Unit Tag Date

Number
Active power MW
Reactive power MVAR
Stator current kA
Stator voltage kV
Rotor current A
-1
Speed s
2
Generator gas pressure kg/cm
0
Slot 1 C
0
2 C
0
Slot temperature 3 C
0
4 C
0
5 C
0
6 C
0
Primary water Measuring point 1 C
0
outlet temperature Measuring point 2 C
0
TE water manifold measuring point 3 C
0
Measuring point 1 C
0
TE Measuring point 2 C
0
Stator core Measuring point 3 C
0
temperature Measuring point 1 C
0
EE Measuring point 2 C
0
Measuring point 3 C
0
Coolers a/b cold C
0
Coolers c/d cold C
0
Gas temperature Coolers a/b hot C
0
Coolers c/d hot C
0
EE After coolers a/b C
0
EE After coolers c/d C
0
Inlet C
0
Bearing oil TE C
Outlet 0
temperature EE C
0
Generator bearing TE C
0
temperatures EE C
2
TE kg/cm
Shaft lift oil pressure 2
EE kg/cm
TE ahv mm
Generator bearing vibration
EE ahv mm
* Data should be recorded during steady-state conditions after constant operation for several hours.

1111E
Job name:………………… SI. No.:……………………… Remark : …………………..
Operating values1) Unit Date

Tag Number
H2 side seal oil drain temperature TE °C MKW06CT001

EE “C MKW07CT001
Air side seal oil drain temperature “C MKW08CT001
Vacuum in the seal oil tank bar MKW10CP501
Seal oil pressure after ACSOP- 1 bar MKW11CP001
bar MKW11CP501
Seal oil pressure after ACSOP-2 bar MKW12CP001
MKW12CP501
Seal Oil Pressure after DCSOP bar MKW13CP001
MKW13CP501
Seal oil differential pressure across duplex filter bar MKW21CP021
Seal oil Temperatures before coolers “C MKW11CT001
MKW11CT501
Seal oil temperature after filter °C MKW21CT001
“C MKW21CT011
“C MKW21CT021
MKW21CT031
Seal oil flow TE dm 3/s MKW31CF551
Seal oil flow EE dm 3/s MKW32CF551
Seal oil pressure before shaft seals bar MKW31CP051
MKW31CP501
3
Ring relief oil volume flow TE dm /s MKW35CF551
Ring relief oil volume flow EE dm 3/s MKW36CF551
1) Data should be recorded during steady-state conditions after constant operation for several hours.

1111E
Operating values* Unit Tag. Date

Number
H2 boottle pressure kg/cm2
CO2 boottle pressure kg/cm2
N2 boottle pressure kg/cm2
H2 purity (elec. purity meter system) % H2
H2 purity (mech. purity meter system)** % H2
Gas flow for measuring H2 purity I/h
H2 casing pressure kg/cm2
Temperature before gas dryer 0

C
Pressure before gas dryer kg/cm2
* Data should be recorded during steady-state conditions after constant operation several hours.
** To be recordced only on failure of electrical purity meter system.

1111E
Operating values* Unit Tag. Date

Number
Generator inlet 0
C
Prinary water Stator winding outlet 0

C
Temperature Bushing outlet 0

C
Before coolers 0
C
After collers 0
C
Stator winding oulet dm 3/s
Bushing outlet U dm 3/s
Prinary water flow Bushing outlet V dm 3/s
Bushing outlet W dm 3/s
Treated water dm 3/s
Primary water Stator winding inlet kg/cm2

pressure After PW pumps 1/2 kg/cm2
Primary water After main filter µS/cm

conductivity After ion exchanges µS/cm
Primary water level in primary water tank %
Gas pressure in primary water tank kg/cm2

1111E
Operation Exciter Supervision
Operating values* Unit Tag Date

Number
0
Cold air C
Main exciter
Cooling air 0
temperature Hot air C
0
Rectifier wheels Hot air C
0
Coolers e/f Inlet C
Cooling water
temperature Cooler e Outlet
0
C
0
Cooler f Outlet C
0
Measuring Point 1 C
Exciter bearing temperature 0
Measuring point 2 C
0
Bearing oil outlet temperature C
Exciter shaft vibration Relative µm
Exciter bearing vibration Absolute µm
Shaft lift oil pressure kg
* Data should be recorded during steady-state conditions after constant operation several hours.

1111E
Turbogenerators Preparations for Starting
Operation Introduction
It is a prerequisite for startup of the turbine generator immediate removal of the hydrogen from the generator.
that continuous contracts be maintained between all plant 1.2.2 Hydrogen (H2)
sections directly or indirectly involved in the starting The hydrogen gas quantity to be provided should
procedure. suffice for displacing the CO2, for filling the generator to
Prior to startup, it should be ascertained that the operating pressure and to compensate for the H2 losses
following auxiliaries are in operation and will continue to during operation [4].
remain in service.
1.2.3 Nitrogen (N2)
Q Seal oil system For primary water purging [4].
Q Gas system
Q Primary water system 1.3 Primary Water Supply
Q Secondary cooling water system The water quantity to be provided for filling the entire
primary water circuit should amount to approximately two
If auxiliaries were taken out of operation, the times the primary water filling quantity. This allows for the
operating media required to fill the auxiliary systems water quantity required for rinsing the primary water circuit.
should be made available.
1.4 Cooling Water Supply
1. Operating Media The coolers to be placed in operation should be filled
with water. To do this, the cooler vents should be opened.
The operating media used, i.e.
Note : Continuous vents should remain open. The vents
Q Turbine oil should be kept open until the air on the water side of
Q Carbon dioxide (CO2) the coolers has been completely expelled.
Q Hydrogen (H2)
Q Nitrogen (N2) Before startup, the operating staff should ensure that
Q Primary water a sufficient cooling water supply is available.
must conform to the specifications [1] and [2]. 2. Checking the Transmitters
1.1 Seal Oil System Prior to startup, all connections should be rechecked.
The seal oil circuits should be filled with turbine oil. This applies to piping as well as to cabling. When checking
The quantity of turbine oil required to fill the seal oil circuits the cabling special attention should be paid to testing the
should be taken into consideration when filling the turbine metering and signal cables. All alarm systems should be
oil tank. checked.
All temperature measuring points should also be
1.2 Gas System checked. This applies to the local as well as the remote
reading thermometers. Unless temperature rises were
1.2.1 Carbon Dioxide (CO2) brought about by other preparatory work at the measuring
The carbon dioxide quantity to be provided should points, temperatures of approximately ambient or room
suffice for two complete generator fillings [3], i.e. for temperature should be indicated. When doubts exist
displacement of the air prior to hydrogen filling and for regarding the electrical temperature measurement,
calibration and line compensation should be repeated.
Also refer to the following information :

[1] 2.1 - 1883 Gas Specification
[2] 2.1 - 1885 Primary Water Specification
[3] 2.3 - 4010 Gas Quantities

1111E
Turbogenerators Hints for Cooler Operation
Operation
1 General Q The amount of suspended material must be as

small as possible.
The heat exchangers of the generator and its Q The growth of micro organisms and, in case of
auxiliaries have copper, copper alloy or stainless steel seawater installations, the growth of mussels must
tubes. Admiralty brass (CuZn28Sn) is primarily used for be prevented.
fresh-water applications, while aluminium brass
(CuZn20Al) is selected for seawater service. Cooling water obtained from a closed secondary
Copper and copper alloy tubes must from a cooling water circuit mostly meets these requirements
protective film on the cooling water side to ensure provided that the necessary care is exercised during
adequate resistance to corrosion attack. The formation initial operation, for example, by flushing the system
and the preservation of the protective film are essentially without passing water through the coolers.
dependent on the conditions during initial commissioning When using water directly obtained from natural
and subsequent service. water sources, adverse influences should be minimized
by suitable treatment procedures (e.g. filtration, dispersant
2 Cooler Tube Materials
dosing, chlorination and similar methods as specified in
The coolers of the unit described have copper, the literature).
copper alloy or stainless steel tubes.
4 Initial Operation of Coolers
Details of the cooler tube materials are specified
in the Technical Data section of this manual [1]. Prior to placing the coolers in operation for the first
time the cooling water system should be thoroughly
2.1 Copper or Copper Alloy Cooler Tubes
cleaned by flushing to remove impurities and foreign
Influences on the cooling water side can cause
matter.
damage to the copper or copper alloy tubes of the
During this flushing procedure, the coolers should
coolers, primarily in the form of erosion/corrosion and
not be in service on their cooling water sides, i.e. bypass
corrosion attack due to
arrangements must ensure that the flushing procedure
can be carried out without passing water through the
Q insufficient protective film formation
coolers. Following the flushing procedure, cooling water
Q excessive cooling water velocity
must be continuously passed through coolers with copper
Q localized, excessive cooling water velocity resulting
alloy materials for the longest possible period of time
from tube blockage by foreign bodies.
(four to eight weeks) to ensure the formation of an
Q deposits on tubes caused by suspended material
effective protective film on the cooler tubes.
and/or remnants of microorganisms which impair
the formation of a protective film and promote 5 Preventing Standstill Corrosion
corrosion, especially in (standby) coolers having
no cooling water flow for some time. Depending on the cooler material and the kind and
properties of the cooling water, standby coolers through
2.2 Stainless Steel Cooler Tubes which no cooling water flows for some period of time are
subjected to all corrosive influences that can occur during
Cooler tubes of stainless steel are susceptible to an outage.
pitting and crevice corrosion under deposits, especially This involves the risk that the microorganisms on
when the cooling water has a high salt content and the tube walls will die due to the lack of oxygen resulting
primarily when no cooling water is passed through the from the loss of fresh water supply and form decay
(standby) coolers for some time. The corrosion rate products during decomposition, such as ammonia.
decreases with increasing cooling water velocity. Depending on the material used, this may lead to
corrosion and/or stress corrosion cracking.
3 Cooling Water Properties Using cooler tubes of stainless steel with cooling
water having a high salt content involves the risk of pitting
The cooling water used for the coolers must meet and crevice corrosion when residual amounts of cooling
the following requirements : water, possibly in conjunction with deposits, produce a
corrosive influence.
Q The cooling water must be free from coarse Corrosion damage can only be safely prevented if
impurities the standby coolers are drained on their water sides,

1111E
cleaned, completely dried, vented, and maintained in a 7. Special Measures for Wet Preservation
dry condition.
For cleaning, the coolers may be flushed with water If a cooler has to be maintained ready for service
having a low salt content (Cl content < 500 mg/l for in filled condition, the water volume in the cooler must
copper alloy tubes, < 100 mg/1 for stainless steel tubes). not be hermetically sealed from the cooling water system
For drying the medium to be cooled can be passed or from the surrounding atmosphere, respectively
through the coolers via the filler and vent pipes. However, improper cooler changeover would then result in heating
this measure cannot be always implemented in practice, and excessive expansion of the cooling water volume,
especially in the case of brief outages and because of leading to damage to the cooler gaskets or piping due to
the need to maintain the cooler ready for operation. excessive pressure.
If a cooler has to maintained ready for service in For wet preservation always open a cooler vent
filed condition, it should be flushed with the full cooling on the water side or a shutoff valve by a small amount
water volume flow for a brief period twice every week. In making sure to avoid a low-velocity water flow that would
addition, it is recommended to perform a cooler promote the entry of suspended material.
changeover once every week so that the normal-service Note : Standby coolers should be maintained ready for
cooler and the standby cooler will be alternately in operation in dry condition in preference to wet
operation. preservation.
6. Preventing Deposits in Cooler Tubes 8. Cooler Changeover
Deposits in the cooler tubes are best prevented Make sure to fill and vent standby coolers on their
by supplying the normal-service coolers with the full water sides prior to changing over the coolers. Fully open
cooling water volume flow. shutoff valves. After cooler changeover, which must be
If the temperature of the medium to be cooled is performed by experienced personnel, perform all
controlled by varying the cooling water volume flow, it is measures required for preservation of the cooler
recommended to supply the normal-service cooler with removed from normal service and now on standby.
the full cooling water volume for a brief period twice every To do this, close shutoff valves upstream and
week in order to flush away any deposits formed on the downstream of the standby cooler, since the cooling
tubes due to insufficient cooling water velocity. water system is mostly designed only for supply of the
During occasional outages of sufficient duration or cooling water flow through the normal-service cooler(s).
during an overhaul, it should than be checked whether Then open the shutoff valve on the outlet side by a small
in-service flushing is sufficient or whether manual amount to avoid the effects of a water expansion due to
cleaning is required. If frequent manual cleaning is water heating.
necessary on account of poor cooling water conditions,
the installation of a high-velocity water cleaning system 8.1 Criteria for Cooler Changeover
or of a cleaning system using sponge rubber balls should A cooler changeover is necessary when, with the
be considered. valves in the cooling water circuit fully open, the
temperature of the medium to be cooled is rising above
the normal level or when required on account of abnormal
events (e.g. leakage).
Also refer to the following information :

[1] 2.1 - 1830 Cooler data
2.3-5003-0600/2
Turbogenerators Filling and Initial Operations
Operation of Seal Oil System
Preparatory Work
Caution: The seal oil system Is to be filled only with oil

complying with our specification [1].
1 Filling and initial operation
of seal oil system PrerequisIte for filling the seal oil circuits :
z Seal oil circuits were cleaned and flushed [2].

z Pump motors were checked for correct direction of
rotatIon.
z Bearing vapor exhauaters were checked for correct
direction of rotation and proper functioning.
2
Preparatory work
2.1
Adjust level detectors in liquid level detec- Carefully drain probe tank and reclose filler connections
tor rack with the probes immersed [3], [4] after completion of the functionaI tset.
2.2
Adjust level detectors for level detection
in seal oil system with the probes im-
mersed [3].
2.3
Check to ensure that regreasing device of axial
Check to ensure that bearing vapor
exhausters are ready for operation shaft seal is filled with a sufflcient quantity of grease.
Fill all existing loop seals in waste gas system with
turbine oil. Close drain valves.
2.4
Check valve positions for agreement Note: Pressure relief valves and seal oil pressure
with valve position list [5]. regulating valves have already been adjusted.
3
Start with filling of seal oil circuits
Also refor to tho following InformatIon

[1] 2.1-1880 Turbine Oil Specification
[2] 2.5-0320 FlushIng the Oil Piping
[3] 2.3-5510 Activating the Level Detector System
for Seal Oil System and Generator
Supervisory System
[4] 2.3-5520 Activating the Level Detector System
for Generator Supervisory System.
[5] 2.3-5108 Valve Positions in Seal Oil System for
Normal Operation

1111E
Turbogenerators Filling and Initial Operation
Operation of Seal Oil Circuit
Prerequisites for filling the air side seal oil circuit:

1 Filling Preparatory work was completed.
seal oil circuit
Valves must have been set according to the valve
position list.
Shutoff valves before all pressure gauges and pressure
transmitters must be open.
Since the oil for the seal oil system is taken from
the seal oil storage tank,the level of the seal oil storage
tank must be monitored when filling the seal oil system.If
required ,the filing of the seal oil system must be
interrupted to allow the seal oil storage tank to be filled
with turbine oil from
2
jacking oil or lubricating oil system being returned
Open shutoff valves MKW01AA276
and MKW10AA101 from the generator bearings.One of the two systems must
be activated during the filling procedure
3
Place vacuum pump and bearing Note: The seal oil cooler should be filled on its water side
vapor exhausters in service
and placed in operation only when the seal oil
temperature rises to >= 380C.
4 Fill seal oil vacuum tank with oil opening shut off
Start seal oil pump MKW11AP001 valves MKW01AA276 and MKW10AA101.
Place one exhauster in operation electrically. Ensure that

second exhauster is ready for startup.
With the seal oil tank filled, seal oil is available at the
seal oil pumps after a short time.
Start seal oil pump 1 (MKW11 AP001)by manual control.
4.1
Note: The seal oil ‘pump is deenergized when the level
Observe formation of oil foam in seal oil tank detector in the seal oil tank activates an alarm for low oil
level in seal oil tank. Seal oil pump is automatically restarted
when the seal oil tank has been refilled to the required
level (dry running protection).
When the oil foam rises above the observable level in

the oil sight glass in the seal oil tank, close shutoff valve
MKW10AA131 (before vacuum pump)
and fully open control valve
MKW10AA 132 (in vacuum pump bypass).
Throttle control valve MKW10AA132 and reopen shut off

valve MKW10AA131 as soon as seal oil tank is free from oil
foam. Repeat this procedure until the formation of oil foam
has ceased.

1111E
4.2
To do this, open valves
Fill and vent seal oil coolers
MKW21AA421 (filling valve, coolers 1 and 2)
MKW21AA251 (vent,cooler 1)
MKW22AA251 (vent,cooler 2).
Close vent valves as soon as oil - emerges from

vent valves without bubbles. Maintain filler valve
MKW21AA421 in open position.
4.3
Fill and vent seal oil filters To do this, open valvess.
MKW21AA131 (filling valve, coolers 1 and 2)

MKW21AA261 (seal oil filter 1)
MKW22AA261 (seal oil filter 2)
Close vent valves as soon as oil emerges from

vent valves. Maintain filling valve MKW21AA131 in open
position.
4.4
Change over pumps
Stop seal oil pump 1(MKW11 AP001) by manual
control. Then-start seal oil pump 2(MKW12 AP001)
and standby seal oil pump(MKW13 AP001). Stop
standby seal oil pump after a few minutes and change
over to seal oil pump 1 or 2.
4.5
Observe oil level in intermediate oil tank
Oil from the hydrogen side of the shaft seal will

continue to flow into intermediate oil tank MKW06
BB001, resulting in a rise of the oil level above the
sight glass. This is caused by the lack of pressure in
the generator.
5
Seal oil circuit is filled

Start with venting of seal oil circuit.

[1] 2.3-5113 Placing Vacuum Pump in Service
2.3-5110-0600/2
Turbogenerators Placing Vacuum Pump is Service
Operation
Placing the vacuum pump in service is required

whenever a seal oil pump is placed in operation.
1 Placing in service Check oil level in sight glass of vacuum pump.
Start vacuum pump Open gas ballast valve and close shutoff valve
MKW11AA21 to avoid the formation of moisture
condensatation as the pump is in cold condition.
3
Open shutoff valve after the pump has been put in
Open shutoff valve MKW11AA121
operation for approximately 30 minutes. Pump must be
warm to touch.
4
Use control valve MKW10AA011 to adjust vacuum
Adjust control valve MKW10AA011
in seal off tank to approximately-0.6 to -0.8 bar.
Vacuum Pump is in service

1111E
Turbogenerators Venting of Seal Oil Circuit
Operation
Prerequisite:
1 Venting seal oil circuit Seal oil circuit was filled and placed in service.
1.1
Keep venting screws open until the oil emerges
Vent pressure retaining valves downstream
of seal oil pumps without bubbles.
1.2
Fill and vent seal oil coolers Vent seal oil coolers by means of vent valves.
MKW21 AA 251 (seal oil cooler 1)

MKW22AA 251 (seal oil cooler 2)
Close vent valves when oil emerges from vent valves

without bubbles. Maintain filler valve in open position.
1.3
Keep vent valves MKW21 AA261 and MKW22AA261
Fill and vent seal oil filters
open until the oil emerges without bubbles. Maintain
filler valve in open position.
1.4
Vent all pressure gauges, except for MKW10CP001
Vent all signal lines to pressure measuring
devices through the venting screw at the and MKW10CP501 through the venting screws at the
respective shutoff valve respective pressure gauge shutoff valves.
1.5
Bypass of volume flow reglators
Briefly open regulating valves MKW35AA011 and
MKW36AA011 to fill pipe with oil and then reclose
regulating valves.
Venting of all components of seal oil

system is completed. Start with setting of the oil pressures.

Turbogenerators Setting of Seal Oil Pressures
Operation
Note: Seal oil units and seal oil valve rack were
subjected to a functional test at manufacturer’s works.
This included setting of seal oil pressures for operating
1 Setting Seal oil pressures
conditions to be expected.
Do not change any setting during commissioning
unless such a change is unavoidable.
2 Pressure regulating valves for seal oil pressures were

set at the manulacturer’s works. Any readjustments are
Seal oil circuit
normally only required after maintenance work or
replacement of the pressure regulating valves.
2.1
Adjust pressure retaining valves Pressure retaining valves

down-stream of seal oil pumps
MKW11 AA 001 (downstream of pump 1)
MKW12 AA 001 (downstream of pump 2)
MKW13 AA 001 (dcwnstream of pump 3)
were adjusted so that the delivery head of each pump

amounts to 13.5 bar when 50 % of the delivery flow is
discharged via the respective pressure retaining valve.
The seal oil pressure downstream of each pump is
adjustable by changing the spring pressure at the
associated pressure retaining valve. To do this, turn the
upper spring retainer in downward direction as
necessary.
2.2
Adjust pressure regulating valves

Pressure retaining valves
MKW31 AA 001 (for normal operation mode)

MKW32 AA 001 (for standby mode)
were adjusted with graded settings to prevent them from

responding simultaneously as far as practicable The
adjustments were make under due consideration of the
control characteristics of the valves [1].
Observe the following general requirements
With 100 % flow, (standby) pressure regulating valve

MKW 32AA001 should maintain the seal oil
pressure at the shaft seals at 1.0 bar above the gas
pressure in the generator.
The seal oil pressure obtainable with the above
setting at a volumetric flow rate of 20 dm3/min should
be equal to the seal oil pressure established by
pressure regulating valve MKW31 AA001 with 100%
flow.

1111E
Turbogenerators Setting of Seal Oil Pressures
Operation
Fig.1 Setting of Pressure Regulating Valves,

Schematic
Any required readjustment should be made as

follows:
Loosen lock nut at the respective valve stem

Turn adjusting nut to set the seal oil pressure
Retighten lock nut.
Set seal oil volumetric flow rate for seal Set seal oil volumetric flow rate for seal ring relief
ring relief by means of volume flow regulators MKW35AA001 and
MKW36AA001
Note: Final adjustment can only be made when the
generator is filled to rated pressure and operated at
rated speed. When making the final volumetric flow
rate setting, also check the turbine-generator vibration
levels, since an incorrectly set seal oil pressure for
seal ring relief may impair smooth running of the
generator.
Setting of the seal oil pressures is Start with setting and checking of alarm and
completed changeover device.

1111E
Turbogenerators Setting of Operating Values
Operation for Seal Oil System
Note: Seal oil units and seal oil valve rack were
subjected to a functIonal test at manufacturer’s works.
1 Setting of operating values This included setting and checkIng of all pressure
transmitters for operatIng conditions to be expected.
2
Alarm contacts at differential pressure indicator is
Differential pressure transmitters at set so that an alarm is activated when a predetermined
seal oil filters degree of fouling is exceeded.
3 Pressure transmitters for alarm and changeover

devices were set at the manufacturer’s works. Do not
Set pressure transmitters
change settings unless such a change is unavoidable.
Resetting is normally only required after replace-
ment of the pressure transmitters.
To do this observe the following procedure:
Close shutoff valve upstream of pressure

transmitter. Remove cap at test connection.
Connect a hand pump with pressure indicator to
test connection (if provided, open shutoff valve for
test connection).
Establish required pressure [1] by means of pump
and set contact.
Relieve pressure (if provided, close shutoff valve
for test connection).
Remove hand pump.
Refit cap to test connection.
4 Low vacuum in seal oil vacuum activates an alarm.

After the vacuum pump has been in operation for
Pressure transmitter for vacuum in seal
sometime, the vacuum in the system should be
oil vacuum tank approximately -0.4 to -0.45 bar.
To perform a leakage test of the seal oil tank, stop
seal oil pumps and close shutoff valves.
MKW11AA101 (upstream of seal oil pump 1)

MKW12AA101 (upstream of standby seal oil pump)
BHEL, Haridwar 2.3-5160-600600/1

MKW10AA101 (oil inlet, seal oil tank)

MKW10AA121 (upstream of vacuum pump)
MKW10AA011 (in vacuum pump bypass)
Check to ensure that pressure in vacuum tank

remains constant for period of 24 hours. Then reopen
5 shutoff valves and start seal oil pumps.
Perform functional test of level detectors in
Note: This check Is only permissible when the
generator prechambers
generator is filled with air at atmospheric pressure.
Perform function test as follows:

Remove hex plugs near the level detectors on TE
and EE stator end shields.
Close shutoff valves MKW06 AA 151 . The oil level in
the seal oil circuit will rise up to the generator
prechambers within a short time.
The alarm is activated as soon as the oil level in the
generator prechamber reaches the level detectors.
After both level detectors have activated an alarm,
which should take place almost simultaneously,
promptly open shutoff valve MKW06AA151 and
secure in position to prevent valve closing.
Cancel the alarm after a short while.
Replace hex plug making sure that a gastight seal
is obtained.
If seal oil flows from the threaded holes without an

alarm being given, reopen shutoff valve MKW06 AA151
immediately and investigate and correct cause of level
detector malfunction. Repeat functional test.
Note: If shutoff valve MKW06AA151 is not opened

and the seal oil pump stopped immediately , seal oil
may flow into the generator.
6
Set limit-value cards for temperature monitoring
(1)

7
Start with measurement of seal oil volumeteric flow
Checking and setting of supervisory rates and setting of flow rates for TE and EE seal ring
equipment are completed relief.

[1] 2.3-4050 Setting and Operating Values

1111E
Turbogenerators Measurement of
Operation Seal Oil Volume Flows
Seal oil volume flows to shaft seals are dependent

on:
1 Measuring seal oil

volume flows clearance between seal ring and rotor shaft
seal oil temperature
generator casing pressure
generator speed
A comparison of the readings will provide

meaningful results only if the readings are taken under
equal steady-state conditions.
2
Measure oil volume flows for seal ring Note: Regulating valves MKW35AA 001 (TE seal ring
relief relief) and MKW36AA 001 (EE seal ring relief) for setting
the volumetric flow rates were set and checked at
manufacturer’s works. Settings were made under due
consideration of operating conditions to be expected.
Do not change any setting unless such a change is
unavoidable.
3
Measurement of seal oil volume flows is Start with functional testing of pumps and exhausters.
completed

1111E
Turbogenerators Activating the Measuring
Operation Device for Vacuum in Seal Oil
Vacuum Tank
1 Activating measuring device If a zero adjustment should be necessary, e.g. as a

result of improper handling, follow the procedure de-
scribed below.
2
Calibration of measuring device Only Barton cells with indicator module can be cali-
brated, since the calibration can only be performed at
the indicator module. Never make any adjustments on
the Barton cell itself.
A calibration will be required to adjust the indicator
module for a torque tube shaft rotation of 8° + 10 %. In
addition, a linearity correction should be made to elimi-
nate any linerarity errors of the cell and indicator mod-
ule.
The calibration should preferably be performed by
comparing the indication with the reading obtained by
means of a U – tube (mercury or water column) con-
nected to the system. The choice of mercury or water
column depends on the measuring range.
When using a mercury column for calibration, make
sure that no mercury will enter the cell.
Exercise utmost care when setting up the instru-
ment on a calibration stand.
Perform the calibration with dry air, making sure
that there is no water in the cell. Remove the bottom
screw plugs before starting with the calibration proce-
dure in order to drain any moisture condensate, etc. from
the cell.
Insert a screw plug on the high-pressure side for
tight sealing. Check to ensure that low-pressure side is
open. Then apply test pressure.
To calibrate measuring transducers with used cells.
Clean the cells before starting with the calibration.
1 Compressed air connection.

2 Precision instrument, e.g. U-tube gauge.
3 Differential pressure gauge
Fig. 1 Arrangement of Metering Connections
Note: Liquid columns in the legs of the U-tube

gauge must be at the same level.

1111E
3
To perform a zero check, equalize the pressure be-
Zero check
tween the high-pressure and low-pressure sides and
isolate both differential pressure transmission lines
(Open equalizing valve. Close shutoff valves). Use a simi-
lar-procedure on pressure and
vacuum measuring systems. Check zero drift at built -in-
indicator or at a similar facility.
In the case of meter systems with suppressed zero,
apply an appropriate pressure to the high-pressure side.
Correct zero drift on indicator module and not on the cell
itself.
Zero drift may be due to improper mounting of the
Barton cell, inclined position of traps, defective equaliz-
ing valve, fouled shutoff valves, fouled pressure cham-
bers in cell, etc. Remove cause.
Trace fault in Barton cell as a last step. The Barton
cell has a high zero constancy.
4
The pointer can be removed from the pointer axle for
Adjustment of indicator a coarse zero adjustment.
Use zero setter in housing bottom for vernier adjust-
ment. A range correction is only required if the actuating
lever was removed from the torque tube shaft, and a
subsequent linearization is only necessary if the Barton
cell was replaced.
The indication can be adjusted by turning the cor-
recting spindle. Clockwise turning shifts the pointer to
the right-hand side.
Linearity can be corrected by cautiously enlarging the
upper slot of the calibration device for a positive deviation
and the lower slot for a negative deviation,
4.1
Connect precision instrument and Connect instrument to a pressure transmitter (see
compressed air feed line Fig.1)
Disconnect pipes between shutoff valve and Barton
cell.
Connect a U-tube pressure gauge or another preci-
sion instrument to the high-pressure side of the
Barton cell.
Remove cover, pull off pointer and remove dial.
Attach calibration dial. It is recommended to use a
standard dial with a 60 mm dia. hole in the center,
affording access to the calibration facilities and en-
abling readings to be taken.
Set pointer to 0 % mark at zero pressure and make
vernier adjustment
Open shutoff valve for compressed

Open shutoff valve for compressed air until U-tube
air carefully gauge or precision instrument indicates full scale value
of indicator.
Apply 100 % pressure and correct full scale indica-

tion if necessary.
Apply 50% pressure and correct possible deviations
by way of a linearity correction.
Recheck 0%and 100% indications and correct again
if necessary.
2.3-5165-0600/2
Repeat calibration procedure until correct 0%,
50%and 100% indications are obtained.
Remove pointer and replace dial and then set
pointer to zero mark as precisely as possible.
Remove U-tube gauge or precision instrument and

reconnect metering lines.
Setting of limit contacts Limit contact settings are not visible from outside.
They should be checked and, if necessary, corrected.
Opening the housing is not required.
The operating points can be adjusted with a
screwdriver at the left-hand and right-hand setting
spindles in the indicator module.
Example: Limit contact C, positive contact; at
connector II, terminals 4,5 and 6, for maximum value
monitoring with rising characteristic, can be adjusted
by turning the upper setting spindle in the left-hand
side wall of the housing (looking on indicator module
from front).
To check the setting, connect a continuity tester,
e.g. ohmmeter. etc., to fixed contact and to one of the
moving contacts (NC or NO contact) and perform
status check. Apply pressure to be monitored to
measuring system. Check limit switch for proper
response and operation.
If the limit switch fails to operate as necessary,
correct setting for the required pressure by turning
the setting spindle. To obtain an optimum setting,
turn setting spindle several times beyond the switch
point in both directions and then approach switch point
position from the higher-pressure side for maximum
contacts and from the lower-pressure side for
minimum contacts.
If the limit switch fails to operate as necessary,
correct setting for the required pressure by turning
the setting spindle. To obtain an optimum setting,
turn setting spindle several times beyond the switch
point in both directions and then approach switch point
from the higher-pressure side for maximum contacts
and from the lower-pressure side for minimum
contacts.
This procedure accounts for the smaller effect of
the switch contact at the switch point. No variation in
the indication occurs before or beyond the switch
point.
Measuring device is ready

for measurement
2.3-5165-0600/3
Turbogenerators Functional Testing of
Operation Pumps and Exhausters
1 Perform functional test
Check standby seal oil pump for proper

operation
Check pumps for automatic operation
When a seal oil temperture more than

40 ° C has been reached, turn on the
cooling supply to cooler selected
for operation so as to obtain the specified
heat removal capacity
5
Measure vacuum in bearing compartments with a
Check bearing vapor exhausters for U-tube manometer while the bearing vapor exhauster is
proper operation
in operation. The vacuum should be between
approximately 5 to 10 mbar.
Filling and startup procedures are completed

Begin normal running routine

1111E
Turbogenerators Startup of Seal Oil System
Operation
Prerequisite:
1 Startup of seal oil system Seal oil circuits must have been filled with oil.
Instructions for placing the seal oil system in service

after a shutdown involving draining of the seal oil circuits
are given elsewhere in this manual [1] .
Check valves for correct positions [2]
3
Activate controls of bearing vapor exhausters,
Place bearing vapor exhausters, vacuum
pump and seal oil pump in operation vacuum pump and all seal oil pumps.
Check seal oil circuits for proper venting

[3]
Seal oil circuits are new in operation Start will normal running routine.

[1] 2.3-5100 Filling and Initial operation
2.3-5163 of Seal Oil System
[2] 2.3-5108 Valve Positions in Seal Oil System
for Normal Operation
[3] 2.3-5130 Venting of Seal Oil Circuits

1111E
Turbogenerators Activating the Level Detector System
Operation for Seal Oil System and Generator
Supervisory System
Prior to activating the level detector system check

Activating level detector system wiring for compliance with circuit arrangement and
1
connection diagrams.
Check power supply voltage.
2
Make adjustment with the probe immersed. Remove
Adjustments
level detectors in seal oil system from their normal
location and place them in a container filled with turbine
oil.
The level detectors in the level detector rack of tne
genrator supervisory system should be adjusted in the
probe tanks. To do this, fill tank with turbine oil via a
separate filler connection until the probe is immersed in
turbine oil. Then adjust level detector.
1. Make sure switches have been properly connected

on the electronic unit.
2. Commission the switch as per the instruments

manuals for the level switch.
2.1
Adjust Level Switch

1111E
2.2
To perform a, functional test, drain turbine oil until
Perform functional test probe is no longer immersed in oil. Fill with turbine oil
via the filler connection. Check to ensure that an alarm
is activated as soon as the probe is immersed. Repeat
the adjustment if no alarm Is activated.
3
The level detector system is now adjusted After completion of adjustment, install level
and ready for initiating a level alarm detectors in seal oil system and then perform a functional
test.
Restore gastight sealing of filter connections in

level detector rack and, drain turbine oil from piping. Close
shutoff valves after sight glasses and open all shutoff
valves before the level detectors.

Turbogenerators Initial operation of Gas System
Operation
CAUTION:
Initial operation of Risk of explosion and fire due to leaking hydrogen
1 gas in cont act with air .Never use fire or an open
Gas System
flame (welding, flame cutting ,smoking etc) in the
vicinity of the generator and the H2 unit ( if availaible)
at any time, even when starting with the
preparations for filling the generator with hydrogen.
Prerequisites for initial operation of Gas system:
• Generator and complete piping system were leak

tested,and no leaks were detected.
• All pressure reducers and relief valves were set [1]
and checked for proper performance.
• The seal oil system and the bearing vapor exhausters
must be in operation and will positively remain in service.
2
Preparatory work
2.1
Preparation of taking in operation of CO2 Connect CO2 cyllinders.
flash evaporator
2.2
NOTE:
Set valve according to valve position list[2] Contrary to the valve position list , all shutoff valves
MKG11should be maintained closed at first.
2.3
Check to ensure that hose between Ensure that the hose is not connected .Making this
control valve MKG25AA501 and Shut off connection should only be done when compressed air from
valve MKGAA509 is not connected the station air system is required for removing the carbon
dioxide(CO2) from the generator or for perforing a leak
test.
2.4
Note :
Check if sufficient carbon dioxide and
The generator is to be filled and operated only
hydrogen are available [3]
with gas complying with our specification[4] .
Preparatory work has been completed Also refer to the following

[1] 2.3-4060 Operating and setting values Gas system
[2] 2.3-6108 Valve position in Gas system for H2 operation
[3] 2.1-1620 Gas quantities
[4] 2.1-1883 Gas specifications

1111E
Turbogenerators Positions of Multi-Way Valves
Operation in Gas System

1111E
Turbogenerators Gas Filling
Operation Replacing Air With CO 2
Never use fire or an open flame (welding, flame-cutting,

smoking, etc.) in the vicinity of the generator and the
Hints and preparatory work. hydrogen system at any time, even when starting with the
1
preparations for generator filling.
Filling and emptying the generator should be performed
with the generator at rest or on turning gear. Filling during
turning gear operation will result in a higher gas
consumption due to the whirling motion between the
medium to be displaced and the medium admitted.
For this reason, do not perform any filling or purging
operations with the generator at higher speeds than during
turning gear operation.
The seal oil system and the bearing vapor exhauster
must be in operation and will positively remain in service
period to starting with the gas filing procedure.
Ensure that CO2 flash evaporator was filled with heat
transfer liquid up to required level.
Ensure that the hose between compressed air filter
MKG25 BT001 and shutoff valve MKG25 AA501 is not
connected. Making this connection should only be done when
compressed air from the station air system is required for
removing the carbon dioxide (CO2) form the generator or for
performing a leakage test.
Check to ensure that all shutoff and three-way valves
in the gas valve rack, at the gas dryer and in the bottle
rack are closed.
2
Fill generator with carbon dioxide (CO2). All lines carrying gas during this procedure are
represented by yellow lines on the mimic diagram of the
gas valve rack.
2.1
Open all pressure gauge shutoff valves.
2.2
Switch on heater of CO2 flash evaporator. Switch on heater of CO2 flash evaporator. Observe
temperature rise of heat transfer liquid at temperature
gauge. Wait until RTD switches off the heater at the preset
temperature.
2.3
Open shutoff and three-way valves. MKG25 AA519 (three-way valve in position H2 vent gas)
MKG25 AA502 (shutoff valve in vent gas line)
MKG25 AA518 (three-way valve in position CO2 filling)
MKG59 AA507 (shutoff valve )

1111E
Then open shutoff valves at CO2 bottle
2.4
Select Range 1 in Gas Analyser
Gas analyser will check the purity of CO2 in air
2.5
Filling with CO2 may be terminated when a purity in excess
Terminate filling with carbon dioxide.
of 95% CO2 in air has been reached. If the open CO2
bottles are not yet completely empty, the residual carbon
dioxide should also be admitted into the generator.
Switch off heater of CO2 flash evaporator.
2.6
MKG25 AA 518 (three-way valve in CO2 filler line)
Close shutoff and three-way valves.
MKG25 AA 519 (three-way valve in H2 filler line)
MKG51 AA 531 (shut off value for CO2 high pressure)
Close all shutoff values of CO2 bottles.
2.7
Prior to starting with H2 filling, check to ensure that a
Check if sufficient CO2 is available for next
sufficient amount of CO2 is available for the next generator
generator purge
purge.
3
Start with H2 filling.
The generator is filled with carbon dioxide.
2.3-6310-0600/2
Turbogenerators Replacement of Empty CO 2 Bottles in
the CO2 Bottle rack
Operation
CAUTION:
Replacement of CO2 bottles in
1 Danger of suffocation due to the escaping CO2.Since
CO2 bottle rack.
CO2 can also escape in a liquid state,goggles must
be worn when replacing the bottles.Liquid CO 2 can
cause severe frostbite if allowed to come into
contact with skin.
Note:
Transportation and replacement of the CO 2 bottles
shall be performed in compliance with the relevant
national codes,standards and regulation as well as
the relevant safety requirements .The work may
only be performed by suitably qualified and trained
personnel and with due care and attention .
2
Replacement of empty CO2 bottles in CO2 bottles with a bottle pressure of less than 10 bar
bottle rack (145 psig) can be classified as empty.
The bottles must not be replaced until all CO2 bottles in
the CO2 bottle rack are empty.The replacement process
should then be performed without any undue delays in
order to keep the inertization process as short as possible.
2.1
Before disconnecting any of the high pressure hoses from
Check valve positions of all empty CO2
bottles the empty bottles to be removed from the rack,It must be
ensured that bottle valve MKG51AA501 and shutoff valve
MKG51AA531 are closed.Any valve found in the open
position must be closed
2.2
Disconnect high pressure hose from The high pressure hoses must be disconnected from the
empty CO2 bottle empty CO2 bottles with due care and attention
CAUTION:
Danger of suffocation due to escaping CO2.The hose
may still contain carbon dioxide at high
pressure.Carbon dioxidewill escape when the
connection is unfastened.
Use a suitable means of transport to transfer the empty

CO2 bottles to the gas storage area.
2.3
Connect full CO2 bottles to the high The full CO2 bottles must be transferred from the gas
pressure hoses. storage area to the bottle rack with due care and attention.
Place the CO2 bottles in the bottle rack and secure the
bottles in position

1111E
Connect the bottles to the corresponding high pressure
hoses(directly above the bottles).
Note:
A bottle may only be connected to the hose located
directly above the bottle.Do not connect bottles to
hoses located above adjacent bottles.When tighten-
ing the screw connections ,particular attention must
be paid to ensure that the hose is not twisted.
2.4
Perform leaktest on high pressure hose and Following replacement of the CO2 bottles,all high pressure
screw connection to bottle valve hoses and screw connections (high pressure hose/CO2
bottle ) must be subjected to leak test as follows:
1) Carefully open the bottle valve.The shutoff valve down-

stream of the high pressure hose
remains closed.
2) Use suitable test agent (e.g foaming agent ,DIPROL) to

check screw connections and high pressure hose for
leaktightness.
A leak (escape of carbon dioxide) is indicated by

bubbles(when using foam) or by a hissing sound.
Close bottle valve and carefully disconnect hose
from bottle.
CAUTION:
Danger of suffocation due to escaping CO 2 .The hose
may still contain carbon dioxide at high
pressure.Carbon dioxide will escape when the
Check high pressure hose and screw connection between

high pressure hose and CO2 bottle and repeat leak test.
If the leak cannot be sealed , this section of the gas supply
system must be isolated as follows.
The bottle valve upstream of the high pressure hose must be
secured in closed position.The leak must then be sealed by
suitably qualified and trained personnel.
3) Close the bottle valves after successful completion of the

leaktest.
2.5
Reset valves for CO2 bottles to Following replacement of the bottles and successful
service position completion of the leaktest of the high pressure hoses and the
screw connections between the high pressure hoses and
bottle valves ,the CO2 falsh evaporator unit can be taken
back into the service by carefully opening the bottle valves
and the shutoff valves .
3
Replacement of CO2 bottles is complete

The CO2 flash evaporator is ready for operation.CO2 filling
of the generator can be continued if required.
2.3-6311-0600/2
Turbogenerators Gas Filling
Operation Replacing CO 2 With H 2
All lines carrying gas during this procedure are

represented by red lines on the mimic diagram of the gas
Fill generator with H2 valve rack.
1 to operating pressure
1.1
Open shutoff and three way MKG25 AA518 (three-way valve in CO2 vent gas
position)
MKG25 AA519 (three-way valve in H2 filling position)
MKG25 AA502 (shutoff valve in vent gas line)
MKG19 AA501 (shut off valve after pressure
reducer 2 )
MKG15 AA502 (shut off valve before pressure
reducer 2 )
MKG15 AA504 (shut off valve )
MKG15 AA501 (shut off valve after pressure
reducer 1 )
MKG11 AA561 (shut off valve before pressure
reducer 1 )
MKG11AA531 (shut off valve)
MKG11 AA501 (H2 bottle)
Check to ensure that H2 pressure reducers adjust

operating pressure.
Note: Pressure after pressure reducers in bottle rack
must be approximately 8 bar. Pressure after pressure
reducers in H2 unit must be set to rated gas pressure.
H2 filling should be performed by operating the H 2
bottles separately.
1.2
Gas analyser will analyse the purity of H2 in CO2
Select Range 2 in Gas analyser
Continue H 2 filling until indicator gives a reading of
approximately 98% H2 in air.
Check and, if required, correct measuring gas flow.
1.3
Gas analyser will analyse the purity of H2 in air.
Select Range 3 in Gas analyser

1111E
1.4
Set contacts for pump control in seal oil system The contact settings for control of the seal oil pumps must be
matched to the respective gas pressures.
Filling the generator to operating pressure may also be
performed during operation at rated speed.
1.5 As soon as the H2 purity of approximately 98% H2 in air has

Fill generator with hydrogen to been reached , close shutoff valve
operating pressure. MKG25 AA502 (shutoff valve in vent gas line)
After the valve has been closed , the generator is filled to
operating pressure.
Filling the generator to operating pressure may also be
performed during operation at rated speed but without raising
the voltage to rated level.
1.6
The generator is filled with H2.
Start with normal running routine
2.3-6320-0600/2
Turbogenerators N 2 Purging After Filing of
After initial filling of the primary water circuit and

following the addition of larger quantities of primary water
(>100 dm3 per month), the primary water tank should be
1 Preparatory work
purged with nitrogen to reduce the oxygen content of the
primary water. During purging, O2 is extracted from the
primary water and discharged to the atmosphere via the
vent gas line.
Prerequisites for N2 purging :
Q The external primary water circuit was filled with water.

Q The primary water pumps must be in operation.
Q A reliable nitrogen supply must be available.
The N2 pressure reducer was set to a gauge pressure
2
Q
of 0.5 bar.
Purging the primary water tank with
nitrogen (N2)
Note : The nitrogen used for purging must have a purity
of 99.99%.
2.1
Open shutoff valves at bottle rack and in
MKG31 AA501 (at N2 bottle)
purging gas system
MKG31 AA502 (at N2 bottle rack manifold)
MKG31 AA503 (before N2 pressure reducer)
MKG35 AA501 (after N2 pressure reducer)
In addition, open shutoff valve for N2 bottle pressure

measurement.
2.2
Check N2 purging gas volume flow
The nitrogen volume flow rate should be 600 dm3/h.

corresponding to a bottle pressure drop of approximately
15 bar/h for a 40 dm3 nitrogen bottle.
2.3
Perform nitrogen purging procedure
Continue nitrogen purging until a sufficiently low oxygen
content (≤ 100 μg/dm3) is reached in the primary water
tank.
A sufficiently low O2 content for the most diverse initial
conditions is obtained after the following purging periods.
Q 30 hours after initial filling with subsequent refilling of

external circuit.
Q 10 hours after a refilling procedure during operation.
Note : The primary water must be continuously maintained

in circulation during nitrogen purging

1111 E
2.4
Terminate nitrogen purging
2.5
Close shutoff valves at bottle rack and in MKG31 AA501 (at N2 bottle)
purging gas system. MKG31 AA502 (at N2 bottle rack manifold)
3
continue filling or operation of primary water
system.
2.3-6810-0600/2
Turbogenerators Filling and Initial Operation of
Primary Water System
Operation
Preparatory Work
Caution : The primary water system may only be filled

with water complying with our specification [1]
Filling and initial operation Prerequisites for filling the primary water system :
1
of primary water system
Q The primary water pumps must have been checked for
proper alignment after installation of the connecting
piping at the generator. The oil levels in the bearings
and direction of rotation must have been checked with
pump uncoupled.
Q Primary water circuit must have been cleaned [2]
Q Primary water circuit must have been leak tested [3]
Q The filter elements of all filters must be installed [4]
Q the ion exchanger must be filled with resins.
2
Preparatory work
2.1
Set mechanical and electrical zeros of the
conductivity meter system [5]
2.2
Adjust primary water tank level system with
probe not immersed [6]
2.3
Adjust the liquid level detectors with probes
immersed [7]
2.4
Check and set primary water volume flow
indicators [8]
2.5
Adjust relief valve for makeup line [9]

1111 E
2.6
Set mechanical zeros of all pressure
gauges
2.7
Set electrical zero of pressure transmitter
2.8
Ensure that pure nitrogen is available at
required pressure and in sufficient quantity. Note : Use only nitrogen complying with our
specification [10]
2.9
Ensure that water is available for filling of The filler line and make-up line should be carefully
the primary water system. flushed with de-ionate prior to being connected to the
primary water system inlet valves.
Water in filler or makeup line should be at a sufficient
pressure (ρ = 2 to 10 bar, 30 to 145 psig.)
~
¯
3
Fill external part of primary water system.
Also refer to following imformations :

[1] 2.1-1885 Primary water specification
[2] 2.5-7382 Flushing external parts of Primary water circuit
[3] 2.5-0310 Leakage tests
[4] 2.4-4740 Maintenance and supervision of Primary water filters
[5] 2.3-7530 Activating the Primary water conductivity meter system
[6] 2.3-7520 Activating the Primary water level monitoring system
[7] 2.3-7510 Activating the Primary water level detector system
[8] 2.3-7540 Activating the Primary water Volume flow meter system
[9] 2.3-4070 Operating and setting values
[10] 2.1-1883 Gas specification
2.3-7100-0600/2
Filling and Initial Operation of
Turbogenerators
Operation Filling of External Section of Primary water
System
Conditions for filling the external section of the primary water

Fill External section of system:
1
Primary water system The Preparatory work has been completed.
The valves are set according to the service position list.
The external section of the primary water system means
the generator cooling system excluding the cooling system
for the
Terminal bushings and connected phase connectors.

Stator winding.
2
MKF35AA251 (water treatment system)
Close shutoff and control valves
MKF35 AA291 (downstream of water treatment system)
MKF41 AA261 (Upstream of stator winding )
MKF41 AA281 (downstream of stator winding)
MKF51 AA251 (Upstream of terminal bushings )
MKF51AA281 (downstream of terminal bushings)
MKF80AA061 (Vent Line)
3
Open shutoff valves
MKF40AA271 (in bypass line to stator winding )
4
Filling of Ion exchanger resins Remove the cover from the ion exchanger tank after
disconnecting the flanged joint and the connected piping.
Remove the upper nozzle tray.
The cation (Lewatit S 100 KR/H-CL.-free) and anion exchanger
resins(Lewatit M 500 KR/OH-CL.-free) must be mixed at a
ratio of 1:1 in a seperate container, and then transferred to
the ion exchanger tank.Mixing of the resins at a ratio 1:1 can
be performed by filling the same amount of both types of
resins in the container before mixing these.to ensure that the
resins are mixed thoroughly ,this should be done while filling
the resins into the mixing tank.
Note:
Only use plastic material and equipment for mixing
the resins
Place the upper nozzle tray (nozle pointing downward)

atop the resin mixture in the full ion exchanger tank and
seal tank with cover.
Ensure that gaskets are properly seated.
Tighten the bolts of the cover flanges in criss-cross
fashion to ensure uniform loading.

1111E
5
Activate power supply to conductivity
metering systems MKF35 CQ001[1]
Note:
6
Resins may decompose during storage.In order
Flushing of Ion exchanger resins to prevent the ingress of decomposition products
into the primary water system,the resin must be
flushed.
Carefully fill the ion exchanger with water to prevent any

disturbance of the mixed resins.
6.1
Open shutoff valve MKF37AA261 in the makeup water
Flush Ion Exchanger line toensure that water ia admitted at a low rate.Do not close
the vent valves until water emerges without any bubbles.
Adjust the drain valve MKF35AA431 in the water treatment
system to set a flushing flow rate of approx 1m3/h (indicated
on flowmeter MKF35CF001)
Discard the water used for flushing procedure.
Terminate flushing procedure by closing drain valve
MKF35AA431 when the conductivity downstream of the ion
exchanger is less than or equal to 1μS/cm (indicated on
conductivity transmitter MKF35 CQ001 )
Vent system repeatedly during this flushing procedure.
7
Filling procedure and Commissioning Slowly open the control valve MKF35 AA291.Fill the entire
of external section of PW system external section of the primary water system with water.
Note
Ensure that water does not enter the purging gas
lines during the filling procedure or when adding
makeup water.
7.1
The vent valves must remain open until only water is
Vent system during filling discharged from them.
The primary water treatment is ensured by means of the

7.2 water flowing through the water treatment section.
Treatment of water in cooling system
2.3-7110-0600/2
7.3
When the coolant level in the primary water tank has reached
Build up gas pressure in PW tank
the 50 % mark on the sight glass,the valve MKF37 AA261
must be throttled.
Close shut off valve.
MKF80 AA061 (vent line)

Briefly open shutoff valve
MKF80 AA412 (vent line drain)
In order to drain any water that may have accumulated in the

vent line.Close the valve again
Following closure of all vent valves, the compressed air
is vented to the vent gas system if the pressure should
exceed the maximum limit set on pressure relief valve
MKF80 AA071 . The pressure in the primary water tank should
be 0.2 bar(20 K Pa).
7.4
Adjust primary water tank level system at the full level[2].
Terminate filling procedure by closing
control valve MKF37AA261 as soon
as PW tank is filled to the 75% mark
on the sight glass
8 Note
It must be insured that dry running of the primary
Startup of primary water pumps
waterpumps is prevented since the mechanical seals
of the pumps must be continuously flushed with
water.
8.1
In order to vent the pressure measuring points of the primary
Thoroughly vent all pressure-
measuring points water system , these must be filled with water via the test
connections at the individual pressure gauge shut off valve.
8.2
Open the control valve MKF25 AA 251 until the volumetric
Place primary water pump 1 into
flow rate through the water treatment system is approx 1
service for approx 10 minutes
m3/hr(indicated on flowmeter MKF35CF001)
8.3
The primary water system must be thoroughly vented by
Vent and flush water system repeatedly opening the vent valves.
Operate the system in recirculating mode for approx. four
hours to clean the piping ,coolers, etc
2.3-7110-0600/3
Repeat venting of the primary water system if and
as necessary.
8.4
Shut down pump 1 and start up pump 2
8.5
Maintain circulation in external section of
primary water system using pump 1 or 2
Purge PW tank with N2[3]
10
Activate conductivity measuring system
MKF20 CQ011[1]
[1] “Purchased Parts”

[2] “Purchased Parts”
[3] 2.3-6810 N2 purging after filling the
PW system.
11
External section of primary water system is

filled with water and water treatment system
is in operation .Start filling of terminal
bushing and phase connectors
2.3-7110-0600/4
Turbogenerators Filling and Initial Operation
of Primary Water System
Operation
Filling the Stator Winding
Conditions for filling the stator winding :

Q The external section of the Primary water sytem ,the
1 Fill Stator Winding Terminal Bushing and the Phase connectors are filled.
Q Drain valves of primary water manifolds were closed
and secured against opening.
Q The conductivity of the water in the system is less than
or equal to 4 μS/cm.
Q The oxygen content of the water in the system is less
than or equal to 100μg/dm3 (100 ppb)
Q The liquid detectors at the generator are adjusted and
activated.
Note :
Do not add make-up water during filling procedure.
Adding make-up water is only permissible after the
stator winding as well as the terminal bushings and
phase connectors were filled with water and isolated
from the external part of the primary water circuit by
closing the respective valves.
2
Open shutoff valves MKF41 AA281 (downstream of stator winding)
3
Filling Process Slowly open shutoff valve MKF41 AA261 at stator winding
inlet.
4
Flush and Vent Stator Winding Throttle shutoff valve MKF40 AA271 in bypass to increase
the volumetric flow rate through the stator winding.
Briefly open vents in inlet and outlet pipes at appropriate
intervals.
The stator winding should be completely vented after
flushing period of approximately 2 hours.
5
Carefully vent all signal lines to the The signal lines to the pressure gauges must be thoroughly
pressure gauge vented via the test connections at the corresponding
pressure gauge shutoff valve.

1111E
6 The following flowmeters must be activated.
Activate flowmeters
MKF41 CF011A,B (volumetric flow rate through the Stator
Winding)
MKF41 CF012 (volumetric flow rate through the Stator
winding)
Check that Instrument circuits connected in parallel indicate

the same flow rates.
7 Before filling the primary water tank to the specified

Isolate stator winding from external (normal ) level,the filled stator winding must be isolated from
section of primary water system the external section of the primary water system.
To do this, fully open shutoff valve.
MKF40 AA271 (in bypass)
and then close shut off valve
MKF41 AA261 (Upstream of stator winding)
8 After the stator winding , the terminal bushing and the

Fill primarywater tank to specified phase connectors have been isolated from the external
(normal) level section of the primary water system , close shutoff valve.
MKF35 AA251 (control valve for ion exchanger)
and then slowly open shut off valve
MKF37AA261 (in makeup water line).
Raise water level in primary water tank to specified normal

level 75% ( approx 225 mm; observe level detector system)
When the primary water tank has been filled to the specified
level , close shut off valve
.
MKF37AA261 (in makeup water line).
and then slowly open shut off valve
MKF35 AA251 (control valve for ion exchanger)
9
By purging the primary water tank with nitrogen,the oxygen
Purge primarywater tank with
content of the water in the external section of the primary
nitrogen[2]
water system is reduced to less than or equal to
100ppb(100μg/dm3)
2.3-7160-0600/2
10 As soon as the oxygen content in the water in the external
section of the primary water system has dropped to less
Place stator winding,terminal bushings and
than or equal to 100 ppb(100 μg/dm3), open the following
phase connectors into service
valves:
MKF41 AA261 (Upstream of Stator windiing)

MKF51AA251 (Upstream of terminal bushings)
MKF51AA281 (Downstream of terminal bushings)
and slowly close shutoff valve
MKF40 AA271 (in bypass)

Use the above control valves to adjust the volumetric
flow rate
11
The stator winding is fliied.Start filling
the primary water coolers on the
cooling water side.
[1] 2.3-7510 Activating the level detector system

[2] 2.3-6810 N2 purging after filling of primary water
system
[3] 2.1-1634 Operating values and settings
2.3-7160-0600/3
Filling and Initial Operation of
Turbogenerators
Operation Filling Primary Water Coolers on sec-
ondary Cooling Water Side
Important:
Fill and vent secondary side of Do not fill secondary side of primary water cooler
1 with water until one day before startup and loading of
primary water coolers
generator.
Conditions for filling secondary side of the primary water

coolers
• The valves are set according to the service position list
2
Check and activate primary water tempera-
ture control system
3
Open shutoff valve for cooling water Although specified otherwise in the service position list ,the
supply shutoff valve(cooling water supply ) must be kept closed
until the cooler is filled on the secondary water side.
The cooler is filled with cooling water after the shutoff valve
4
has been opened.The vent valves must remain open until
Filling procedure only water is discharged from them
Primary water cooling system is ready for

operation.Perform the necessary checks
prior to generator startup

1111E
Turbogenerators Reactivation of Primary Water Sys-
tem after a Shutdown of Less Than 48
Operation Hours
It must be ensured that the primary cooling water system

Reactivate primary water system is still filled with water.
1 after a shutdown of less than 48 hours Please refer to section of this manual for the instructions
for reactivating the primary water system after a shutdown
during which the entire system or a section of system was
drained.[1]
2.1
Start up one primary water pump and ens-
ure that the second pump is in standby mode.
2
no
Primary water pumps ready
yes
3.3
Reactivate the primary water supply to the stator
winding by slowly opening valve MKF41AA251
3.2
Rectivate the primary water supply to the terminal
bushings and phase connectors by slowly
opening valves MKF51 AA251 and MKF51 AA281
3.1
Rectivate the water treatment system by slowly
opening valves MKF35 AA251 and MKF35 AA291
no
3
Entire primary water system ready
Yes

1111E
10
Perform necessary checks prior to
start up
11
Primary water system is now
reactivated.Start operational monitoring
routines

[1] 2.3-7100 Filling and Commissioning of
2.3-7180 the Primary Water system.
[2] 2.3-7610 Commissioning of the Primary
Water System-Checks prior to
Startup
2.3-7210-0600/2
Turbogenerators Activating Primary Water System
After a Shutdown of More Than 48
Operation Hours
Activate primary
1 water system after a shutdown
of more than 48 hours
2.1
Fill and activate primary water system or
any branch circuits [1]
2 no
Primary water circuit is completely filled
3
Perform checks necessary prior to startup
4
Primary water system is now in service;
start with normal running routine

[1] 2.3-7100 Filling and Initial Operation of
.. to .. Primary Water System
2.3-7180
[2] 2.3-7610 Checks Prior to Startup

1111E
Turbogenerators
Activating the Primary Water
Operation Conductivity Meter System
Conditions for activating the conductivity meter system
1 Activate conductivity meter system The wiring has been checked for compliance with the circuit
diagram and the terminal connection diagram
The power supply voltage has been checked.
Set and check mechanical zero by adjusting zero setting

2 screw on the indicator.
Check mechanical zero of conductivity
indicator
Note : This check can only be performed if conductivity

3 transmitter is completely dry and therefore should be
Check electrical zero performed prior to filling the primary water system.
.
The check may be performed either before or after filling

primary water system.
For further information,refer to the
manufacturer’s documentation.
4
Check conductivity meter system with
test selector switch or test resistor
5
Conductivity meter system is ready for
continuous monitoring of the primary
water conductivity

1111E
Turbogenerators
Activating the Primary Water
Operation Volume Flow Meter System
Prior to activating the flow meter system check wiring

for compliance with circuit arrangement and connection
1 Activate volume flow meter system diagrams.
Check power supply voltage.
1 Span Potentiometer
2 Zero indicator
3 Zero switch
4 Test jack
5 Zero Potentiometer
Fig.1 Differential Pressure Tranmitter
2
Vent medium-pressure cell
With primary water cooling circuit filled and required
primary water flow available, open equalizing valve and
the two shutoff valves and vent measuring mechanism. To
do this, follow descriptions [1] and [2].
After venting, close equalizing valve.
The measuring mechanism is now subjected to the
differential pressure to be measured.
3
Switch on auxiliary power supply
The differential pressure transmitter is now ready for

checking the lower range limit and upper range limit.
4
Check lower range limit and upper range
limit
Lower range limit and upper range limit can be
readjusted independently from each other.

1111E
4.1
Set zero switch to T (test) position For zero check, set zero switch to T (test) position.
4.2
Apply zero differential pressure to To do this, open equalizing valve of the equalizing valve
measuring mechanism assembly.
4.3 The electrical zero setting is indicated by the zero

Check indication of zero indicator indicator.
4.4
Correct zero setting If the pointer of the zero indicator is not exactly in the
center position, the zero setting can be corrected with the
zero potentiometer (item 5).
4.5
Set zero to N (normal) position After checking or correction of zero setting, reset zero
switch to its N (normal) operating position.
4.6
Apply upper range differential pressure to Note : Check to ensure that no impurities are introduced
meausring mechanism (upper range value into the primary water circuit (apply upper range pressure
< orifice design) at pressure gauge calibration rack).
4.7
Correct upper range pressure setting
An ammeter (voltage drop < 300 mV at 20 mA)
connected to the test jack, should indicate the upper range
value of the output current = 20 mA. Any required correction
can be made with the span potentiometer (item 1).
4.8
Re-apply differential pressure to measuring
mechanism To do this, close equalizing valve of the equalizing valve
assembly.
Flowmeter system is now ready for operation.
5
Equipment is ready for volume flow
measurement

[1] 2.1-7370 Primary Water Volume flow
Meter System
[2] 2.1-8412 Pressure Transmitters
2.3-7540-0600/2
Turbogenerators
Initial Operation of Primary Water
Operation System
Checks Prior to Startup
1 Perform necessary checks

prior to startup
2
All primary water coolers are filled on their
primary water side. Ensure that all three coolers are filled on their primary
water sides.
3
Check or adjust vent and drain valves at Make sure to open valves
primary water coolers
MKF52 AA521 (shell side drain at primary water cooler1)
MKF52 AA531 (shell side vent at primary water cooler1)
and close valves
MKF52 AA544 (shell side drain manifold of primary water

coolers)
MKF52 AA545 (shell side vent manifold of primary water
coolers)
4
All units of primary water system are
Perform check by briefly opening shutoff valves
properly vented.
MKF52 AA541 (vent before primary water cooler)

MKF52 AA578 (vent after primary water cooler)
MKF82 AA502 (vent before stator winding)
MKF82 AA503 (vent after stator winding)
MKF60 AA512 (vent at fine filter)
MKF60 AA503 (vent at ion exchanger)
MKF52 AA582 (vent at main filter)
MKF52 AA545 (shell side vent manifold of
primary water cooler)
5
All pressure gauges and pressure
transmitters are properly vented. Perform check by briefly opening vent plug at each
respective pressure gauge shutoff valve.

1111E
6
Two primary water coolers are filled and
Check that primary water coolers are filled on their cooling
vented on their cooling water sides
water sides and properly vented.
7
Primary Water Temperature control system
is ready for operation
8
Primary water circuit is ready for operation;
start with regular monitoring of operation
2.3-7610-0600/2
Turbogenerators
Turning Gear Operation and
Operation Runup of Generator
1 General During runup of the turbine-generator, the cold air

The generator should be operated on the turning gear temperature requires particular attention. Open control
and brought up to speed in accordance with the turbine valves in cooling water outlet lines as soon as the cold air
startup diagrams. temperature has risen to > 400C. Open control valves only
to the extent required to adjust a cold air temperature of <
2 Turning Gear Operation 400C in the exciter. In addition, adjust the two control valves
Prior to operating the generator on turning gear, the so that equal cooling water outlet temperatures are obtained
shaft lift oil pump and the bearing oil system must be placed downstream of the cooler sections (measured by means
into operation. of the thermometers in the outlet lines).
The seal oil system for lubrication and sealing of that After load pickup, adjust control valves for a cold air
shaft seals and the primary water system must be placed temperature of < 400C.
into operation.
The oil flow to the bearings and shaft seals should be 5 Runup
checked prior to turning gear operation to ensure an During runup to rated speed, the bearing oil inlet
adequate flow. In addition, drains should be inspected for temperature should not be less than 350C but not higher
proper operation. than 450C. The oil inlet temperature at the shaft seals should
The generator may be filled with hydrogen prior to or not be less than 380C.
during turning gear operation provided that leakage tests Note : Do not run up generator to rated speed and
have been performed and the seal oil system is in operation. voltage as long as generator casing pressure [1] is not
at rated value.
3 Generator Cooling Gas Temperatures During runup, the critical speed ranges should be
The hydrogen coolers should be placed into service passed through quickly and at a uniform rate.
on their cooling, water sides as soon as the generator is Smooth running depends on several factors. Even
filled with hydrogen and on turning gear. The H2 coolant minor temperature differences of 1-2 deg C between
temperature control system should be changed over from opposite sides of the rotor may result in rotor distortion
the Automatic to the Manual mode. Use manual mode to which could lead to inadmissible vibrations due to
adjust a cooling water volume flow through the hydrogen unbalance.
coolers of approximately 5 to 10% of the nominal flow rate. During runup, the bearing and oil temperatures should
This results in a lower dew point temperature in the be read and recorded at short intervals.
generator interior due to the condensation of moisture To prevent these thermal unbalances during runup, the
contained in the gas on the cooler tubes and fins. turbine-generator should be run on turning gear. If the
The cooling water volume flow through the hydrogen generator is run up following prolonged turning gear
coolers should not be increased as long as the H2 cold gas operation, no restriction regarding the rate of runup need
temperature is not at rated value. be observed other than those required for the turbine.
During runup, the cooling water volume flow through
the hydrogen coolers should be increased by manual 6 Generator Air Operation
adjustment to maintain the cold gas temperature at least Besides the above mentioned operating conditions. It
5 K below the primary water inlet temperature. Changing may be necessary in certain exceptional cases to operate
over the H2 coolant temperature control system from the the generator without hydrogen. i.e. during initial runup of
Manual to the Automatic mode is permissible as soon as the unit to check the bearings and vibrations and for clean-
the primary water temperature control system, set for the up. In view of the high windage losses and the resulting
automatic mode, opens the final control element for the high temperature rise of the air such air operation is only
cooling water downstream of the primary water coolers. permissible for brief periods and only with generator non-
excited.
4 Exciter Temperatures The cold air temperature downstream of the coolers
The exciter coolers must be filled with water and vented. should not exceed 400C. At higher cold air temperatures,
The shutoff valves in the lines upstream of the coolers are the hydrogen coolers should be placed into service.
open, and the control valves in the lines downstream of During generator air operation, the supply of seal oil to
the coolers are closed. the shaft seals must be ensured as well.
[1] 2.1-1850 Reactive capability curve

1111E
Turbogenerators
Generator Startup Diagram
Operation
1 Command : Start up generator Actual condition
Bearing vapour exhausters in operation

Exciter drying system in operation
Primary water system in operation
Seal oil system in operation
Seal oil inlet temperature t = approx. 380C.
Generator hydrogen pressure p = rated gas pressure

Hydrogen purity > 96%
Measuring devices and supervisory equipment in operation
Gas drying system in operation
Hydrogen coolers in service with reduced flow (approx. 10% of norminal flow)
Primary water coolers in operation and vented
Exciter cooler filled with water and vented, control valves closed
Coolant temperature control in operation
Automatic voltage regulator ready for operation
2 Command : Run up generator
Drying system n >= 4 s–1 out of service

Heating system n >= 4 s–1 out of service
Bearing vibration normal

Bearing metal temperature normal
Exciter cooler at r cold air > 400C, adjust cooling water flow required for
removal of loss heat.
Speed n= approximately 90%

1111E
Differential temperature between H2 cooling gas >5K
and cold primary water
Field circuit breaker closed
Set point for rated voltage

set
Speed n = rated speed

Primary water volume flows set
Bearing vibrations set seal ring relief oil pressure for shaft seals
3 Synchronizing, parallelling and loading
Synchronizing
Paralleling
Loading to required load, only within the region of the capability

curve
2.3-8011-0600/2
Turbogenerator
Permissible Synchronizing Criteria
Operation

1111E
Turbogenerators
Permissible Load Limits of Generator
Operation
1 Load Limits
may arise at the generator which require the generator to
be operated at reduced load in order to avoid damage to
For permissible generator loading, refer to the reactive
the unit. The following restrictions should be observed for
capability curve [1]. The following conditions are required
the conditions indicated :
:
4.1 Operation With Hydrogen Coolers Out of Service

Q Primary water cooling system is fully operational.
If one of the four hydrogen cooler sections is out of
Q Generator is filled with hydrogen at the rated pressure
service, operation of the generator is permissible at not
and all four hydrogen cooler sections are in operation.
more than 67% of rated load.
Q Generator is operated at rated frequency
Operation at reduced load is only possible if the
Q Generator is operated at rated voltage.
following conditions are filled
Q Primary water cooling system of generator is fully
Any desired load setting is possible within the limits
operational.
indicated on the Reactive Capability Curve provided the load
Q Dew point temperature of hydrogen atmosphere in
is not increased beyond the specified limit.
generator is sufficiently below cold gas temperature.
Load operation for long periods of time at reduced H2
pressure is, however, not permissible, since the stator
This condition is normally obtained by drying the
primary water pressure may then exceed the hydrogen
closed generator with the gas drying system for not less
pressure.Any leak in the primary water system inside the
than four weeks, with no leak developing in the generator
generator could lead to water coming into contact with high
interior during this period.
voltage components and thus to a catastrophic failure due
Note : The actual-value transmitter for the hydrogen
to short circuiting.
temperature control are located downstream of
coolers A/B and C/D(max. value selection)
2 Rate of Loading
4.2 Deviation of Rated Hydrogen Pressure

During operation load variation is permissible within
If the specified hydrogen pressure [1] cannot be
the limits or the reactive capability curve. The permissible
maintained for unforeseeable reasons (e.g. lack of gas,
rate of loading depends on the condition of the winding
high gas losses), the generator must be unloaded and
insulation Generators with a Micalastic stator winding
de-excited when the rated pressure has dropped by 0.4
insulation and a rotor winding of silver-alloyed copper with
kg/cm 2. The cause of the gas loss should be identified
glass laminate insulation can be suddenly loaded and
and corrected.
unloaded if an automatic coolant control system is
provided and fully operational. The actual rate of loading
4.3 Loss of Primary Water Supply
should be matched to the permissible limits of the turbine.
If loss of primary water supply occurs, the generator
is disconnected from the system by the generator
3 Unbalanced Load
mechanical equipment protection and de-excited.
Operation of the generator without full primary water
The continuously permissible unbalanced load as
service is not permissible.
specified [2] must not be exceeded under any operating
condition. Unbalanced load is defined as the ratio of
4.4 Deviation of Rated Voltage and Rated Frequency
negative sequence current to rated current, with the rated
Loading of the generator with deviations from the
current [2] not being exceeded in any of the three phases.
rated generator voltage and/or frequency is only
permissible up to the limits shown in the attached
4 Load Restrictions
diagram [3].
During the service life of the generator, operating conditions

[1] 2.1 - 1850 Reactive Capability curve
[2] 2.1 - 1810 General and Electrical Data
[3] 2.3 - 8181 Permissible Loading at Rated P.F.
during voltage and frequency deviations

1111 E
Turbogenerators Permissible Loading at Rated P.F.
During Voltage and Frequency
Operation
Deviations
40
30
PERMISSIBLE SHORT TIME
OPERATION (IN MINUTES) WITH
RATED MVA AT RATED PF WITH 20
10% VOLTAGE DEVIATION
10
10
5
VOLTAGE DEVIATION (%)
0
-12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5
-1
Continuous Operation At Rated MVA
Only Short Duration Operation At Rated

MVA (But Continuous Operation at reduced
load not permitted)
Continuous Operation At Reduced MVA OR
Rated MVA for Short Duration
-5
FREQUENCY DEVIATION (%)

1111E
Turbogenerators Generator Capability With Hydrogen
Coolers Out of Service on Water Side
Operation
Continuous Short time operation

Operatopn Only permissible for cooler cleaning
100 % 66.6 %
MVA MVA
123456
123456
123456
123456
123456
123456
123456
123456
123456
123456 Cooler in service
Cooler out of service
Operation with less coolers or higher output than shown is not allowed

1111E
Turbogenerators Unbalanced Load-Time Curve
Operation
BHEL, Haridwar 2.3-8187-0 6 0 0 /1

1111E
OVERLOAD CAPABILITY
BHEL, Haridwar
2.4
Operation
Turbogenerators
2.2
1. ARMATURE WINDING SHORT TIME THERMAL
1 REQUIREMENTS (STATOR CURRENT VS TIME)
2 2. FIELD WINDING SHORT-TIME THERMAL

REQUIREMENTS (FIELD VOLTAGE VS TIME)
1.8
VOLTAGE (P.U.)
1.6
2
STATOR CURRENT (P.U.)

FIELD
1.4
1.2
1
Current Overload Capability
1 10 100 1000
TIME IN SEC
1111E
2.3-8188-0600/1
Turbogenerators
Runback for Loss of Stator coolant
Operation
50
CAUTION
49 IF STATOR COOLANT IS NOT
RESTORED WITHIN 50 MIN-
UTES OF INITIATION OF
48 RUNBACK, THE TURBINE-
GENERATOR MUST BE
TRIPPED.
TIME IN MINUTES
47
0
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
CURRENT PER UNIT AMPERE

1111E
Turbogenerators
Shutdown of Generator
Operation
1 General
3 Hydrogen Coolers
During shutdown of the generator, the shaft lift oil
Before the unit reaches turning gear speed, adjust
pump must be started as soon as the unit reaches the
a cooling water flow of at least 5 % of the nominal
speed specified in the Turbine Instruction Manual.
flow rate.This results in a lower dew point
temperature in the generator interior due to the
condensation of moisture contained in the gas on
2 Turning Gear operation
the cooler tubes and fins.The coolers should be
To prevent any difficulties during a subsequent runup
operated with this cooling water volume flow for
due to thermal unbalances and the resulting rotor
approximately 15 hours.
distortion, the turning gear must be started as soon as
the turbine-generator coasts down to the speed (turning
4 Exciter Coolers
gear speed) specified for the turbine (normally
Close shutoff valves downstream of the coolers.
automatic) and maintained in operation without
interruption until the rotor has cooled down to nearly
room temperature.
5 Exciter drying System
Check to ensure that the exciter dryer is placed into
service after the turning speed has been reached.

1111E
Turbogenerators
Generator Shutdown Diagram
Operation
1 Command : Unload generator Actual condition
Generator load SN < 0.05 SN
Generator main circuit breaker automatic trip through reverse-power protection.
Speed approximately 90%
Excitation field circuit breaker tripped
Exciter dryer n<3.5s–1 inoperation

Anticondensation heating system n<3.5s–1 inoperation
Turning gear operation see Turbine Instruciton Maual
Seal oil system in operation
Gas system in operation
Primary water system in operation
Speed n = 0 s–1; at room temperature
Shutdown procedures completed

1111E
Turbogenerators Supervision of Generator During
Standstill
Operation General
1 Generator at Standstill With Seal Oil, Gas and their water sides, dried and maintained in dry
Primary Water System in Operation condition to prevent standstill corrosion in the cooler
tubes.
Due to operational conditions, it may become
necessary to shut down the generator for a short 2 Generator at Standstill With Seal Oil, Gas and
period. With the unit at rest or on turning gear, the Primary Water System Out of Operation
mechanical hydrogen purity meter cannot give an
indication due to the lack of differential fan pressure. Preservation measures will have to be taken when
When the unit at standstill, the bearing oil system can the generator is to be shut down for a period
be taken out of service. In the absence of any exceeding two months with the seal oil, gas and
operational needs. e.g. inspection or faults on primary water systems to be taken out of operation.
generator, the water and hydrogen should remain in The scope of the preservation work required depends
the generator in order to retain the most favorable on the duration of the shutdown, on the overall
prerequisites for a dry condition. All observation conditions in the vicinity of the unit and on the extent
required for a generator partly taken into service to which checks and inspections are possible during
should be performed, such observations being such period.
essentially limited to the seal oil, gas and primary After removal of the hydrogen from the generator,
water systems. it is recommended to open the generator by removing
Normally it can be assumed that the generator was two manhole covers and to connect a dryer or hot air
operated with the gas dryer during the preceding blower for continuous drying or circulation of the air
service period. The generator interior will thus be in in the generator. Care should be taken to ensure that
dry condition provided that the cooling gas was not this equipment is connected in such a way that a
replaced. circulation through the entire generator interior will
Special measures should be taken to prevent be accomplished.
corrosion damage to the tubes of the hydrogen, To maintain the generator in satisfactory dry
primary water and exciter coolers during idle periods. condition, the exciter enclosure must be kept closed
During a brief outage, the coolers should be supplied and the exciter drying system must remain in
with a small water flow. In addition, the coolers should operation.
be flushed with the full water flow twice weekly. The hydrogen, primary water, exciter and seal oil
In the case of prolonged outages, the coolers coolers should be drained to their water sides and
should be drained on their water sides and dried. dried by suitable measures.
To prevent the formation of a moisture film due to These measures are intended to prevent any
condensation on the exciter coolers., the cooling condensation in the generator interior even under
water supply should be isolated immediately after varying environmental conditions to minimize the risk
shutdown of the unit, making sure that the exciter of stress corrosion cracking of the austenitic rotor
drying system is functioning properly. In the case of retaining rings.
prolonged outages, the coolers should be drained on

1111E
Operation During Standatill
Coolers
Danger:
Suitable measures will have to be taken on all coolers Fire and explosion hazard due to hydrogen
taken out of service to prevent standstill corrosion in the accumulation in the drained hydrogen cooler.This
cooler tubes. applies in cases where hydrogen is not removed
from generator after the hydrogen cooler or a
In the case of a brief outage, it will mostly be sufficient
cooler section has been drained.Becuse it is not
to supply the coolers with a small water flow and to flush possible to rule out the ingress of hydrogen into
them with the full water flow twice weekly. the drained hydrogen cooler as a resut of
In the case of a prolonged outage, the coolers should difusuion through the gaskets of the water return
however, be drained on their cooling water sides and dried. channels or as part of the normal hydrogen
migration within the system,it is recommended that
the generator be filled with air atmospheric
pressure before draining the hydrogen cooler.
You do not have to remove the hydrogen
from the generator if the drained cooler is
continually and adequately ventilated via the drain
and bleed valves.The compressed air supply
hose should be connected to the drain valve.

1111E
During Standstill
After gas removal from the generator, the seal oil monitoring of the generator must be continued. All seal
system can be taken out of operation, and monitoring of oil pressure and temperature should be recorded at the
the generator is no longer required. previous intervals, and attention should be given to all
However, if the seal oil system remains activated, special occurrences.

1111E
Turbogenerators Shutdown of Seal Oil System
Operation
Caution: Taking the seal oil system out of service is only

permissible with the generetor at standstill (n–0s-1) and
filled with air at atmospheric pressure.
1 Shutdown of seal oil The seal oil system should thus be taken out of
system service only after occurrence of major faults or for a
prolonged shutdown of the generator.
2
Shutdown turbine-generator
3
Remove H2 gas from generator After lowering of the H2 gauge pressure in the generator
remove hydrogen from generator by admitting CO2.Then
purge CO2 by means of compressed air.
4
Stop seal oil pumps, vacuum pump and
bearing vapor exhausters
5
Terminate normal running routine
6
Partial or complete draining of the seal oil system
Seal oil system is out of service; start with will only be necessary for work requiring an empty
corrective actions, e.g. replacing defective system. Refill piping or branch circuits with oil prior to
valves and fittings restarting the seal oil system.
If the cooling water supply is stopped for more
than three days, the seal oil coolers should be drained
and dried on their cooling water sides.
If operation can be expected to be resumed after
three days, the coolers may remain filled with cooling
water provided that the cooler tubes are free of deposits
If deposits are detected, the cooling water should be
drained and the tubes cleaned and flushed with clean
water. Water channels should remain open until the
system is restarted.
During brief outages (< three days), it is permissible
to maintain the system in operation at low cooling water
velocities (slow-motion flow) in order to avoid deposits
in the tubes.

1111E
Turbogenerators Draining Seal Oil Circuit
Operation
Prerequisites:
1 Draining seal oil circuit • Turbine-generator was shut down
• Generator rotor must be at standstill (n = 0 s–1)
• Generator is filled with air
• seal oil pumps are out of operation.
• Vacuum pump is out of operation
2
Drain seal oil tank MKW10 BB001
2.1
Close shutoff valves MKW01 AA276 (Shutoff valve at seal oil storage tank)
MKW13 AA261 (Before seal oil pump MKW13AP001)
MKW31 AA101 (Before differential pressure control
valve 1)
MKW32 AA101 ((Before differential pressure control
valve 2)
MKW35 AA101 (before TE seal ring float system)
MKW36 AA101 (before EE seal ring float system)
2.2
Open shutoff valve MKW11AA185
2.3 The level detector MKW10 CL002 deactivates the seal oil
Start seal oil pump MKW11AP001 pump after a brief period(dry running protection).
The remaining seal oil can be drained through the drain
plug in bottom of seal oil tank
Drain intermediate oil tanks MKW06 BB001 The remaining seal oil can be drained from the intermediate
oil tank after removal of the drain plug

1111E
4
Drain seal oil coolers
4.1
MKW21 AA251 (Seal oil vent valve,cooler 1)
Open cooler drain and vent valves on oil side MKW22 AA251 (Seal oil vent valve,cooler 2)
MKW21 AA201 (Seal oil drain valve,cooler 1)
MKW22 AA201 (Seal oil drain valve,cooler 2)
The coolers should be drained via the drain valves.
4.2
Open cooler drain and vent valves After draining on their water sides,the coolers should be
on water side dried to prevent standstill corrosion of the cooler plates.
Drain seal oil filters and piping To do this, open valves
MKW21 AA261 (vent valve ,filter 1)

MKW22 AA261 (vent valve , filter 2)
MKW21 AA211 (drain valve,filter 1)
MKW22 AA211 (drain valve,filter 2)
valve 1)
valve 2)
MKW35 AA101 (before TE seal ring float system)
MKW36 AA101 (before EE seal ring float system)
The filters and piping should be drained via the drain valve
Drain seal oil filters and piping Open drain valve MKW06 AA201 at loop seal and drain
seal oil.
Draining of seal oil circuit is complete
2.3-8520-0600/2
Turbogenerators Supervision of Generator During
Standstill
It is recommended to leave the hydrogen in the normal operation.

generator and to reduce the hydrogen pressure if the
generator is to be shut down for a period up to two The gas must, however, be removed from the generator
months. if the seal oil system is taken out of service or for carrying
It should, however, be observed that all alarm out welding work within the range of the gas supply
devices must be set to the new operating values. system or work on the generator. If the generator is filled
Monitoring of the gas system must be continued as during with air, the seal oil system can be taken out of service.

1111E
Turbogenerators Gas Removal
Operation Lowering Hydrogen Gas Pressure
in Generator
Prior to removing hydrogen (H 2) from the generator

1 Preparatory work
housing, the generator must be at standstill or on the
turning gear.
Carbon dioxide must be available in sufficient
quantity. Check to ensure that the CO 2 flash evaporator
is filled with heat transfer liquid up to lower edge of riser.
1.1
Check zero setting of Gas Analyser
1.2
MKG19 AA501 (after H2 pressure reducer, H 2 unit)
Close shutoff valves and three-way valves
MKG19 AA502 (after H2 pressure reducer, H2 unit)
MKG15 AA502 (before H2 pressure reducer 1, H2 unit)
MKG17 AA505 (before H2 pressure reducer 2, H2 unit)
MKG15 AA504 (for H2 high pressure)
MKG15 AA501 (after H2 pressure reducer 1,
H2 bottle rack)
MKG11 AA561 (before H 2 pressure reducer 1,
H2 bottle rack)
MKG16 AA501 (after H2 pressure reducer 2,
H2 bottle rack)
MKG12 AA501 (before H 2 pressure reducer 2,
H2 bottle rack)
Close all shutoff valves at H 2 bottle rack manifold

and at H 2 bottles.
1.3
Lower the gas pressure in the generator to
Lower gas pressure in the generator
approximately 0.1 bar by opening shutoff valve MKG25
AA 502. Switch three way valve MKG25 AA519 in position
H2 Vent Gas and vent the gas to atmosphere via orifice
MKG25 BP502.
2
Generator is ready for filling with CO2

1111E
Replacing H2 With CO2
Operation
Prerequisite for filling generator with CO2

1 Replacing H2 with CO2
• Hydrogen gas pressure in generator was lowered [1].
• Connected CO2 bottles in CO2 rack are filled with CO2.
2
Change setting of multi-way valves in H2 unit as follows[2]:
Change settings of multi-way valves in
MKG25 AA519 to position 2
H2 unit.
MKG25 AA 518 to position 1
3
Open Shut off valve MKG25 AA502
4
Select range (100-0% H2 in CO2)
in both Gas analysers
5
Fill generator with CO2 All lines carrying gas during this procedure are
represented by yellow lines on the mimic diagram on the H2
unit.
Note:
Filling the generator with carbon dioxide should
be performed with the generator at stanstill or on
turning gear.Filling during turning gear opeartion will
result in higher CO 2 consumption due to the whirling
motion between the CO 2 gas admitted and the
hydrogen to be displaced.For this reason , do not
perform any CO2 filling opeartions with the generator
at higher speeds than during turning gear operation.
The number of CO 2 bottles required depends on gas
consumption[4] and on the contents of the CO2 bottles.
5.1
Switch on heater of CO 2 flash evaporator.Observe
Switch on heater of CO2 flash evaporator
temperature rise of heat transmitting liquid at the temperature
gauge.

1111E
5.2
Open shutoff valves downstream of Open all Shutoff valves:
CO2 bottles
MKG51 AA531 (downstream of CO2 bottle )
MKG51 AA561 (Upstream of CO2 evaporator)
Empty condition of the bottles is indicated by a sudden

collapse of the CO2 bottle pressure indication.When this
condition occurs replace empty bottles with full ones after
having closed the shutoff valves on and downsream of the
bottles.
Do not open more new connected CO2 bottles than
necessary.
6
Filling with CO2 can be terminated when the indicators of
Terminate filling with carbon dioxide
the Gas analyser indicate a purity of less than 10% H2 in CO2
(CO2 )
if the open CO2 bottles are not completely empty, the
residual CO2 should also be admitted into the generator.
6.1
Switch off CO2 flash evaporator Switch off CO2 flash evaporator as soon as the CO2
bottle pressure indicated has collapsed.
6.2
Close shutoff valves downstream of Close all Shut off valves:
CO2 bottles
MKG51 AA531 (downstream of CO2 bottle )
MKG51 AA561 (Upstream of CO2 evaporator)
Replace empty CO2 bottles by full ones
6.3
Change setting of multi-way valves in Having decreased the CO2 pressure in the generator down
H2 unit to less than or equal to 0.2 bar , see indication of gauge
MKG25 CP503, the multiway valves in the H2 unit are to be
switched as follows
MKG25 AA519 to position 0

MKG25 AA 518 to position 0
2.3-8620-0600/2
6.4
Close shutoff valve MKG25 AA 502
Caution:
Danger of suffocation due to CO2 leaks;do not open
manholes or piping.
Start with air filling.

7
The generator is filled with CO2
[1] 2.3-8610 Lowering H2 gas pressure in generator.

[2] 2.3-6107 Position of Multi-Way Valves in Gas system
2.3-8620-0600/3
Replacing CO2 With Air
Operation
Prerequisite for filling generator with air
1 Replacing CO2 with air Generator was filled with CO2 [1].
CAUTION:
Danger of suffocation due to CO 2
leaks ; do not
open manholes or piping.
2
Set Multi way valve MKG25 AA518 to
position 2 [2].
3
Open Shut off valve MKG25 AA502
4
Select range (0-100 % CO2 in air)
in both Gas analysers
5
Establish hose connection between Connect hose of shutoff valve MKG25AA509 to control valve
H2 unit and compressed air supply MKG25 AA501 by means of fittings
Fill generator with air Open valves

MKG25 AA501
MKG25 AA509
to admit compressed air into the generator.
Adjust the compressed air pressure by means of control

vlave MKG25 AA501 so that the pressure in the generator
will not exceed 1 bar.
All lines carrying gas during this procedure arer
represented by blue lines on the mimic diagram on the H2 unit.
Note: Ensure that the compressed air complies with
our specification[3].

1111E
When the indicator of the Gas analyser gives a reading
7
of 0% CO2 in air , the carbon dioxide has been driven out of
Terminate filling with air the generator.
Open shutoff valves downstream of the liquid level
detectors in the level detector rack and close shut off valve
MKG25 AA502 for purging with compressed air the pipes to
the level detectors.
After purging , reopen Shutoff valve MKG25 AA502 and
close shutoff valves downstream of level detectors.
Close valves MKG25 AA501 and MKG25 AA509.
Note :
8
International standards specify a clear seperation
Remove hose connection between
between the compressed air system and the H 2
H2 unit and compressed air supply
unit.Ensure that the hose between control valve
MKG25 AA501 and shutoff valve MKG25 AA 509 is
removed or at least disconnected from the
compressed air system by opening the fittings at the
side of the shutoff valve MKG25 AA509.
9
De-energize measuring and supervisory
equipment
10
The generator is filled with air;stop With the generator rotor at Standstill (n=0s-1), the seal oil
normal running routine og gas system
system may also be shut dowm.
CAUTION :
Before passing the generator , the unit has to be
purged for 8 hrs amd measurements should be
performed to check on H 2 - freeness.

[1] 2.3-8620 Replacing H2 with CO2
[2] 2.3-6107 Position of Multi-way valves in the Gas
System.
[3] 2.1-1640 Gas Specification
2.3-8630-0600/2
Turbogenerators N2 Purging Before Draining
of Primary Water System
Operation
Primary water tank must be purged with nitrogen prior

Instructions and
1 to complete or partial draining of primary water circuit to
preparatory work
ensure a removal of the H2 atmosphere and of the H2
contained in the primary water. During purging, the
hydrogen removed is vented to the atmosphere via the
vent gas line.
Conditions for Purging with Nitrogen:
Q The Primary water pumps are in operation.

Q A reliable nitrogen supply is available.
2
Purging the primary water tank with
Nitrogen(N2) Note : The nitrogen used for purging must have a
purity of 99.99%.
2.1
Open shutoff valves in N2 bottle rack and
purging gas system. MKG31 AA502 (at N2 bottle rack manifold)
MKF01 AA251 (in N2 purging gas line)
2.2
Check nitrogen flow rate The volumetric flow rate must be 600 dm 3 /hr
corresponding to a drop in bottle pressure of approx 15
bar/hr for a 40 litre nitrogen bottle.
2.3
The purging procedure must be performed for a
Start nitrogen purging procedure
minimum of 12 hrs to ensure that the hydrogen atmosphere
and the hydrogen content in the primary water are reduced
to a safe level.
2.4
Terminate nitrogen purging
2.5
Close shutoff valves in N2 bottle MKG31 AA501 (after N2 pressure reducer)
and purging gas system MKG31 AA502 (at N2 bottle rack manifold)
3 MKF01 AA251 (in N2 purging gas line)
Continue shutdown of the primary

water system

1111E
Turbogenerators Supervision of Generator During Standstill
Operation
After shutdown of the turbine-generator, the primary Water circulation in the primary water circuit or in
water supply to the generator is maintained by keeping individual branch circuits can be stopped for shutdowns
the primary water pumps in service. This condition is up to 48 hours if work must be performed on the primary
permissible for a prolonged period of time. Monitoring water system. If the water circulation is to be stopped
of the primary water system must be continued as during for longer periods of time, complete or partial draining
normal operation. of the primary water circuit will be required.

1111E
Turbogenerators Shutdown of Primary Water System
for Less Than 48 Hours
Operation
Caution : The primary water system may only be shut

Shut down primary down when generator is carrying no load and has been
1 water system for less taken out of operation (n = 0s–1).
than 48 hours Shutdown is defined as any of the following.
Q Stopping water circulation in branch circuits by

closing respective valves.
Q Completely or partially draining primary water system.
2
Will entire primary water cooling circuit
be deactivated? No If primary water circulation cannot be maintained
because of faults in the primary water cooling circuit,
Yes the entire cooling circuit may be shut down for a period
up to 48 hours.
2.1
Stop primary water circulation Primary water circulation is stopped by taking primary
water pumps out of service.
2.2
Primary water cooling circuit can be left
in this condition for a period up to
48 hours
3
Shutdown of System sections When Shutting down system sections, the primary
water pumps can be maintained in operation.
Instructions for draining individual system sections are
detailed in the following documents
3.1
Shutdown of stator winding section Note!
Before shutting down the stator winding section,
valve MKF40 AA271 must be opened.
Close shutoff valve MKF41AA261 and MKF41AA281

1111E
3.2
This section of the primary water system can be isolated
Shutdown of terminal bushings and phase
by closing the following valves:
connector sections
MKF51AA251 (Control valve upstream of terminal

bushing)
MKF51AA281 (Shutoff valve downstream of terminal
bushings)
3.3
This section of the primary water system is isolated by
Shutdown of water treatment section
slowly closing the following valves:
MKF35AA251 (Control valve for water treatment

system)
MKF35AA291 (Shutoff valve downstream of water
treatment system)
Primary water may be left in Individual system

sections for upto 48 hrs
2.3-8720-0600/2
Turbogenerators Shutdown of Primary Water System
Operation for More Than 48 Hours
Caution : The primary water system may only be shut

Shut down primary water
1 down when generator is carrying no load and has been
system for more than
shut down (n = 0s–1).
48 hours
The primary water system should be deactivated only
when faults occur in primary water system or during
prolonged turbine-generator shutdowns requiring
preservation measures.
For shut downs of more than 48 hours complete of
partial draining of the primary water circuit is required.
2
Caution : Primary water contains dissolved hydrogen.
Purge primary water tank with nitrogen
Primary water tank must be purged with nitrogen prior
(N2)[1]
to complete or partial draining of primary water cooling
system, purge with inert gas for 12 hours to avoid
potential hazards due to hydrogen atmosphere.
During nitrogen purging, the primary water must be
circulated by means of the primary water pump to ensure
a uniform removal of the H2 gas in the entire primary
water system.
3
Reduce pressure in primary water tank
Reduce pressure in primary water tank to
atmospheric level by adjusting overflow controller in the
vent line.
4
De-energize electrical equipment in
De-energize :
primary water system
Q Conductivity transmitters
Q Level detector system at primary water tank
Q Volume flow indicators for stator winding and
bushings
Q Temperature detectors
Q Coolant temperature control system
Q Power circuits of pumps
5
Drain compelete primary water circuit or
Complete of partial draining of primary water circuit
branch circuits
is necessary only if work must be performed on the circuit
which requires an empty system.
If only one branch circuit is drained for performing
the repair works, remaining branch circuits may remain
filled following nitrogen purging if
Q Electrical measuring devices in remaining branch

1111E
circuits remain activated.
Q Nitrogen purging of primary watertank is continued.

Q Primary water is treated.
Q Primary water circulation is maintained by primary
water pumps
Draining of individual branch circuits should be

performed in accordance with the following instruction.
6
Stop operational monitoring routine of branch
circuits taken out of service
2.3-8730-0600/2
Turbogenerators
Draining the Primary Water System
Operation Primary Water Coolers (Cooling Water Side)
If the coling water circulation is stopped for more than

three days, the coolers shoud be drained and dried.
If operation can presumably be resumed within three days,
1 Drain primary water coolers
the coolers may remain filled with cooling water provided
on cooling water side
that the cooler tubes are free from deposits. With deposti
build-up, the cooling water should be drained and the
tubescleaned and flushed with clean water.
During brief shutdowns (less that three days) the coolers
may also be kept in service at low cooling water velocities if
this serves to avoid deposits in the tubes.
2
Close shutoff valve before and after coolers filled on
Close shutoff valves before and after
their cooling water sides.
coolers
3
Open drain and vent valves at coolers
Open drain and vent valves of coolers filled on their cooling
water sides.
4
Establish a compressed air connection at vent manifold
Dry coolers with compressed air
of primary water coolers.
Make sure that compressed air is free from oil, dust
and other contaminants.
Blowing out may be rerminate when air leaving the drain
vlaves is free of atomized water.
5
Primary water coolers are dained and dry
on their cooling water sides

1111E
Turbogenerators
Draining the Primary Water System
Operation Stator Winding
The stator winding system may be drained if:
1 Drain stator winding Q The Primary water tank has been purged with N2 [1].
Q The Measuring instruments and supervisory
equipement for this primary water section are
deactivated.
2
Close Valves:
Preparatory work prior to draining
MKF41 AA261 (shutoff valve upstream of stator
winding)
MKF41 AA281 (shutoff valve Downstream of stator
winding)
Remove inlet and outlet pipes, If required, clean the

two strainers in the stator winding inlet and outlet. Establish
hose connections between waste water system and drain,
valves of primary water manifolds.
3 The stator winding must be drained by blowing out

Blow out stator winding with compressed with compressed air.
air Ensure that the compressed air is free from oil, dust
Establish a compressed air connection at primary
water inlet flange of exciter end water manifold.
Open drain valves at primary water manifolds.
Close drain valve at exciter end primary water
manifold when water is no longer being drained.
Briefly open compressed air valve briefly at appropriate
intervals, to ensure that removed water can drain via the
drain valve at the turbine end primary water manifold.
Fully open the compressed air valve when the water
volume is reduced to a small amount.
Shut off compressed air supply for short periods to
enable any water left in the system to accumulate.
Repeatedly open drain valve at exciter end primary
water manifold for short periods to blow out any water
that may have accumulated.
The blow out procedure may be terminated when the
air leaving the system is free of atomized water.
4
Slowly empty one nitrogen bottle to enable purging of
Purge stator winding with N2
the Stator winding .Connect the nitrogen supply to the
primary water inlet flange of exciter end manifold. The
purging period should amount to approximately two hours.
Carefully close inlet and outlet after purging. N 2 purging
should be performed daily.

1111E
The stator winding must be preserved for a prolonged
5 shutdown periods( no water in winding) .Please contact
the service dept of manufacturer.
Preserve stator winding
Stator winding is drained and preserved

[1] 2.3-8650 N2 Purging before Draining of Primary
Water System
2.3-8734-0600/2
Turbogenerators Draining the Primary Water System
Terminal Bushings and Phase Connectors
Operation
The terminal bushings and phase connectors may be

1 Drain terminal bushings drained if :
and phase connectors Q The Primary water tank has been purged with N2 [1].
Q The Measuring instruments and supervisory equipement
for this primary water section are deactivated.
2 Close valves:
Preparatory work prior to draining

MKF51 AA251 (Control valve upstream of bushings)
MKF51 AA281 (Shut off valve downstream of
bushings)
Remove inlet pipe near the neutral point.
3
Blow out phase conectors and bushings
with compressed air Phase connectors and bushings must be drained by
blowing them out with compressed air.
Ensure that the compressed air is free from oil, dust and
other contaminants.
Connect a compressed air source to inlet flange.
Establish a hose connection between the waste water
system and the outlet fkange.
Deactivate voulumetric flowmeters
MKF51 CF0011A,B (phase U bushings)

MKF51 CF0012 (phase U bushings)
MKF51 CF021A,B (phase V bushings)
MKF83 CF0022 (phase V bushings)
MKF83 CF031A,B (phase W bushings)
MKF83 CF032B (phase W bushings)
Open the compressed air valve, and blow out phase

connectors and bushings for several hours.
Shut off compressed air supply for short periods to enable
any water left in the system to accumulate.
The blowout procedure may be terminated when air
leaving the system is free of atomized water.
4
Purge phase conectors and bushings Purge phase connectors and bushings with nitrogen.
with N2 Connect nitrogen supply to the inlet flange. The purging period
should amount to approximately two hours,and the bottle
pressure should drop by approximately 5 bar (70 psi).
Carefully close inlets and others after purging. N2 purging
should be performed daily.

1111E
The phase connectors and terminal busings must be
5 preserved for a polonged shutdown periods. ( no water in
phase connectors or bushings ).
Pressure phase conectors and bushings Please contact the service department of the manufacturer.
6
Phase conectors and bushings are
drained and preserved
After refer to the following information

[1] 2.3-8650 N2 Purging Before Draining the Primary
Water System
2.3-8738-0600/2
Water Treatment System
Operation
The water treatment system may be drained if

1 Drain water treatemnt system
Q The Primary water tank was purged with N2 [1].
Q The Measuring instruments and supervisory equipement
for this primary water section are deactivated.
Note:
2
When draining primary water treatment system,
Take ion exchanger out of service it must be insured that ion exchanger resins remain
immersed in water .
To do this, isolate ion exchanger by closing valves:
MKF35 AA251 (control valve upstream of ion

exchanger)
MKF35 AA261 (shutoff valve downstream of ion
exchanger).
Drain water treatment system To do this, close valve
MKF35AA291 (shutoff valve downstream of

primary water treatment system)
and opening shutoff valves:
MKF35 AA421 (drain,fine filter)

MKF35AA521 (vent, fine filter)
MKF35 AA431 (drain,water treatment system)
4
Connect vent valve MKF35 AA521 to compressed air
Drain and dry piping system with
system.
compressed air
Ensure that the compressed air is free from oil, dust and
other contaminants.
The Blowout proceduremay be terminated when the air
leaving the system is free of atomized water.
Water treatment system is drained and dry

[1] 2.3-8650 N2 Purging Before draining of Primary
Water System

1111E
Operation External Part of Primary Water Circuit
Prerequisites for draining :
Q Primary water tank was purged with N2 [1].

1 Drain external part of Q All branch circuits were drained or isolated from external
primary water circuit part of primary water circuit by closing valves. Isolating
branch circuits is, however, only permissible if external
part of primary water circuit is filled again with water
and taken into service within 48 hours.
Q Primary water pumps are not in service.
Drain primary water from external primary water circuit

by closing all drain and vent valves in the external
primary water circuit.
2 Establish a connection to the compressed air system at a

Dry piping system with compressed air suitable point (high static head of the external primary water
circuit.
Make sure that the compressed air is free from oil, dust
Blowing out can be terminated when air leaving the
vent and drain valves is free of atomized air.
3
External part of primary water circuit is
drained and dry

[1] 2.3-8650 N2 Purging Before Draining the Primary
Water System

1111E
During Standstill
Operation
Exciter
With the generator on turning gear or at standstill, make-up air filter.

the dryer and the space heaters must be in operation. The brushes of the ground fault detection system
The filter pads installed at the dryer inlet should should be lifted off the measuring sliprings to prevent
be carefully checked for contamination at regular the formation of rust on the sliprings. In the case of a
intervals and cleaned or replaced in due time. prolonged outage, a protective coating should be
Caution : Never place dryer into operation without applied to the measuring sliprings.

1111E
Turbogenerators Fault Tracing
General
Operation
The details given herein on faults, their possible causes Unless corrective measures can be taken in accordance
and the corrective measures cannot be considered with the following instruction. The turbine-generator should
complete in every respect, since all possible troubles cannot be shout down and the hydrogen should be replaced with
be covered in advance. In most cases, the operator will carbon dioxide. If required, the services of the manufacturer
have to decide on the measures to be taken. The individual should be requested. In most cases, however, sufficient
measures required depend on the mode of operation. details will be found in the Turbogenerator Manual.

1111E
Stator and Generator Supervisory
Operation Equipment
Fault/Cause Remedy
Differences in slot temperatures between individual The embedded RTD's should be checked when
phases of stator winding 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
rest and in non-excited condition. The check should
include resistance measurements as well as testing of
the detector leads, the measuring point selector switches
and the indicators. Care should be taken during
resistance measurements of the embedded RTD's to
ensure that they are not heated as this will falsify the
results. In many cases, a fault can be cleared by
recalibration of the RTD's.
High hot gas temperature Note: If cold gas temperature continues to rise, a
and/or turbine trip is activated via the generator mechanical
High cold gas temperature equipment protection.
Q Hydrogen temperature control is disturbed. Insufficient Verify cause of disturbance by checking analog
cooling water flow volume through hydrogen coolers. indicators (uniform rise of temperatures at all coolers).
Q Insufficient cooling water volume flow through a Verify cause of disturbance by checking analog indicators
single hydrogen cooler. (temperature rise at one cooler).
Check to ensure that the cooling water inlet valve is
fully open. Lower cold gas temperature of disturbed
cooler by adjusting the cooling water volume flow with
the cooling water outlet valve. Ensure that cold gas
temperatures after all hydrogen coolers are of equal
magnitude.
Unbalanced load due to unequal phase loading of If the generator is operated with unbalanced load due
the system connected to generator to particular system conditions, care must be taken that
the continuously permissible unbalanced load is not
exceeded [1]. 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 stator phase. When the 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.
Liquid in generator 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
moisture condensate.
To do this, close shutoff valve before level detector

1111 E
Fault/Cause Remedy
which activated the alarm. Drain the liquid via the shutoff
valve after the level detector and inspect liquid.
Then close shutoff value after level detector and

reopen shutoff valve before level detector.
Repeat this procedure until no liquid is drained from
the shutoff valve.
If the liquid cannot be drained from the generator in
this manner within a reasonable period of time, which
will be the case on occurrence of a large leakage, the
generator should be shut down immediately.
Q Moisture condensate Very small water quantities are indicative of moisture

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.
Q Cooling water from a defective hydrogen cooler Larger amounts of water point to a leaking cooler
section.
Identify defective cooler section. Reduce generator
load [2] and take cooler section out of service by closing
the shutoff valves. Then take measures outlined in the
respective instruction [3].
Q 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 larger leakage (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 de-excited, take primary water pumps
out of service and close control valves before stator
winding and bushings. Remove hydrogen from the
generator immediately. Fault tracing and corrective
action may be started as soon as the generator is filled
with air.
Q Oil Oil level control in seal oil tank is disturbed.

Prechambers in generator are overflowing.
Take corrective actions as described in [4]
immediately.

[1] 2.1-1810 General and Electrical Data
[2] 2.3-8170 Permissible Load Limits of Generator
[3] 2.3-9440 Fault Tracing-Coolers
[4] 2.3-9561 Fault Tracing- Oil Level in Seal Oil System
2.3-9200-0600/2
Generator Supervisory Equipment
Operation Coolant Temperature Control
Fault/Cause Remedy
Low coolant differential temperature
The temperature difference between the cold primary
water and the cold gas amounts to 3 K only.
Q Hydrogen temperature control is disturbed. Cooling Verify cause of disturbance at analog indicators.
water volume flow through hydrogen coolers is Change over control to manual mode and increase
insufficient. cooling water volume flow until a temperature difference
of 5 K is obtained. If necessary, open control valve
manually on unit.
If the temperature difference cannot be increased by
this corrective measure, change primary water
temperature control over to manual mode and throttle
cooling water volume flow through primary water coolers.
Q Primary water temperature control is disturbed. Cooling Verify cause of disturbance at analog indicators.
water volume flow through primary water coolers is Change over control to manual mode and increase
excessive.
cooling water volume flow until a temperature difference
of 5 K is obtained. If necessary, throttle control valve
manually on unit.
If the temperature difference cannot be increased by
this corrective measure, change hydrogen temperature
control over to manual mode and increase cooling water
volume flow through hydrogen coolers.
Low coolant differential temperature

Caution: Temperature difference between cold
primary water and cold gas has dropped to 1 K.
Condensation may occur on primary water cooled
components when surface temperature of these
components drops below dew point of surrounding
hydrogen atmosphere.
Q Hydrogen or primary water temperature control is If the temperature difference between the cold
disturbed. primary water and the cold gas cannot be increased by\
the above corrective measures, it is recommended to
unload and de-excite the generator at once.
Note: On-load running is possible when the dew point
temperature of the hydrogen in the machine is
sufficiently below the cold gas temperature. This will
normally be the case when the closed generator was
dried with the gas dryer for not less than four weeks
and provided that no leakage occurred in the generator
interior during this period.

1111E
Rotor
Operation
Remedy
Fault/Cause
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
manufacturer's product service personnel.

1111E
Coolers
Operation
Fault/Cause Remedy
Liquid in Generator
CAUTION :
Q Leak or defective H2 cooler tube.
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.
De-excite the generator and shut down.Close the valves

in the cooling water supply lines upstream of the hydrogen
cooler sections.
Reduce the hydrogen pressure in the generator (see 2.3-

8610). The hydrogen must be removed from the generator by
scavenging the unit with carbon dioxide.Subsequently purge
the generator with air to remove the carbon dioxide (2.3-
8620 and 2.3-8630)
1 Liquid from cooling header, coolers A/B

2 Liquid from cooling header , center
3 Liquid from cooling header, coolers C/D
4 Sight glass
5 Shutoff valve upstream of liquid level detector rack
6 Liquid level detector
7 Shutoff valve downstream of liquid level detector rack
Fig. 1 Liquid Level detector rack

1111E
Fault/Cause Remedy
Check the liquid level detector rack to identify the defective

cooler section.Drain the water from the rack (see 2.3-9200)
Disconnect the piping as well as the upper inlet and outlet

water channels from the cooler.
Pressurize the generator with air up to 0.5 through 1 bar

gauge pressure.
The defective cooler tube should now be easily identifiable

by the air bubbles escaping from the break location.Mark the
defective tube and depressurize the generator.Subsequently
unfasten the bottom gas seal cover and lower(see 2.5-4100).
The defective cooler section can be drained by opening the

drain plug in the return water channel . Be sure that the
water being drained from the cooler is routed to a suitable
container or , if availaible , to a water treatment plant.
Plug the defective tube at both ends as shown in Fig. 2.

Suitable materials for the plugs are hardwood, cooper or
brass. Force the plugs into tube by lightly striking them with a
suitable mallet , and cut off the end of the plug so that it is
flush with the tubesheet. Note that no more thann 3% of the
tubes of a single cooler section may be selaed.
1 Plug
2 Upper tubesheet
3 Cooler tube
4 Lower tubesheet
Fig. 2 Plugging a Defective Cooler Tube
Reinstall the return and inlet / outlet water channels as well

as the gas seal cover using new gaskets. Snug down the
hexagon bolts as specified in 2.5-4100
Re-connect the piping to the inlet and outlet water channels.
Flood cooler sections by slowly opening the shutoff valves.
Close drain and vent valves as soon as the water discharged
from the cooler sections is free from air bubbles. Carry out
2.3-9440-0600/2 Leaktest of all flanged joints.
Bearings
Operation
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 temperatures should be carefully
monitored to ensure the limit temperature is not
exceeded.
If a deviation occurs, first check cold oil
temperature (oil 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 down.
Bearing oil pressure indicated in the shaft lift oil pipe drops. Oil pressure depends in part on the bearing oil inlet
temperature. 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 valve,
the check valve is leaking. Replace or repair the check
valve at the next shutdown or inspection. A precise
adjustment of the throttling element will again be
necessary during re-commissioning.

1111E
Bearing Vapour Exhausters
Operation
Fault/Cause Remedy
Bearing vapour exhauster 1 failed.
Q Fuses or thermal overload device have tripped main Bearing vapor exhauster 2 automatically takes over
contactor, resulting in failure of bearing vapour venting of generator bearing compartments. Verify that
exhauster 1. voltage is a available. Check fuses and thermal overload
device. Examine bearing vapor exhauster 1 for proper
electrical and mechanical condition. Check operating points
of flow transmitters.
Bearing vapour exhauster 2 failed.
Q Fuses or thermal overload device have tripped main Bearing vapor exhauster 1 automatically takes over
contactor, resulting in failure of bearing vapour venting of generator bearing compartments. Verify that
exhauster. voltage is available. Check fuses and thermal overload
device. Examine bearing vapor exhauster 2 for proper
electrical and mechanical condition. Check operating points
of flow transmitters.
Bearing vapour exhauster 1, loss of control voltage.
Q Fuse has blown, resulting in loss of control voltage. Identify cause of blown fuse (overcurrent or short in
cable). Replace defective fuse and restart bearing vapor
exhauster 1.
Bearing vapour exhauster 2, loss of control voltage.
Q Fuse has blown, resulting in loss of control voltage. Identify cause of blown fuse (overcurrent or short in
cable). Replace defective fuse and restart bearing vapor
exhauster 2.

1111E
Operation Seal Oil Pumps
Fault/Cause Remedy
Seal oil pump 1 MKW11 AP001 failed In the event of a failure of seal oil pump 1, seal oil
Fuses or thermal overload device have tripped the pump 2 MKW12 AP001 automatically takes over the
main contactor, resulting in failure of seal oil pump 1. seal oil supply to the shaft seals.
Check if voltage is available. Check fuses and
thermal over load device. Examine seal oil pump 1 for
proper mechanical and electrical condition.
Correct fault immediately so that seal oil pump 1
can be promptly restarted.
Level detector for low oil level in seal oil tank MKW10 See under Low oil level in seal oil tank MKW10
CL002 has stopped seal oil pump 1. BB001 in [1].
Seal oil pump 2 MKW12 AP001 failed

Fuses or thermal overload device have tripped the The standby seal oil pump MKW13
main contactor, resulting in failure of seal oil pump 2 AP001automatically taxes over the seal oil supply to
the shaft seals if seal oil pump 2 has failed as well.
Caution: If thes seal oil supply to the shaft seals has

been taken over by the standby seal oil pump, make all
preparations for shutdown of generator and ga s
removal.
Check if voltage is available. Check fuses and
thermal overload device. Examine seal oil pump 2 for
proper mechanical and electrical condition.
Correct fault immediately so that seal oil pumps
1 and 2 can be promptly restarted
Level detector for low oil level in seal oil tank MKW10
See under Low oil level in seal oil tank MKW10
CL002 has stopped seal oil pump 2. .
BB001 [1].
Standby seal oil pump MKW13 AP001 failed

Sealing and lubrication of shaft seals with seal
Fuses or thermal overload device have tripped the
oil can no longer be maintained
main contactor, resulting in failure of the standby
Caution: Hydrogen flows into generator bearing
seal oil pumps.
compartments via sealing gap and is extr acted by
bearing vapor exhauster in service. Place all Power
House exhausters into operation immediately.
If another seal oil pump cannot be started
immediately, promptly de-excite and shut down
generator and remove hydrogen gas. Close shutoff
valve MKG 11 AA 531 and open shutoff valve MKG25
AA502 for vent gas.
As soon as the hydrogen gauge pressure of the
generator has been reduced to atmospheric level, the
generator may be filled with CO2 [2] and afterwards
with air [3].

1111E
Remedy
Fault/Cause
In the event of a failure of seal oil pump 1, seal oil

Seal oil pump 1 MKW11 AP001, loss of control voltage pump 2 MKW12 AP001 automatically takes over the
Fuse has blown, resulting in loss of control voltage. seal oil supply to the shaft seals.
Identify cause of blown fuse (overcurrent or short in

cable). Replace defective fuse and ensure that seal oil
pump 1 can be restarted.
Seal oil pump 2 MKW12 AP001, loss of control voltage

Fuse has blown, resulting in loss of control voltage The standby seal oil pump MKW13
AP001automatically taxes over the seal oil supply to the
shaft seals if seal oil pump 2 has failed as well.

cable). Replace defective fuse and ensure that seal oil
pump 2 can be restarted.
Standby seal oil pump MKW13 AP001, loss of control Sealing and Lubrication of shaft Seals with Seal oil
voltage can no longer be maintained.
Fuse has blown, resulting in loss of control voltage. Caution: Hydrogen flows into Generator bearing
compartment via sealing gap and is extracted by
bearing vapor exhauster in service.Place all power
house exhausters into operation immediately.
If another seal oil pump cannot be started
immediately ,promptly de-excite and shut down
generator and remove hydrogen gas.Close shutoff valve
MKG 11 AA 531 and open shutoff valve MKG25 AA502 for
vent gas.
As soon as the hydrogen gauge pressure of the
generator has been reduced to atmospheric level ,the
generator may be filled with CO2 [2] and afterwards with
air[3].
cable). Replace defective fuse and ensure that standby
seal oil pump can be restarted.

[1] 2.3-9561 Fault tracing - Oil Level in Seal Oil System
[2] 2.3-8620 Replacing H2 with CO2
[3] 2.3-8630 Replacing CO2 with Air

Operation Seal Oil Pressures and Temperatures
Fault/Cause Remedy
Low seal oil pressure. TE/EE
Differential pressure valve no longer controls to Check setting of Differential pressure valve.
operating value.
Pressure collapses during pump changeover. Trace and correct cause of pump changeover.
Seal oil filter in service is contaminated. For remedial measures, see below.
High differential pressure across seal oil filter
Seal oil filter MKW21AT001 or MKW22AT001 is con- Place standby filter in service and remove
taminated contaminated filter from service by means of the
changeover valve assembly.The shut off valve in the
filter inlet line must be closed .[1]
Depressurize filter housing via the drain and vent valve
by draining approx 1 dm3 of oil.Remove the filter cover
and throughly clean basket type strainer.Rinse basket
type strainer with turbine oil prior to reassembly to
remove any solvent residue.Reassemble
filter.Following reassembly ,open the shutoff valve in the
filter inlet line in order to vent the filter.
Low vacuum in seal oil tank
Vacuum bypass valve MKW10AA132 is open. Throttle vacuum bypass valve MKW10AA132
Shutoff valve MKW11AA131 is closed. Opon shutoff valve MKW11AA131
Vacuum pump MKW10 AN002 has failed. For remedial measures, see [1 ]
Screw caps on relief valves M KW11AA031 and Refit screw caps to ensure that vacuum pump cannot
MKW12AA031 are missing. draw any air via the relief valves.
High seal oil temperature after cooler

Cooling water volumetric flow rate is too low Verify that correct relationship exists between cooling
or cooler is contaminated. water volumetric flow rate and heat to be dissipated.If
not increase the cooling water volumetric rate flow
by further opening the regulating valve in the cooling
water outlet pipe.Failure of seal oil temperature to
decrease is indicative of dirty cooler.
Fill , vent and place stanby cooler in service on its
cooling water side.Then place standby cooler in
operation on oil side by means of three way valve.
Throughly clean the cooler taken out of operation
on its cooling water side.

Remedy
Fault/Cause
Low seal oil temperature after cooler Adjust regulating valve in cooling water outlet pipe
Cooling water volumetric flow rate is too high. so that seal oil temperature downstream of cooler
amounts to operating temperature .
Varying pressure gauge indications
Entrapped air in pipes. Variations in oil pressure are usually, due to entrapped air in
regulating valves or oil delivery lines. Thoroughly vent all lines and
regulating valves.
Transmission of Mechanical vibrations Check whether mechanical vibrations transmitted to pressure

elements originate from pipes or from the foundation
[1] 2.4-4550 Maintenance and Supervision - Seal oil filters
[2] 2.3-9526 Fault Tracing -Vacuum Pump
[3] 2.3-1638 Operating and setting values - Seal oil system

Operation Oil Level in Seal Oil System
Fault/Cause Remedy
High oil level in TE/EE prechambers
Shutoff valve MKW06AA151, which must always be Open shutoff valve MKW06AA 151 and secure against
open and secured against closing, was opened closing
without authorization after removal of lock. (Shutoff
valve MKW06AA151 should only be opened for
setting of level detectors MKA06CL001 and MKW07
CL001 in generator prechambers.)
Level control valve MKA06AA001 does no longer If the fault is due to failure of level control valve the fault
operate properly. The valve remains fully closed or cannot be cleared without removing the level control
opens insufficiently. valve
The indication is given when the oil level in the seal
all drain Iines has risen to such a height that level
detectors MKA06CL001 and MKA07CL001 in the
generator prechambers are immersed in seal oil. Open
control valve MKW06 AA273 so that the oil level will
drop. When the oil level in intermediate oil tank MKW06
BB001 has fallen to such an extent that level detector
MKW06CL001 is no longer immersed in seal oil, the
indication Low oil Ievel in Intermediate oil tankis given.
Then close regulating valve MKW06AA273.
Caution: if the control valve is not closed, the complete
oil volume contained In the intermediate oil tank is
forced Into the seal oil storage tank and hydrogen flows
Into the seal oil storage tank.
If the cause of the trouble is not removed, the oil
level In the seal oil drains lines starts to rise again and
the procedure described above is repeated. Removal of
fault is only practicable following shutdown and emptying
of generator and lowering of oil level in intermediate oil
tank MKW06 BB001.
Emergency operatlon for brief periodsis possible
with manual adjustment of control valve MKW06AA273.
Close shut off valve MKW06 AA151. Make sure that oil
level remains visible in oil sight glass.
Low oil level In Intermediate vacuum oil tank
Control valve MKW06 AA273 which must always Close control valve MKW06AA273
be closed , was opened without authorization
If the fault is due to failure of level control valve the fault

Level control valve MKA06AA001 does no longer cannot be cleared without removing the level control
operate properly. The valve remains fully closed or valve.
opens insufficiently. The indication is given when the oil level in the
intermediate oil tank MKW06 BB001 has dropped to such
an extent that level detectors MKW06CL001 is no longer
immersed in seal oil.
Close shutoff valve MKW06AA151

Fault/Cause Remedy
Caution: if the shutoff valve MKW06 AA151 is not

closed, the complete oil volume contained In the
intermediate oil tank is forced Into the seal oil storage
tank and hydrogen flows Into the seal oil storage tank.
When shut off valve MKW06 AA151 is closed ,the oil
level will rise until the level detector MKA06 CL001 and
MKA07 CL001 in the generator prechambers TE/EE
gives indication HIgh oil level in TE/EE
prechambers.Open control valve MKW06 AA151 again.
If the fault is not eliminated , the oil level In the seal
oil drains will drop again and indication Low oil level in
Intermediate oil tank will occur again . Fault repair can
only be performed following generator shutdown , and
after all hydrogen has been removed
Emergency operatlon for brief periods is possible
by closing MKW06AA151 and with manual adjustment
of control valve MKW06AA273. Make sure that oil level
remains visible in oil sight glass.
High oil level in Seal oil tank MKW10CL001 Close shutoff valve MKW10AA101 and reopen only when
the oil level becomes visible in the sight glass of seal
Oil level in seal oil tank MKW10 BB001 has risen to oil tank MKW10 BB001. If the oil level starts rising again,
such a height that level detector MKW10 Cl001 is throttle oil supply to seal oil tank MKW10 BB001 by
immersed in seal oil. The oil level is no longer means of valve MKW10AA101 so that approximately
visible in the sight glass of seal oil tank MKW10 normal oil level is maintained.
BB001 since it has risen above the upper edge of Operation of the generator can be continued
the sight glass.Level detector MKW10 , covered with without removing the fault. The fault should, however,
seal oil switches off the operating vacuum pump be cleared during the next outage.
MKW10 AN002 so that it can draw no seal oil.
Level detector MKW10CL001 automatically restarts
the vacuum pump when the level detector is no longer
immersed in oil .Level control valve MKW10
AA001 does not close even if the oil level in seal oil
tank MKW10 BB001 continues to rise above its
normal level
Low oil level in seal oil vacuum tank
Oil level in seal all tank MKW10 BB001 has dropped

to such an extent that level detector MKW10 CL002
is no longer immersed in oil. (Oil level is no longer
observable in sight glass of seal oil tank MKW10
BB001.)
Shutoff valve MKW10AA101 was closed. Open shutoff valve MKW10AA101.
Shutoff valve MKW01AA151 in the connection Open shutoff valve MKW01AA151.

between the seal oil storage tank and the seal oil
system was closed.
Level control valve MKW10AA001 in binding. If the fault is due to a failure of level control valve
MKW10AA001 seal oil pumps MKW11AP001 and
MKW12 AP001 are automatically switched off by level .
detector MKW10CL002. The pump is automatically
restarted when the level detector is immersed in seal
oil.
After stopping of the seal oil pump, B valve MKW13
AA001 takes over the seal all supply to the shaft seals
without any interruption. Stop the vacuum pump and open
vacuum bypass valve MKW10AA132 to break the vacuum.
Close MKW10AA132 and start Vacuum pump .Open
and close shutoff valve MKW10 AA132 several times if
the failure cannot be eliminated , it is recommended to
shut down the generator and repair the level control
valve MKW10 AA001.
Caution
In the event of seal oil being supplied to the shaft

seals by standby seal oil pump , all preparations for
shutting down the generator and for removing the
gas from the generator must be made.

Gas Pressures
Operation
Fault/Cause Remedy
Low H 2 bottle pressure.
Q H2 bottle connected is empty. Connect now H2 bottle.
Low H2 casing pressure.
Q There are leaks at generator or piping. Identify leaks by means of a leak detector.
Check whether leaks are due to generator, piping or
gas dryer.
Note: Reduce load when gas pressure drop amounts
to 0.4 bar. Unload and shut down generator when
pressure continues to drop.
Q Setting of pressure reducers incorrect. Set H2 pressure reducers to operating pressure.

1111E
Gas Purity Meter System
Operation
Fault/Cause Remedy
Low H2 purity
Seal oil pump MKW13 AP001 supplying the hydrogen The H 2 purity should be re-established through
side of the shaft seal has failed. In this case, the air scavenging with Hydrogen. Momentarily bring three-way
entrained in the air side seal oil circuit will escape into valve MKG25 AA518 to CO2 vent gas position. Pressure
the generator, resulting in deterioration of the H 2 purity. in generator will decrease. Pure hydrogen is
automatically replenished via the pressure reducers.
The supply of measuring gas to CO2 /H2 purity transmitter Check the complete meter system for CO 2/H 2 purity
MKG25 CQ001 has been interrupted, resulting in faulty transmitter MKG25 CQ001. To do this, interrupt
indication of the instrument. measuring gas flow to meter system by means of three-
way valve MKG25 AA519. Bring three-way valve MKG25
AA507 in H2 calibration position and re-calibrate meter
system with pure hydrogen.
No indication at indicators of purity meter system. Check power supply voltage at power supply input.
Check power supply fuses and, if required, replace
fuses.
Check bridge supply current

Switch off power supply voltage ahead of power supply.
Connect an ammeter with an internal resistance of
750 mili-ohm and of an accuracy class below 0.5% to
the positive terminal of the power supply and the lead
originating at this terminal.
Warning: Be sure no explosion hazard exists.
Switch on power supply.
The bridge supply current can be set to the desired
value of 335 ± 1.7 mA by means of potentiometer R6.
Deviations from the desired value of more than 10 mA
are indicative of a fault in the power supply.
Switch off power supply voltage and disconnect
ammeter.
Check output voltage of transmitter by means of a
voltmeter.
Faulty indication of electrical purity meter system. Check output voltage of transmitter by means of a
voltmeter.
Check setting of electrical zero.
If when setting the electrical zero, the indication is
higher than 100% H2 and cannot be reset to zero by the
zero point adjuster, leaking comparison gas cell is
indicated. The thermal gas analyser cell should then be
replaced.
Warning: Isolate all H2 carrying lines prior to opening
gas flow path to prevent mixing of gases.
Check bridge supply current.
Check burden resistor for correct value and ensure
that all necessary equivalent resistors have been
Gas flow decreases in spite of constant operating inserted.
pressure.
Isolate measuring gas supply to meter system by
means of three-way valve MKG25 AA519 and remove

1111E
Fault/Cause Remedy
and clean dust filter.

If required, insert new filter.
Remove and clean throttle by means of a throttle
needle; re-insert throttle.
Warning: Do not perform any work on purity transmitters
other than that described under Fault Tracing, since the
explosion proof design may be adversely affected.
Warning: Isolate all H2 carrying lines prior to opening gas
flow path to prevent mixing of gases.
2.3-9680-0600/2
Primary Water Pumps
Operation
Fault/Cause Remedy
Primary water pump 1 failed

or
Primary water pump 2 failed
Q The fuses or thermal overload devices have Check whether voltage is available. Check fuses or
operated. miniature automatic circuit breakers and thermal
Q The starting contactor has dropped out due to loss overload devices. Check pump for mechanical defect.
of voltage After clearing the fault, return pump to service
immediately.
In the event of a failure, the standby pump is
automatically started and takes over the water circulation
as long as the fault prevails. The pump is activated either
by a drop of the pressure downstream of the pre-selected
pump or by a loss of voltage.
Primary water pump 1, loss of control voltage

or
Primary water pump 2, loss of control voltage
Q The fuses have operated. The starting contactor has Take corrective actions as described for the above fault.
dropped out due to loss of voltage.

1111E
Water Pressures and Temperatures
Operation in Primary Water System
Fault/Cause Remedy
Low pressure downstream of primary water Ensure that the cause is identified and the fault remedied
pump 1 promptly.Generator operation with insufficient cooling
or water pressure will impair cooling of the unit and is thus
Low pressure downstream of primary water not permissible.
pump 2 The standby pump is automatically started and takes
Q Fault in primary water system. over the water circulation.
High pressure in primary water tank Reduce rate of make-up primary water.
Q The Gas cushion in primary water tank is compressed

due to primary water being added at an excessive rate,
and relief valve cannot vent the gas at corresponding
rate . Check system for hydrogen leakage by determining
hydrogen losses of generator. In the event of a leak ,reduce
Q Hydrogen leak with discharge rates beyond the design the H2 casing pressure (in order to reduce the discharge
limits of the relief valve. flow); if necessary shut down generator.
High differential pressure across fine filter Shut down the water treatment system and replace
Fine filter is fouled. the filter cartridges[1].
High differential pressure across main filter The external section t of primary water system is
Main filter is fouled. assembled with extreme care and thoroughly flushed and
cleaned prior to startup. A contamination of the main filter
will thus normally not occur, and contaminations from
outside are also not feasible. Contaminations originating
from the primary water systems are possible due to resins
in the water treatment systems and due to corrosion
products.However, due to precautions inherent in the plant
design and mode of operation the occurrence of such a
fault is very unlikely. Should such a fault occur ,the main
filter must be taken out of service and filter elements
replaced.
After filter cleaning, operation of the primary water
system can be continued with the cleaned filter .
Low pressure in stator winding Cleaning the main filter during operation as described
Main filter is fouled. above.

1111 E
Fault/Cause Remedy
High temperature after primary water cooler

Q Cooler fouling (cooling water side). In case of cooler fouling, place standby primary water
cooler into operation and take fouled cooler out of service
by cooler changeover.
After cooler cleaning, return cooler to service by
cooler changeover. The standby cooler should be drained
or, its cooling water side and, if necessary, cleaned and
dried.
Always check vents prior to performing any cooler
changeover.
Q Primary water temperature control disturbed. Check the primary water temperature control system
and, if required, change over to manual control.
Q Insufficient venting of coolers. Open vent values (primary water side and cooling
water side) until only water emerges.
[1] 2.4-4740 Maintenance and Supervision of Primary Water

Filters
[2] 2.3-9740 Filters in Primary Water System
2.3-9730-0600/2
Operation Filters in Primary Water System
Fault/Cause Remedy
High differential pressure across fine filter

Q Fine filter is contaminated. Take fine filter out of service by closing shutoff valves:
MKF35 AA261 (after ion exchange).
MKF35 AA281 (after fine filter).
Open shutoff valves:
MKF35 AA521 (vent at fine filter)

MKF35 AA421 (drain at fine filter)
Drain the water from the Fine filter and discard .

Open the filter housing and replace filter cartridge [1].
Recommissioning the fine filter:

Close shutoff valve
MKF35 AA421 (drain at fine filter).
Open shutoff valve
MKF35 AA261 (after ion exchange)

to admit primary water into the fine filter.Do not close the
vent valve MKF35 AA521 until only water is discharged.
Open shutoff valve
MKF35 AA281 (after fine filter)
High differential pressure across main filter The external section of the primary water system is
Q Main filter is contaminated. assembled with extreme care and thoroughly flushed and
cleaned prior to startup. A contamination of the main filter
will thus normally not occur, and contaminations from
outside the system is virtually precluded . Contaminations
originating from the primary water circuit are possible due
to resins in the water treatment system and due to
corrosion products. However, due to precautions inherent
in the plant design and mode of operation the occurrence
of such a fault is very unlikely. Should it nevertheless
occur, the main filter bypass must be opened and the main
filter taken out of service(see Section 2.4-4740,
Maintenance and Supervision of Primary water Filters)

1111E
Operation Water Level in Primary Water Tank
Fault/Cause Remedy
High water level in primary water tank

Q Natural expansion of primary water due to A rise of the primary water level in the tank above the
temperature rise. high level mark calls for particular attention. If the tank
overflows, water will enter into the waste gas system
causing damage to the equipment.
The primary water tank is dimensioned so that
expansion of water due to temperature rise during operation
will not cause the water level to rise above the high level
mark if the tank is filled to an excessive level, the level
should be corrected by draining.
Q Defective primary water cooler. Should the rise of the water level be due to leakage of
cooling water, the defective cooler should be taken out of
service by primary water cooler changeover.
Any leakage of cooling water into the primary water
circuit can only take place when the pressure in the cooling
water circuit is higher than in the primary water circuit.
Low water level in primary tank
Q Leakage in primary water system. Immediately take measures for shutdown of the turbine-
generator. If it is no longer practicable to maintain water
circulation, shut down generator.
Stop the leakage and restore normal water level in
primary water tank by adding fully demineralised water.
If the primary water pressure exceeds the pressure in
the cooling water system, the primary water cooler should
likewise be checked for leaks.
Q Water losses due to filling operation, evaporation and Add water to restore required water level in primary
water sampling. water tank.

1111E
Operation Conductivity in Primary Water System
Fault/Cause Remedy
High conductivity after ion exchanger

Q Faulty instrument circuit (conductivity transmitter). Check the conductivity meter system .
Q Malfunction of alkalizer unit , resulting in excessive Note: If the conductivity continues to rise , the
NaOH feeding into the primary water system. Dosing pump is stopped.Due to this after some time
conductivity downstream of the ion exchanger
becomes low which in turn activates an alarm
Check and if necessary , correct control setting.
Q Flow rate of high-conductivity makeup water to high Acknowledge alarm on alkalizer unit following completion
causing high limit violation. of filling procedure.No further action required.
Q Ion exchanger resins are exhausted and must be Deactivate the water treatment system by closing valves.
replaced
MKF35 AA251 (control valve for water treatment
system)
MKF35 AA291 (shutoff valve after water treatment
system).
Drain water from ion exchanger tank by opening

shutoff valves:
MKF60 AA503 (vent before ion exchanger).

MKF60 AA510 (drain after ion exchanger).
Terminate draining by closing shutoff valves:
MKF35 AA511 (vent before ion exchanger).

MKF35 AA411 (drain after ion exchanger).
Remove the cover from the ion exchanger tank after

disconnecting the flanged joint and the connected piping.
Remove the upper nozzle tray.Tilt tank in its tilting device;
remove exhausted resin mixture from the tank and discard
it taking care that the nozzles in the lower nozzle tray aer
not damaged.
Fill ion exchanger with new resins of quality KR and
place ion exchanger into service again [1],[2].
Note: The use of reactivated resins is only

permissible in exceptional cases.In such cases ,
the resins must be throughly flushed to prevent
the ingress of reactivating agent into the primary
water system.
High conductivity in main system
Take corrective action as described above.

Q Faulty instrument circuit(conductivity transmitter)

1111 E
Fault/Cause Remedy
Q Ion exchanger resins are exhausted and must be Take corrective action as described above.
replaced.
Q Malfunction of alakalizer unit , resulting in excessive Take corrective action as described above .
NaOH feeding into the primary water system
Q Defective primary water cooler A defective primary water cooler will result in a rise in
primary water conductivity upstream of the generator ,
but minimum effect on the conductivity downstream of the
ion exchanger . In such cases , the defective cooler should
be identified and taken out of service by means of cooler
changeover.The generator output must be adjusted
accordingly.
Any leakage of secondary cooling water into the
primary water system can only take place when the
pressure in the secondary cooling water system is higher
than the primary water system.

[1] 2.1-1639 Specification of Ion Exchanger resins
[2] 2.3-7120 Filling the Water treatment system
[3] 2.3-9785 Fault Tracing - Alkalizer unit
.
2.3-9782-0600/2
Volume Flow Rates in Primary Water
Operation System
Fault/Cause Remedy
Flow rate through stator winding low An insufficient cooling water flow results in insufficient
Q Insufficient discharge pressure, clogging or leakage. heat removal and mostly in serious damage to the
(both measuring system have responded) generator.
Since the loss of the cooling system affects the
generator operation extremely quickly, any further drop
in the flow rate causes the signals to be transmitted to
the electronic generator protection.The generator is
then isolated from the system and shut dowm.
Prior to reloading the generator, the fault must be
removed and/or identified.
Flow rate in primary water tank supply low

Q Insufficient discharge pressure, insufficient flow rate An insufficient flow rate through the supply line for the
in main system ,clogging ,leakage or closed control valve primary water tank may result in an insufficient flow of
in tank return H 2 into the primary water tank.
In order to prevent
an unallowable buildup of H 2 in the system,this fault
must be remedied immediately

1111E
Alkalizer Unit for Primary Water System
Operation
Fault/Cause Remedy
Note: All possible alkalizer unit faults are displayed

as single alarms on the control panel of the alkalizer
unit and normally also as a group alarm in the control
room. Apart from the faults/causes covered in this
instruction, also faults of the alkalizer unit itself are
possible which can lead to a deactivation or failure
of the alkalizer unit. For details on fault tracing or
repair of the alkalizer unit, see manufacturer's
instructions.
If the alkalizer unit has been deactivated due to a fault,
the loss of primary water conditioning will not immediately
result in a risk for the generator. It should, however, be always
attempted to continue NaOH injection by changing over the
metering pump from the automatic to the manual mode.
Maintaining the alkalizer unit in operation on occurrence
of faults in the general supervisory system of the generator
is only permissible with intensive operator supervision !
Low conductivity after water treatment.
Cancel alarm by pressing the acknowledge key on
the alkalizer unit as soon as the conductivity has
decreased below the limit value after fault removal.
Q Measuring circuit of conductivity transmitter is faulty. Check the conductivity meter system.
.
Q Make-up water was added too quickly. Adding make-up water to the primary water circuit
too quickly can result in a decrease in conductivity below
the limit value. Cancel alarm at the alkalizer unit after
the addition of make-up water has been completed. No
further action required.
Q Alkalizer unit has been deactivated because dosing The following criteria result in stopping of the metering
pump was stopped pump and thus in deactivation of the alkalizer unit:
— Low volumetric flow rate in treatment system

— High conductivitydownstream of water treatment
system
— High conductivity in main system.
— Open instrument circuit
— Defect of metering pump
Trace and correct fault, taking into account also other

alarms prevailing at the same time.
Conductivity has decreased because the pump was
stopped. The controller attempts to restore the conductivity
to the proper level. Since the conductivity does not respond
after the metering pump has been stopped, the controller
output current rises to the maximum value preset by
parameterizing. It is therefore recommended that the controller
be switched to “Manual” before activating the metering pump

1111E
Fault/Cause Remedy
and that the controller output current be set to zero.Then

start metering pump and reset the controller to “Control”. The
controller adjusts the conductivity to the set point level within
approximately 10 to 15 minutes.
Q Controller Faulty. Check controller[1].
Low conductivity in main circuit Cancel alarm by pressing the acknowledge key as soon
as the conductivity has decreased below the limit value
after fault removal.
Q Measuring circuit of conductivity transmitter is faulty. Take corrective actions as described above.
Q Alkalizer unit has been deactivated for several hours. Take corrective actions as described above.
If possible ,change over metering pump to manual mode[2]
at once and adjust stroke rate to obtain the required
conductivity.
Low NaOH level in tank

Q Sodium hydroxide solution has been largely consumed. Fill NaOH tank with dilute sodium hydroxide solution [3].
Remaining quantity its only sufficient for about 40 hours. Then renew soda lime filter [1].
Low volumetric flow rate in treatment circuit Note: The alarm signal also stops the metering
pump, which in turn adivates an alarm for low
conductivity downstream of the water treatment
system after a short time.
Check valve positions in water treatment system and

Q A valve in treatment circuit was throttled or closed due
readjust volumetric flow rate.
to incorrect operation.
Check valve positions in water treatment system and
Q Volumetirc flow rate through water treatment system
readjust volumetric flow rate.
decreased due to incorrect operation.
High conductivity downstream of water treatment

system
and/or
High conductivity in main system
Note: If the conductivity continues to rise, the
metering pump is stopped, with in turn activates an
alarm for low conductivity downstream of the water
treatment system after a short time.
The alarm is signalled to the control room and to the

generator supervisory control board as a single alarm.
Details on possible causes and the corrective actions
required are given elsewhere in this manual [4].
2.3-9785-0600/2
Fault/Cause Turbogenerators Remedy
Operation
Note: The following status indications are signalled If one of the lamps fails to light up during NaOH injection,
by lamps on the alkalizer unit. a lamp test should be performed first. To do this, press
lamp test key. All pilot and status indicating lamps should
light up.
Loss of supply voltage The supply voltage lamp on the control panel is
extinguished. A group fault alarm is displayed in the
control room.
After fault removal, reactivate alkalizer unit as follows:
— Press acknowledge key.

— Press On key for controller.
— Press Metering Pump On key .
Q Power supply of alkalizer unit has failed. Correct fault and switch on supply voltage.
Q Automatic circuit breaker F1 has tripped. Re-close automatic circuit breaker F1 in control
cabinet of alkalizer unit.
If circuit breaker is tripped again, identify and correct
tripping cause.
Controller deactivated The lamp is extinguished when the controller is

deactivated.
Metering pump stopped The Metering Pump On lamp is extinguished when

the pump has been stopped by a planned shutdown or
due to a limit-value violation.
Reclose automatic circuit breaker F3 in control cabinet of

Automatic circuit breaker F3 has tripped.
alkalizer unit.
Q
If the circuit breaker is tripped again , identify and correct

tripping cause.

1111E
Fuses on Rectifier Wheels
Operation
Fault/Cause Remedy
Fuse indicator operated Note: After operation of one or several fuses, it

Q Failure of one or several diodes. may be necessary to observe the respective
operating limitations [1].
If the number of blown fuses per bridge arm and
rectifier wheel has reached the maximum admissible
value, it si no longer permissible to continue on-load
operation of the generator. The number of blown fuses
indicates a severe fault in the excitation system, the
cause of which must be identified and removed. To
do this, the turbine-generator must be shut down
immediately.
Work on the exciter should be performed with the
field ground fault detection system shown and the
measuring brushes lifted off the sliprings. Remove the
exciter enclosure and half of the enclosure over the
rotating rectifier wheels. Rotate entire shaft assembly
of turbine-generator until defective fuse is brought to
an accessible position. While rotating the shaft,
visually check all fuses in both wheels. To remove
defective fuse, detach contact splice strap of the heat
sink by unscrewing lock nut. Unlock and unscrew the
screw attaching the fuse to the wheel on front side. A
continuity test of the fuse will indicate whether fuse
failed due to an electrical or mechanical fault. A
mechanical fault is unlikely.
If fuse failed electrically, the cause of the fault
(defective diode) should be located by megger test.
To do this, disconnect flexible lead from the three-
phase power lead. In cases where two diodes are
mounted in each heat sink, both flexible leads must
be disconnected. A controlled DC voltage source of
not less than 1000V with constant output voltage must
be available for the measurements. Apply DC voltage
to diode in reverse direction. Use another connection
to tie the rectifier wheel to the voltage potential.
Connect a micro-ammeter for determination of reverse
current in circuit between the voltage source and the
diode connection.
To obtain the blocking characteristic of a diode,
increase applied voltage in steps up to a maximum level
of 1000 V and determine the reverse current for each
step. At least three measurements are necessary for
plotting the characteristic, the recommended voltage
steps being 500 V, 750 V and 1000 V. The maximum
permissible reverse current at 1000 V amounts to 500
µ A. If this limit is exceeded, the diode must be replaced.
If the shaft assembly cannot be shut down for
several hours, e.g. because cool down of turbine is
still in progress, the measuring setup described above
can probably not implemented. In such a case, the

1111E
Fault/Cause Remedy
shaft should be stopped for brief periods only to
enable a replacement of the diode(s) in the respective
branch circuit. Plotting the blocking characteristic and
assessing the reusability of the diode(s) can then be
done while the unit is running.
The defective diode(s) should be cautiously
unscrewed from the heat sink using the special diode
wrench.
B e f o r e i n s ta l l i n g n e w d i o d e s a n d f u s e s , t h e
following checks must be made:
After cleaning the heat sink, the insulation
resistance between isolated heat sink and wheel must
be measured using a 500 to 1000 volt megger.
Insulation resistance should be more than 10 MΩ Ω.
Fuses and diodes are both individually tested at
the BHEL factory. Checking the characteristic data
before installing new diodes and fuses will thus not
be required. Only make sure that each replacement
diode is of the same type as the defective diode
(observe forward direction).
Before installing any replacement diodes, apply a
lubricant (Teflon spray) to the threads and coat diode/
heat sink contact surface with a contact agent (silicone
paste). Diodes should be screwed into the heat sink by
hand and then torqued to 10 mkg.
Use self-locking nuts for attaching the flexible
leads to the three-phase power lead.
Be sure that the contact surface (front face) of fuse
bears flush against the contact surface of wheel. After
the fuse has been properly screwed into the wheel
and strap of the heat sink, check clearances between
fuse and wheel using a feeler gage. If a distance of
more than 0.1 mm is measured between fuse and
wheel, fuse should be re-filing of bore in fuse strap.
Finally, the front-side set screw should be locked. If
several fuses and diodes are to be replaced, this
procedure should be repeated.
No replacement of fuses or diodes must take place
without checking.
Running behaviour of the exciter will not be
affected by an exchange of diodes and fuses because
of small differences in the weights of replacement
parts.
Prior to re-assembly of the exciter enclosures,
i n s u l a t i o n r e s i s t a n c e o f e x c i t e r, i n c l u d i n g r o t o r
winding, should be checked. If measured by a megger
applying a measuring voltage of 500 volts, insulation
resistance must not be below 1 M Ω.
Af t e r i n s t a l l a t i o n o f the enclosures and
reactivation of field ground fault detection system, the
generator may again be placed in service.

2.3-9901-0600/2
Exciter Temperatures
Operation
Fault/Cause Remedy
High hot air temperature at main exciter

and/ or
High hot air temperature at rectifier exciter
Q The cause is a change in the cooling water With a rise in cold water temperature, higher
conditions. cooling water flow is required for removal of the loss
heat. Increase cooling water flow.
High cool air temperature

Q The cause is an insufficient cooling water flow. Increase cooling water volumetric flow rate up to
the maximum permissible limit.
Q Trapped air has accumulated in cooler. Vent cooler by means of vent screws.
Q Cooler is fouled on water side. If the cold air temperature continues to rise above
the permissible level, the generator should be
operated at a reduced load.
Unload and shutdown the generator at the next
possible occasion.
Remove the exciter enclosure, isolate the cooling
water supply and detach return water channel for
cooler cleaning.
Thoroughly clean individual cooler tubes with a
tube cleaning brush. If this should not lead to the
desired result, the coolers should be disassembled
and cleaned by hydraulic or chemical means.
Use new gaskets for refitting water channels.
We recommend cleaning the exciter coolers on the
air side as weld. Make sure the emergency ventilation
flaps are in the emergency ventilation position so that
the dirt removed from the fins cannot enter the exciter.
For this purpose, cover main exciter, rectifier
wheels and pilot exciter with a tarpanlin. Blow out
coolers with clean and dry compressed air. After
careful cleaning, the trapanlins should be removed
and the exciter enclosure placed in position over the
exciter. Check to make sure the seals are tight around
the exciter enclosure to prevent the exciter from
drawing unfiltered air into the enclosure.

1111E
Operation Exciter Cooler
Fault/Cause Remedy
Liquid in exciter
Q The cause is a leak or a tube rupture at the cooler Unload and shut down turbine-generator.
tube bundle.
Identify the defective cooler section. Close cooling
water inlet and outlet of this cooler section.
Drain the water from the cooler. If the defective
cooler tube cannot be identified by a simple visual
examination, disassemble the cooler section remove
water inlet/outlet and return water channels. All cooler
tubes must be separately subjected to a leakage test.
Leakage Test of Individual Tubes

To perform the leakage test, use rubber plugs at
one end and a hollow plug with a small tube fitting for
connection to a water or air line at the opposite end.
See Fig. 1.
1 2 3 4 5 6 7
1 Compressed air hose 5 Tube

2 Hose 6 Plug
3 Hollow Plug 7 Tube sheet
4 Cooler section
Fig. 1 Identifying a Defective Cooler Tube
Plug the tube to be tested at both ends and apply

a low test pressure via the air or water line.
For checking purposes, a pressure gauge can be
installed in the line, which will indicate a pressure
drops even for minor leaks after a short time.
If the leakage test in performed without pressure
gauge, a visual examination on the air side must be
possible.
Leakage Test With Air in Water

Dry the individual tubes by blowing air through the
tubes. Plug all tubes of the cooler section at one end
and place cooler section in a water basin. Each tube
can now be leak tested with air at 0.5 bar, max. During
the leakage test, air bubbles will escape from the
tube(s).
Note that isolated air bubbles may rise from
accumulations of trapped air in the cooler section

1111E
Fault/Cause
1 2 3 4
1 Plug
2 Tube sheet
3 Cooler tube
4 Tube sheet
Fig. 2 Plugging a Defective Cooler Tube
which have nothing to do with the leak to be identified.

Note: If several defective tubes are identified, it
must be decided right away whether the heat
removal capacity remaining after plugging of the
defective tubes is sufficient for emergency
operation.
Plug the defective tube at both ends as shown in

Fig.2. Remove all plugs from the remaining tubes.
Then bolt on water inlet/outlet and return water
channels and perform a leakage test of the cooler
section at the specified test pressure. If no leak is
detected, the cooler section should be installed, filled
with water and vented. The cooler section may remain
in operation until the next inspection or outage, at
which time the cooler section should be replaced.
2.3-9914-0600/2
Stroboscope
Operation Type LX5 (220 V)
Fault/Cause Remedy
Stroboscope defective
Pins 2 and 9 on plug board 2 are interconnected for Check to ensure that supply voltage is available at
a supply voltage of 220 V. pins 1 and 9 on plug board 2. If no voltage is available,
check cable and fuse.
Note: Voltage specified below may vary within a
tolerance range of ± 15 %.
Printed circuit board 1 defective

Supply voltage of 220 V is available at pins 3 and 8. Verify that following voltages are available:
Plug board 1, printed circuit board viewed from below Ground/pin 12 abt. 310 V DC
Ground/pin 6 abt. 23 V DC
1 2 3 4 5 6 7 Ground/pin 7 abt. 5 V AC
Ground/pin 11 abt. 24 V AC
Replace printed circuit board if, on pressing the On

8 9 10 11 12 13 push button (hold push button if relay fails to pick up) the
supply voltage is available at pin 2/3 and 8/9 and is not
available at pins 6, 7, 11 and 12. If one of the voltages
measured at these pins greatly deviates from the specified
value, the cause may be a short on another printed circuit
board. Extract printed circuit boards 2 to 4: voltages at the
pins must now reach or exceed the specified value. Switch
off stroboscope and insert one printed circuit board after
the other until voltage at the respective measuring point
collapses. Replace printed circuit board identified in this
manner.

Supply voltage of 220 V is available at pins 1 and 9.
Relay d1 must pick up on depressing the On push
Plug board 2, printed circuit board viewed from below button. If the relay drops out again on releasing the push
button, the push button should be pressed again and held
1 2 3 4 5 6 7 in position. Measure voltage at pins 11 and 5 with respect
to ground (15 V DC). If no voltage is available, replace
printed circuit board 3. If voltage is available, replace printed
circuit board 2.
8 9 10 11 12 13

Plug board 3, printed circuit board viewed from below
1 2 3 4 5 6 7 Ground/pin 13 abt. 23 V DC
Ground/pin 11 abt. 5 V AC
Ground/pin 9 abt. 6-9 V AC
8 9 10 11 12 13
If no voltage is available at pin 7 or with 15 V or 0 V at
pin 9, replace printed circuit board provided that voltage is
available at pins 13 + 11.

1111E
Fault/Cause Remedy
Defect on plug board 4

Plug board 4, printed circuit board viewed from below Verify that the following voltages are available:
1 2 3 4 5 6 7 Ground/pin 12 abt. 310 V DC

Ground/pin 9 voltage should not exceed 280 V but must
not be zero. Replace printed circuit board if above voltages
8 9 10 11 12 13 are not obtained.
One flash tube failed If only one flash tube functions properly, the cause of
the malfunction is the flash tube and not the control unit.
Replace failed flash tube.
Functional check: Interchange the flash tube connectors.
2.3-9941-0600/2
Exciter Drying System
Operation
Fault/Cause Remedy
Exciter dryer disturbed
• Limit switch failed to operate, i.e. motor-actuated flap Set lever for manual operation at flap shaft to
is hot in Open position. Open position and lock lever with locking device.
Check flap including actuator for proper
mechanical condition.
Check 6.3A fine-wire fuse of flap motor for
continuity.
After fault removal and loosening of the lever lock,
the lever should remain in the Open position.
• Overheat protection has switched off the exciter Open door in exciter enclosure behind which the
dryer. In most cause is no or an insufficient air dryer is located from the operating floor. Following a
flow. short cool down period, the overheat protection
automatically returns the dryer to service.
Check whether air is drawn in via the intake parts
on both side of the air dryer.
If yes, the air flow passage is obstructed. Inspect
prefilter in door for contamination [1].
If air is drawn only ,via one intake part,the free flow of
dry air or regeneration air is obstructed .Restore free flow
condition
If no air is drawn in via both intake parts, the

ventilator motor in the dryer has failed. The exciter
dryer should be de-energized, disassembled and
returned to the manufacturer’s works for repair. A2 kW
heater-blower should be used inside the exciter
enclosure for dehumidification as long as the dryer is
not available due to repair.

1111E
Ground Fault Detection System
Operation in Exciter Field Circuit
Fault/Cause Remedy
Ground fault detection system disturbed

Q Carbon brushes have poor or no contact with Install carbon brushes and plug-in brush holders
measuring sliprings. strictly in accordance with maintenance instruction [1].
Q Exciter voltage response takes longer than 5 s. Fault alarm is automatically extinguished after
removal of cause.
High-resistance ground fault in exciter circuit Immediately investigate cause of ground fault alarm.
(RE < 80 k Ω ) Measure insulation resistance in exciter circuit if the
generator can be disconnected from the system and de-
excited [2].
If an insufficient insulation resistance is measured,
operation of the generator should be continued only after
consultation with the manufacturer to avoid possible
major damage.
Low-resistance ground fault in exciter circuit At RE < 5 k Ω, a TUSA trip is activated by the electrical
(RE < 5 k Ω) generator protection, and the generator is disconnected
from the system and de-excited.
If the insulation resistance measurement confirms the
ground fault, the generator must be removed from
service. The manufacturer should be notified and
entrusted with the fault removal.
If no ground fault can be identified by the insulation
resistance measurement, check system once more for
ground faults at rated speed before exciting the generator
again.

[1] 2.4-4990 Maintenance and Supervision or Ground
Fault Detection System
[2] 2.5-3300 Insulation Resistance Measurements on
Rotor and Exciter Windings

1111E
Turbogenerators Maintenance and Supervision
Introduction
Maintenance
The turbogenerator and its auxiliaries require

continuous maintenance and supervision to as-
sure reliable operation and serviceability of the
complete plant. Maintenance and monitoring are
required both during operation and when the unit
is at standstill.
Some maintenance work should

preferably be performed with the unit
at rest, e.g. in the case of any special
conditions being noted in the operat-
ing log, while other maintenance work
may be carried out during normal
operation.
The maintenance work required on the

generator described herein is specified in
detail in the following.

1111E
Turbogenerators Survey on Maintenance and Supervision
Operation

1111E
Turbogenerators Survey on Maintenance and Supervision
Operation

Turbogenerators
Maintenance and Supervision of Stator
Maintenance
Maintenance Intervals
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check grounding brushes ×
Check sight glasses after level detectors for liquid level ×
1 Monitoring the Temperature of Components cooling water inlet valves at the individual cooler
sections should be fully opened.
It is important that all temperatures remain within To prevent undue stressing of the generator, it is
the specified upper and lower limits. If a temperature desirable to maintain a constant temperature in the
deviation is observed the cause must be determined generator by control of the cooling water flow.
immediately and the original temperature restored. In addition to the gas temperatures, the cooling
If there exists the danger of overheating, a water temperature is also measured. The cooling
corresponding load reduction should be made. water inlet temperature of all cooler sections should
The temperature between the top and bottom bars be measured in the cooling water inlet pipes, while
of the stator winding are measured with resistance the cooling water outlet temperature should be
temperature detectors (RTD’s). measured separately for each cooler section in the
The RTD’s are embedded in the winding and cooling water outlet pipe after each cooler section.
distributed uniformly over the three phases. The
RT D ’s i n t h e s t a t o r w i n d i n g s h o u l d t r a n s m i t 3 Hydrogen Pressure in Generator
approximately identical values for identical currents
in all three phases. If different temperatures are On-load running should always be performed at
indicated with identical currents in the three phases, the specified hydrogen pressure, since it results in
a check should be performed to determine if the slot minimum thermal stresses in the generator interior.
RTD’s are correctly calibrated and/or compensated. If the specified hydrogen pressure cannot be
Differences in the temperature indication upto 5°C maintained for unforeseeable reasons (e.g. lack of
m a y b e d u e t o t o l e r a n c e s i n t h e s l o t RT D ’s, gas, high gas losses), the generator should be
compensating resistors and tolerances caused by unloaded and de-excited when the pressure has
differences in the contact at the measuring point dropped by 0.4 bar (5.7 psig).
selector switch. Other small temperature differences
may be due to different mounting conditions at the 4 Primary Water Flow Rates
RTD’s.
An insufficient primary water flow results in
2 Monitoring the Cooling Gas and Cooling Water insufficient cooling of the water-cooled components.
Temperatures Therefore, the flow rate must not fall below the lower
limit value.
The temperature of the cooling gas in the
generator is measured with one RTD before and after 5 Primary Water Temperature
each cooler section. The RTD’s installed after the
coolers indicate the temperature of the gas used for Continuous recording of the primary water
generator cooling. The cooling water supply to the temperature is essential to ensure safe on-load
individual cooler sections should be adjusted so that running of the turbine-generator. Many faults can thus
the gas outlet temperatures at all cooler sections are be recognised and remedied at an early stage. This
approximately identical. The setting of the cooling is particularly important for a disturbed cooler
water flow should be made by changing the performance (fouling, venting etc.).
adjustment of the cooling water outlet valves. The

1111E
Note: The temperature of the cold primary of a disturbance in uniform cooling in individual branch
water should be higher than the H 2 cold gas circuits. To avoid any risk in cooling of the stator
temperature by not less than 5°K (9°F) under winding, it is recommended to contact manufacturer’s
all conditions of operation in order to positively product service department and to ask for removal of
avoid the formation of moisture condensate on the cause.
the components carrying primary water. The
d i ff e r e n c e b e t w e e n t h e p r i m a r y w a t e r i n l e t 7 Liquid Leakage Detection at Level Detectors
temperature and the cold gas temperature is
measured directly and monitored continuously. An Liquid entering the generator housing is sensed
a l a r m i s a c t i v a t e d w h e n t h i s d i ff e r e n t i a l by level detectors. Sight glasses, located before and
temperature drops below the predetermined value. after the level detectors, permit any leakage to be
When no differential temperature exists any longer readily detected before the liquid level will have risen
or when the primary water inlet temperature is up to the level detectors.
even lower than cold gas temperature, the
generator must be unloaded and de-excited at 8 Grounding Brushes
once.
The carbon brushes should be checked at regular
6 Primary Water Pressure Before Stator Winding intervals. During operation, the useful length of each
individual carbon brush can be determined by a visual
The pressure of the primary water before entering inspection. For limits of wear, see Description [1].
the stator winding can be taken as a reliable criteria The carbon brushes should be replaced with new
for a safe cooling water supply to the various branch ones having contact faces which match the rotor shaft
circuits. contour.
A small change in pressure up to a maximum of
10% has no influence on cooling of the stator winding. Note: Ensure to insert the grounding brushes so
Major changes with rising tendency may be indicative that the brush with carbon layer is followed by a
brush with silver layer when looking in the
direction of rotation of the rotor shaft.
[1] 2.1-1820 Mechanical data

2.4-4210-0600/2
Turbogenerators
Maintenance and Supervision
Maintenance of Generator Coolers
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check cooler vents ×
1 General the measures outlined below should be taken.
Special measures should be taken to prevent corro- 2 Coolers

sion damage to the cooler [1]. Cooler sections having
no cooling water flows for some time may be subject to During normal operation, the cooling water flow
standstill corrosion. In addition to many other corrosive through all cooler sections. Since the coolers are de-
influences, such as the different elements of the cooling signed for 100 % capacity at maximum cooling water
water, locally differing deposits, raw materials, etc., there temperature, the condition may arise that the coolers
exists the danger that microorganisms on the tube walls are supplied with smaller cooling water flows for long
may die and decay due to a loss of fresh water supply periods. Depending on the purity of the cooling water,
(lack of oxygen). Ammonia is formed from such decay this may result in deposits due to the lower water veloc-
which may lead to stress corrosion cracking. Corrosion ity in the cooler. To prevent cooler damage, it is there-
damage can only be properly prevented if the cooler is fore recommended to rinse the coolers with the full wa-
drained on the water side, cleaned, completely dried and ter flow during short outages. In addition, the coolers
maintained in a dry condition. With the generator in com- should be frequently cleaned with brushes. For heavy
mercial operation, such measures are often unfeasible, cooler contamination and if operational restrictions and
particularly in cases of short outages. In such cases, shutdowns are undesirable, it is recommended to install
a continuous cooler water purification system.
Fig. 1 Cooler Section (disassembled) Fig. 2 Purification Brush
[1] 2.3-5003 Hints for cooler operation

1111E
Turbogenerators
Maintenance of Bearings
Maintenance interval
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check EE ground bearing insulation X
Check EE shaft seal insulation
X
Check exciter bearing insulation
X
1 General
During normal operation, no service or maintenance spective bearings should be checked. Such pressure re-
work is required on the bearings of the generator, how- duction may be indicative of damage in the area of con-
ever, bearing vibrations, bearing temperatures, oil tem- tact surface, the bearing babbitt, leaking supply pipes,
peratures, and oil pressures should be continuously or defective pressure limiting and check valves.
monitored. The temperature of the lubricating oil supplied to the
The generator bearings require particular attention bearings is controlled by the cooling water flow to the
during each new startup, following brief shutdown. Care- bearing oil cooler. The temperature of the generator
ful monitoring will also be necessary within the first few sleeve bearings are displayed in the control room.
minutes after runup until the normal operating values
are restored. If the operating values prevailing after a 2 Checking the Shaft Seal and Bearing Insulation
restart exceed the permissible limit values, the unit Checking the shaft seal and bearing insulation dur-
should be shut down immediately. ing operation [1] may be done by way of the shaft volt-
The lift oil pressure for the shaft journals should be age prevailing with the generator running in an excited
adjusted so that the shaft is lifted by not more than 50 % condition. For the purpose, the potential of the insulated
of the bearing top clearance (top clearance amounts to shaft seals and bearings is accessible external to the
0.12 % of the bearing diameter). To prevent any dam- generator. With the generator running, the components
age to the bearings the shaft lift oil system must be in coming into contact with the shaft are separated from
operation at speeds as specified in the turbine instruc- the shaft by an oil film, which has insulating properties.
tion manual. Consequently, a non-defined resistance value is set up
At higher speeds, the lift oil pressure will settle at 40 at the potential measuring points of the shaft seals and
to 80 bar. The oil pressure should be recorded in the bearing sleeves which is dictated by the magnitude of
operating log. If a lower oil pressure is observed the re- the resistances of the oil film and insulating parts.
Fig. 1 Generator Bearing and Seal Insulation Also refer to the following information
[1] 2.5-0300 Checking the Bearing and Seal Insulation

1111E
Turbogenerators
Maintenance of Rotor
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Measure insulation resistance ×
1 Monitoring Rotor Vibrations service personnel determine the cause and assist in
correcting any problems.
The vibrations of the generator rotor should be moni-
tored and any change should be carefully observed. 2 Measuring Insulation Resistance
Should a change in vibration characteristics be noted, it
is recommended to have the manufacturer’s product The insulation resistance of the rotor winding towards
ground should be measured once a year [1].

[1] 2.5 – 3300 Insulation Resistance Measurement
on Rotor and Exciter Windings

1111E
Maintenance Seal Oil Pumps and
Bearing Vapor Exhausters
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Check over seal oil pumps 1 and 2 x
Perform functional check of standby seal oil pump x
Change over bearing vapor exhausters x
Repack regreasing devices of bearing vapor exhauster shaft seals with gease x
1. Seal Oil Pumps showing that the standby seal oil pump is in operation
To prevent dry running of the pump and to ensure are displayed during the short running period.
proper lubrication of the shaft seal, each new or Perform changeover to standby pump once per
overhauled seal oil pump should be filled with turbine oil month. Check pump delivery pressure and then change
via the oil filling plug, unless this has already been over to normal-service pump.
accomplished through the oil supplied to the oil inlet of
the pump. In addition, the oil ensures proper seallng of 2. Bearing Vapor Exhausters
the shafts for pump priming. The bearing vapor exhausters are provided with a
Change over seal oil pumps 1 and 2 at monthly regreasing device for the axial shaft seal. Repack
intervals. To do this start standby pump by manual regreasing devices with grease every six months.
control. Then stop pump so far in service by manual The exhausters should be changed over once per
control. month. To do this follow the same procedure as for the
Perform functional check of standby seal oil pump seal oil pumps.
3 once per month. To do this. start standby pump by
manual control. After a short running period, this pump
will then be automatically stopped again after elapse of
a preset time delay. Check to ensure that the indications
1. Venting Screw/ Oil filling Plug 3. Pressure Relief Valve 1. Regreasing device
2. Discharge Flange 4. Drive Shaft 2. Drive Motor
Fig.1 Seal Oil Pump Fig.2 Bearing Vapour Exhauster

1111E
Maintenance Seal Oil Coolers
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Briefly flush satndby cooler with cooling water at full flow rate( wet layup only ) 2x
Changeover coolers(at regular intervals-wet layup only) x
Check active cooler for proper venting. x
Check seal oil supply lines and shutoff valves for leaks. x
1. General 2 . Cooler changeover

One of the two seal oil coolers is in service while Prior to changing over from one cooler to the other,the
the other remains in standby.The cooler in stanby mode water side of the cooler in standby mode must be filled.
must be filled with oil but its water side must be Care must be taken to ensure that the oil and water
empty,clean and dry in order to prevent any corrosion sides of the cooler are adequately vented.
that could be induced due to stagnant condition(dry layup) When the cooling water flow through the standby
.The drain and vent valves must be open to ensure that cooler is at full flow rate,the oil side changeover can be
the water side of the cooler is maintained in a dry performed.The changeover is executed by operating
condition. the 3 -way valve at the inlet of the cooler.
With wet layup , be sure that the water side of Stop the cooling water flow through the now
the standby is continually flushed at a low rate.In addition inactive seal oil cooler by closing the corresponding
,the standby cooler must be flushed with cooling water cooling water valves upstream and downsttream of the
at full flow rate twice weekly.For this purpose open the cooler.
corresponding cooling water valves upstream and
downstream of the standby cooler.
1 2 3
1 Oil side vent
2 Three way valve
3 Oil side drain
Fig.1 Seal Oil Cooler

1111E
Seal Oil Filters
Maintenance
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check degree of contamination of seal oil filters ×
The seal oil filters are designed for easy in service The housing of the contaminated filter must then be
monitoring. The degree of filter contamination can be depressurized by opening the drain and vent valves
read off by the differential pressure indicator.The por- ,and by draining approximately 1 dm 3 of oil. Subse-
tion of the displayed red dial corresponds to the differ- quently , the filter cover must be removed to enable
ential pressure i.e. the degree of filter contamination. acess to the filter element. This should then be removed
An alarm is activated when the differential pressure from the housing and cleaned thoroughly.
reaches a specified upper limit.
Prior to reassembly , the filter element must be
Following the activation of an alarm , the standby flushed with turbine oil to remove any traces of sol-
filter element must be taken into service and the con- vent.
taminated filter out of service by means of the
Following reassembly, open the shutoff valve in th
changeover valve. The shutoff valve in the filter inlet
efilter inlet line in order to vent the filter.This valve must
line must be closed.
remain open after completion of the venting
procedure.The filter elements must be cleaned during
each inspection.

1111E
Turbogenerators
Maintenance Gas Consumption
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check gas consumption ×
Check shutoff valves for free movement ×
Check shutoff valves with magnetic drive for function and gastight ×
Check gas supply lines and shutoff valves for leaks ×
1 General
of the hydrogen flowing out continuously via the purity
meter system for measuring the gas purity in the generator,
Caution: The CO2 bottle rack should be equipped with
and the gas removed from the generator through the seal
full bottles so that a sufficient quantity of carbon dioxide
oil and discharged into the waste gas line.
will be available for any required displacement of the
Gas quantities escaping uncontrolled are those lost
hydrogen.
through leaks in the generator and gas system.
A sufficient number of full hydrogen bottles should
If an undue loss of gas occurs on the unit, the location
be kept in stock at all times taking into consideration the
of the leak must be determined [1]. To do this ,We
gas consumption rate of the unit and the availability of
recommend the Exotector Type G634P gas analyzer.
new hydrogen.These bottles are to be used if the central
Since this leakage gas may present a danger to the
H unit fails..The leak gas volume to be supplied to the
2 environment, it should not amount to more than 18m3 (s.t.p.)
generator in normal operation stems from central H supply.
2 during 24 hours. In the event of the gas leakage losses
On occurrence of a central H supply system
2 exceeding 18m3 (s.t.p.) during 24 hours, leak tests should
failure,The H bottles supply thr generator.
2 be performed and the gas losses reduced below this limit.
According to section 4.6e in VDE 0530, Part 3, not
3 In case such measures are not successful, even on
more than 2-3 H 2 bottles(approx 20 m s.t.p) should be
reduction of the gas pressure in connection with a
connected and open during normal operation.
corresponding load reduction, the unit should be shut
On occurrence of a leak and the resulting higher gas
down and the hydrogen removed from the generator (see
consumption, only the open H2 bottles would be emptied
section 4.6d in VDE 0530, Part 3).
at a faster rate. In addition an alarm is activate to alert
the operator in due time.
2.1 Leak detection by means of the Exotector
It is recommended that, to improve the operating
reliability, only the hydrogen bottles in service should be
The suction nozzle of the Exotector should be led
connected to the hydrogen bottle rack, while the other
over the surface of the test object as slowly as possible.
connections should be isolated by means of the shutoff
Note that the leak detection should be carried out above
valves at the H2 bottle rack manifold.
the test object if the leakage gas is lighter than air and
The connection of new gas bottles should be entered
below the test object if the leakage gas is heavier than air.
in the operating logs.
2 Gas Consumption
During operation, the loss of H 2 gas must be

monitored continuously on the basis of daily gas
consumption.
The total gas consumption consists of the hydrogen
quantities escaping both controlled and uncontrolled. Also refer to the following information
The gas quantity escaping under control is composed [1] 2.5-0310 Leakage Tests

1111E
Turbogenerators Changeover between H 2 Bottles and
Replacement of Empty H 2 Bottles in
Operation H2 Bottle rack
CAUTION:
Fire and explosion hazard due to escaping
Changeover and Replace- hydrogen gas.Do not use fire or an open flame
1
ment of H2 bottles
(welding ,oxygen cutting,smoking etc) in the vicinity
of the H 2 bottle rack or the H 2 unit (if avalaible).Use
non sparking tools when working in the vicinity of
the H2 bottle rack or the H2 unit (if avalaible).
NOTE:
In accordace with the requirements of VDE and IEC ,
no more than two bottles may be open at the same
time.The remaining bottles shall be
closed.Transportation and replacement of the H 2
bottles shall be performed in compliance with the
relevant national codes,standards and regulations
as well as the relevant safety requirements.The
work may only be performed by suitably qualified
and trained personnel, and with due care and
attention.
2 When the pressure transmitter MKG11CP001 signals that

the H 2 bottle pressure has dropped below a specific low
Ensure H2 supply to generator by
changeover to different bottles limit, the connected H2 bottles are empty and must be
isolated the gas supply system.The continued gas supply
to the generator must be insured by changing over to two
different , full H2 bottles.
2.1 Close the bottle valves of the empty H2 bottles .The empty
Isolate empty H2 bottles from gas supply H2 bottles must be marked with a sign clearly indicating
system that the bottles are empty .
2.2 Open the corresponding H2 bottles

Connect the next two full H2 bottles
to the gas supply system NOTE:
Record connection of a new bottles and analyze gas
consumption for continuous assessment of
tightness of entire system.If a major gas loss due
to leakage is suspected, identify leaks immediately.

1111E
3
Replacement of Empty H2 bottles in The bottles must not be replaced until all H2 bottles in the
bottle rack H2 bottle rack are empty.The replacement process should
then be performed without any undue delays since the
gas supply to generator is interrupted for the duration of
the replacement process
3.1
Before disconnecting any of the high pressure hoses
Check valve positions of all empty H2
bottles from the empty bottles to be removed from the rack ,it must
be ensured that all bottle valves are closed.Any valves
found in the open position must be cosed.
3.2
The high pressure hoses must be disconnected from the
Disconnect high pressure hose from empty
H2 bottle empty H2 bottles with due care and attention(use non
sparking tools).
CAUTION:
hydrogen gas.The hose may still contain hydrogen
at high pressure.Hydrogen will escape when the
Use a suitable means of transport to transfer the empty H2

bottles to the gas storage area.
3.3 The full H2 bottles must be transfered from the gas

Connect full H2 bottles to high pressure storage area to the bottles rack with due care and
hoses attention.Place the H2 bottles in the bottle rack , and secure
the bottles in position.
Connect the bottles to the corresponding high pressure
hose (directly above the bottles).
NOTE:
A bottle may only be connected to the hose
located directly above the bottle. Do not connect
bottles to hoseslocated above adjacent
bottles.When tightening the screw connection,
particular attention must be paid to ensure that
the hose is not twisted.
3.4
Following replacement of the H2 bottles, all high pressure
Perform leaktest on high pressure hose and
screw connection to bottle valve hoses and screw connections (high pressure hose/H 2
bottle) must be subjected to leaktest as follows:
1) Carefully open the bottle valve.The shutoff valve

downstream of the high pressure hose remains closed.
2) Use suitable test agent (e.g. foaming agent ,DIPROL) to
check screw connection and high pressure hose for
leaktightness.
2.4-4611-0600/2
A leak (escape of hydrogen ) is indicated by bubbles
(when using foam ) or by a hissing sound.
Close bottle valve and carefully disconnect hose from bottle.
CAUTION:
Fire and explosion hazards due to escapimg
hydrogen gas.The hose may still contain hydrogen
at high pressure.Hydrogen will escape when the
Check high pressure hose and screw connection between

high pressure hose and H2 bottle and repeat leakfest.
If the leak cannot be sealed , this section of the gas supply
system must be isolated as follows:
The bottle valve upstream of the high pressure hose must
be secured in the closed position.The leak must then be
sealed by suitably qualified and trained personnel.
3) Close the bottle valves after successful completion of the

leaktest
4
Following replacements of the bottles and successful
Re-enable H2 supply to generator
completion of the leaktest of the high pressure hoses and
the screw connections between the high pressure hoses
and the bottle valves,the H2 supply to generator can be
enabled again by opening the first two gas supply
lines.This is done by carefully opening the bottle valves
and shutoff valve downstream of high pressure hoses
connected to this bottles.
NOTE: The bottle valves of remaining H2 bottles must

remain close until the first two bottles are
empty.
Replacement of the H2 bottles is com-

plete .The hydrogen supply system to
the generator is in operation
2.4-4611-0600/3
Turbogenerators
Maintenance Primary Water Pumps
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check oil level in bearing housings of primary water pumps ×
Check that standby primary water pump is ready for operation ×
Change over primary water pumps ×
1 Checking Oil Levels in Pump Bearing Housings 2 Checking Readiness for Starting
The shafts of the primary water pumps are supported To ensure that the standby pump is ready for
in oil-lubricated bearings. Check oil levels in bearings at operation on a continuous basis, start and immediately
regular intervals. stop this pump once a week.
The exact oil level in the pump in service cannot be
determined at the oil sight glass due to oil foaming. The 3 Changing Over Pumps
oil level in the pump in service should be visible in the The primary water pumps should be changed over
middle of the oil sight glass. The oil should be changed at regular intervals (at least once a month) so that
after about 3000 operating hours (at least once a year). they will be alternately in service.

1111E
Turbogenerators
Maintenance Primary Water Filters
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check degree of fouling of main filter ×
Check degree of fouling of fine filter ×
1 General The main filter bypass is open . After the filter has been
The Primary water filters are easy to monitor during cleaned ,restart the main filter as follows
generator operation , and the degree of fouling of the
primary water filters is shown on the differential pressure Open the Shutoff valves
indicator .
During each inspection of the unit , the main filters must MKF27AA251 (Upstream of main filter )
be cleaned and the cartridge of the fine filter be replaced. MKF29AA251 (Downstream of main filter )
Caution : Explosion hazard due to hydrogen Close shutoff valves

escaping from the water .
Primary water contains dissolved hydrogen .The MKF27AA256 (Upstream of main filter bypass)
filters must be drained with due care and attention MKF27AA286 (Downstream of main filter bypass)
due to the fact that the hydrogen escapes from the
water Close the drain valve MKF27AA411.Do not close the
vent valve MKF27AA511 until only water ( not containing
2 Main Filter air bubbles ) is discharged from the valve.
Due to the purity of the primary water and the cleaness Following restart of the main filter , briefly open vent
of the entire primary water system , the main filter is not valves MKF27AA511 at appropriate intervals to ensure that
subjected to major contamination even during long periods the main filter is vented thoroughly.
of operation.An in-service cleaning is therefore not
normally required .In the event that it is required that the
main filter be cleaned , the main filter bypass must be 3 Fine Filter
opened and the main filter taken out of service, the In order to replace the disposable cartridge of the fine
following procedure shall be adopted: filter, this can be taken out of service for brief periods
Open the main filter bypass by slowly opening shutoff during opeartion.
valves
MKF27AA256 (Upstream of main filter bypass) Change the cartridge as follows:
MKF27AA286 (Downstream of main filter bypass)
Take fine filter out of service (see section 2.3-9740,
Close the Shutoff valves Primary Water system Filters)
Remove old cartridge
MKF27AA251 (Upstream of main filter )
MKF29AA251 (Downstream of main filter ) The fine filter is now ready for use and can be taken back
into service
Open Shutoff valves
MKF27AA411 (Main filter drain valve)

MKF27AA511(Main filter vent valve)

1111E
Turbogenerators
Maintenance of Primary Water Coolers
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check primary water cooler vents x
1 Maintenance of Coolers on Primary Water Side During normal operation, the cooling water flows
Under normal cooling water conditions and generator through the coolers and since the coolers are
operation at rated load,both coolers are in operation. designed for 100 % capacity at maximum cooling water
temperature, it is possible that cooling water flow
2 Maintenance of Secondary water side of coolers through the coolers frquently drops to low flow rates
In order to avoid corrosion -induced damage to the coolers, for prolonged periods. Depending on the purity of the
it is necessary to take special precautions.Coolers which cooling water, this may result in formation of deposits
are not used for a period of time ,i.e. in which there is no and in order to prevent any damge to the cooler it is
flow of cooling water are susceptible to damage induced recommended therefore that the coolers be flushed
by corrosion phenomena associated with stagnant with cooling water at maximum floe rate at appropriate
conditions.Aside from a large number of other corrosive intervals.In addition , the coolers should be cleaned
influences such as the different constituents of the cooling as specified in the opearting instructions[1].In the
water ,locally differencing deposits ,plate materials event of heavy contamination and if restrictions
etc,the micro-organisms on the Heat exchanger plates imposed on the operation or outages are not desired
can die and decay due to lack of fresh water (and or not feasible, It is recommended that a continuous
cosequently due to the lack of oxygen).when micro- cooler water purificatin system be installed .Any
organisms decay ,ammonia is produced,and this can lead planned permanent vents must be checked to ensure
to stress corrosion cracking.Corrosion - induced damage proper functioning.
can only be prevented if the water is drained from the
cooler ,and the cooler cleaned,dried and maintained in a
dry condition.When the generator is in commercial
operation ,this approach is not always
feasible,particularily not in the case of short outages and
due to the fact that the geneartor must be ready for
operation at all times.In such cases,the measures outline
below should be taken.

1111E
of Water Level in Primary Water Tank
Maintenance
The Primary water tank is mounted on the stator frame Note: During make-up operation, the flow velocity
and serves as an expansion tank during operation. A should not be higher than during normal operation
sufficient water level in the primary water tank is the of the water treatment system. Check volume flow
prerequisite for reliable primary water circulation. at volume flow meter MKF35 CF001.
The water level in the primary water tank is
displayed on a local water level gauge. One capacitive During make-up operation, a maximum of 100
level monitoring system is provided to activate a low
3
dm (26 US gallons) of water may be added to the
water level alarm. primary water circuit. Added water volume is
Any loss of primary water in the system can be totaled by volume flow meter MKF37 CF501.
compensated for by introducing make-up water upstream However, if this amount of make-up water is
of the ion exchanger. The quantity of make-up water is insufficient, purge the primary water tank with
totaled by a water flow meter and is indicative of the nitrogen [1].
leak tightness of the primary water system. Nitrogen purging must also be performed if the
If it is necessary to add make-up water to the cumulative amount of added water exceeds
primary water system during operation, close control 100dm 3 within the past month.
valve. During this procedure, the water level in the
primary water tank should be observed carefully,
MKF35 AA251 (Upstream of water treatment ) making sure that no primary water enters the vent
gas system.
and then open shutoff valve
Addition of water is stopped by closing shutoff valve
MKF37 AA261 (in make-up line)
MKF37 AA261 (in make-up line)
to admit water into the primary water system via the
ion exchanger. as soon as the water level in the primary water tank has
reached its nominal value.
Reopen shutoff valve
MKF35 AA251 (Upstream of water treatment ).
[1] 2.3-6810 N2 Purging After Filling of Primary Water

system

1111E
Turbogenerators Replacement of Empty N 2 bottle in N 2
bottle rack
Maintenance
CAUTION:
Replacement of N2 bottle in Danger of suffocation due to escaping N 2.
1
N2 Bottle rack
NOTE:
Transportation and replacement of the N 2 bottle shall
be performed in compliance with the relevant
national codes,standards and regulations as well as
the relevant safety requirements.The work may only
be performed by suitably qualified and trained
personnel,and with due care and attention.
2
When the pressure gauge signals MKG31 CP502 signals that
Replacement of empty N2 bottle in N2 bottle
N2 bottle pressure has dropped below a specified low limit,
rack
the connected N2 bottle is empty and must be replaced.
2.1
Before disconnecting the high pressure hose from the empty
Check valve positions of the empty N2 bottle
bottle to be removed from the rack,it must be insured that the
bottle valve is closed , and shutoff valve MKG31 AA502 is
closed
Any valves found in the open position must be closed.
2.2
Disconnect high pressure hose from empty The high pressure hose must be disconnected from the
N2 bottle empty N2 bottle with due care and attention
CAUTION:
Danger of suffocation due to escaping N 2.The
hose may still contain nitrogen at high pressure .
Nitrogen will escape when the connection is unfas-
tened.
Use a suitable means of transport to transfer the empty N2

bottle to gas storage area.
2.2
Connect full N2 bottles to the high presure The full N2 bottle must be transferred from the gas storage
hose area to the N2 bottle rack with due care and attention.Place
the N2 bottle in the bottle rack and secure the bottle in
position.
Connect the bottle to the corresponding high pressure hose
(directly above the bottle).
NOTE:
When tightening the screw connection ,particular
attention must be paid to ensure that the hose is not
twisted.

1111E
2.4 Following replacement of the N2 bottle , the high pressure
hose and screw connection (high pressure hose/ N2 bottle)
Perform leaktest on high pressure hose must be subjected to a leaktest as follows
and screw connection to bottle valve
1) Carefully open the bottle valve.The shutoff valve MKG31

AA502 remains closed.
2) Use suitable test agent (e.g. foaming agent,DIPROL) to

check screw connections and high pressure hose for
leaktightness.
A leak (escape of nitrogen) is indicated by bubbles ( when

using foam) or by a hissing sound.
Close bottle valve and carefully disconnect hose from bottle.
CAUTION:
Danger of suffocation due to escaping N 2 .The
hose may still contain nitrogen at high pressure .
Nitrogen will escape when the connection is unfas-
tened.
Check high pressure hose ans screw connection between

high pressure hose and N2 bottle and repeat leaktest.
If the leak cannot be sealed , the nitrogen supply system
must remain isolated from the gas supply system.
The leak must be sealed by suitably qualified and trained
personnel at the earliest convenience.
3) Leave the bottle valve in the open position after success-

ful completion of the leaktest
Replacement of the N2 bottle is complete

[1],[2].
[1] 2.3-8650 N2 purging before draining the Primary water

system.
[2] 2.4-4760 Maintenance and Supervision -

Water level in Primary Water tank
2.4-4761-0600/2
Conductivity Meter System
Maintenance
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Record conductivity after ion exchanger and in main circuit ×
Check conductivity meter system by means of test selector switch ×
1 Conductivity Meter System 2. Ion Exchanger
The Conductivity Transmitter are microprocessor based 2.1 Replacing Ion Exchanger Resins
which offer self diagonistic and error reporting feature. A replacement of the ion exchanger resins is required
The error is displayed on LCD screen of Conductivity when the conductivity downstream of the ion exchanger
transmitter and enable the user to identify the possible is higher than in main circuit or rises to a value 0.5μmho/
causes of the problem.Please refer to the O&M Manual cm.
of Generator C&I for detailed information The main circuit may be left in operation during resin
replacement. The various operations for resin replacement
should be accomplished so that the work will be completed
before a conductivity of 1.5mmho/cm has been reached
in the main circuit. With the ion exchanger out of operation,
this value will be obtained after a few days only.
For details on the replacement of the ion exchanger
resins, see under Fault Tracing [1].

[1] 2.3-9782 Conductivity Meter System

1111E
Maintenance Alkalizer Unit
Maintenance Interval
Every 3 Months
Every 6 Months
Annualy
Monthly
Weekly
Daily
Work required
Check Volumetric flow rate through alkalizer unit x
Check level in NaOH tank ×

Analyze water sample taken from primary water circuit ×
Analyze water sample taken from treatment circuit ×
The controller in the alkalizer unit maintains the Prepare concentrated sodium hydroxide solution in
conductivity of the treated primary water at a constant laboratory (observing the specification [1]). To do
value. this, dissolve the necessary quantity of sodium
Alkalizer unit monitoring requires regular checking of hydroxide (caustic soda) in approximately 8-10dm 3 of
the volumetric flow rate and level in the NaOH tank and water [2] to obtain the specified concentration of 10
water sampling. to 20g of NaOH per dm3.
Caution: When handling sodium hydroxide (caustic soda),
make sure to observe the applicable safety regulations.
1 Volumetric Flow Rate Monitoring
Check and record the volumetric flow rate through the Set controller in control cabinet of alkalizer unit to
treatment path during daily inspection of Turbogeneartor.The manual control and then lower manipulated variable
volumetric flow rate can be read at the volume flow meter (controller output current) to zero.
and should amount to about 1100l/h.If necessary ,the flow Open NaOH tank and add concentrated sodium
rate can be corrected by means of the control valve at the hydroxide solution.
treatment path inlet Fill NaOH tank with water [2] to the required level,
Stir solution for proper mixing.
2 Level in NaOH Tank Reclose NaOH tank so that it is tightly sealed and
Check and record level in NaOH tank during daily secure against opening.
inspection of turbogenerator. Reset controller for automatic control.
About 2dm3 of dilute sodium hydroxide is injected
into the primary water systen every day. Note: Due to temporary deactivation of the alkalizer unit,
With the given capacity of the NaOH tank, refilling the conductivity of the treated water will drop to < 0.1
the tank with sodium hydroxide will be required at mmho/cm, and a corresponding alarm will be activated
intervals of about two months. in the control cabinet of the alkalizer unit. Cancel the
The NAOH tank must be filled with dilute sodium alarm by pressing the Acknowledge button as soon as
hydroxide solution if a low level alrm has been issued. conductivity of the treated water has been restored to its
nominal value.
1.1 Adding Sodium Hydroxide Solution Replace the lime filter in the NaOH tank vent each
When preparing the sodium hydroxide solution and time the NaOH tank is refilled.
filling the NaOH tank of the alkalizer unit, make sure to
avoid the formation of carbonates as far as possible by
reducing the time of exposure to the atmosphere to the
absolute minimum.
To prepare the sodium hydroxide solution and to fill
the NaOH tank, observe the following procedure:

1111E
2 Water Analysis conductivity of the water should be measured downstream
We recommended chemical analysis of the primary of a highly acidic cation exchanger (H + form). The
water in the main system and water treatment system conductivity provides information on the presence of other
(sampling downstream of fine filter) at monthly intervals. unwanted anions in addition to the OH ions that determine
Keeping the sample excluded from the atmosphere at a the alkalinity. The measurement should be performed with
constant temperature of 25 oC, the following parameters the sample excluded from the atmosphere to prevent a
should be determined: falsification of the reading by the carbon dioxide contained
in the ambient air. When correct water treatment, the
Conductivity
conductivity at 25oC should be ≤ 0.1 μmho/cm.
pH
Unwanted anions, such as HCO3-, CO3- -, SO4- - and Cl-
Na+ ion concentration
can be admitted with
Cu concentration (total)
Fe concentration (total)
the makeup water
Table 1 shows the normal and limit values to be air or H2 leakage
expected. filter elements or ion exchanger resins not
complying with the specifications [3].
Parameters Normal Limit
Conductivity 1.5-1.8 μmho/cm 2.0 μmho/cm The anions are normally absorbed by the anion
pH 8.5-9 exchanger resins in the mixed-bed filters and can have
Na+ ion a permanently detrimental effect on the alkalization
concentration 25 to 250 ppb 300 ppb process only when the ion exchanger is exhausted.
Cu concentration <5 ppb 10 ppb
Fe concentration <5 ppb 15 ppb
Table1 Normal and Limit V alues of Primary W ater

Chemistry
Operation at the limits given in Table1 involves no
imminent risk for the generator: these limits, however,
indicate abnormalities and the cause must be investigated.
If the results of the water analysis do not provide
conclusive proof of correct water treatment, the

[1] 2.1-1639 Additive Specification for Alkalizer Unit
[2] 2.1-1639/1 Primary Water Specification
[3] 2.1-1639/2 Specification for Ion Exchange Resins
2.4-4785-0600/2
Turbogenerators Generator Drying System
Operation
1 General The tubular ducts are dimensioned so that a lami-

A dryer (dehumidifier) should be connected to the gen- nar flow with low pressure loss is obtained even at high air
erator to avoid the formation of moisture condensate inside velocity.
the stator frame housing with the turbine-generator at rest The moisture absorbed by the dryer wheel is re-
after removal of the hydrogen gas or during overhauls. The moved in a regeneration section by a stream of hot air di-
dry air inlet and outlet connections are located in the stator rected through the wheel in the opposite direction of the inlet
end shields. air and then discharged to the atmosphere.
For connection of the dryer, the covers in the up- After regneration, the dryer wheel material is again
per half end shields should be removed and replaced by the capable of absorbing moisture.
covers comprising the dryer connection branches. The dryer The absorption of moisture and regeneration of
should be connected with fiexible hoses and then placed into the dryer wheel material take place simultaneously, using
operation. separate air streams, which ensures a continuous drying of
the air.
3 Operating Principle of Adsorption Dryers

Dehumidification takes place in a slowly rotating dryer
wheel (approximately 7 revolutions per hour). The honey-
comb dryer wheel consists of a magnesium silicaa alloy
containing crystalline lithium chloride. The inlet side of the
dryer wheel is subdivided so that 1/4 is available for
regeneration and 3/4 for the absorption section.
1 Regeneration air outlet 5 Filter

2 Dryer Wheel 6 Dry air outlet
3 Heater 7 Shutoff valve, motor driven
4 Ventilator
Fig. 2 Schematic Diagram
4 Absorption Section of Dryer

The air be dehumidified passes through the absorption
section of the dryer wheel, with part of the moisture con-
1 Stator Frame 3 End shiled tained in the air being removed by the absorbent material, i.e.
2 Cover lithium chloride. The moisture is removed as a result of the
Fig. 1 End Shields partial pressure drop existing between the air and the absor-
bent material.
2. Mode of Operation of Dryer
The dryer dehumidifies the air within the stator frame 5 Regeneration Section of Dryer
housing. The dryer wheel is made of a nonflammable mate- In the reneration section of the dryer wheel, the accu-
rial. On its inlet side, the wheel is provided with a system of mulated moisture is removed from the dryer wheel by the
tubular ducts, the surface of which are impregnated with a heated regeneration air.
highly hygroscopic material. Continuous rotation of the dryer wheel ensures
continuous dehumidification of the air.

1111E
Turbogenerators
Maintenance Fuses on Rectifier Wheels
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check Fuses ×
Measure insulation resistance ×
1 Fuse Monitoring
arm can be determined from the color marking above
With the aid of the stroboscope whose light fre- the fuse on the edge of the rectifier wheel.
quency is automatically controlled, it is possible to The operating limitations [1] must be observed if
observe each separate fuse on both wheels. To acti- several fuses have blown.
vate the stroboscope, press the On push-button. It is In normal operation, the fuses should be monitored
then possible to select either flash tube 1 or flash tube at least once each day. A check is required at once
2 by pressing the corresponding push-button Lamp1 following abnormal operating conditions, e.g. short-
or Lamp2 to observe each successive fuse on the circuit on the system close to the power plant, asyn-
rectifier wheel. By pressing the feed or return push- chronous running, etc. If the exciter is operated with
button, the flashes can be timed so that a continuous defective fuses, monitoring should be done on an
slow-motion observation of each fuse is possible. hourly basis. If no additional fuses have blown after
two further shifts, normal running routine may be con-
The position of the fuse indicator shows whether tinued.
a fuse is intact or blown due to diode failure. If the
color-coded fuse indicator has taken a radial position, 2 Measuring the Insulation Resistances
the fuse has blown. To determine the condition of the
entire rectifier wheel, it is necessary to know in which Check the insulation resistances of the windings
arm of the bridge each blown fuse belongs. The bridge to ground and the insulation resistances between the
diode heat sinks and the rectifier wheel [2].

[2] 2.5-9000 Excitation System

1111E
Turbogenerators
Maintenance
Exciter Dryer
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Inspect and, if necessary, replace prefilter ×
Inspect and, if necessary, replace dust filter in Exciter dryer ×
Note : The life of the prefilter depends on the dust con- 2 Dust Filters
centration in the power house and on the service hours
of the exciter dryer. It is recommended to inspect the One dust filter each is provided behind the intake
prefilter at shorter intervals during the commissioning branches on both sides of the exciter dryer. With
phase because of the high dust content of the air and proper and regular maintenance of the prefilter, dust
the relatively long period of exciter dryer operation. filters will be required only once per year.
1 Prefilter 2.1 Replacing the Dust Filters
The prefilter is installed in the door behind which the De-energize the exciter dryer.
exciter dryer is located. This door is an integral part of Open the door containing the prefilter.
the exciter enclosure. Disconnect electrical and mechanical connections,
The prefilter consists of a coarse (Acelan) filter and if necessary, and remove dryer.
a fine (Microsorlit-F) filter. The coarse filter is located Loosen screws at connection branch by about
upstream of the fine filter. three turns
Turn connection branch counterclockwise for
1.1 Replacing the Prefilter removal.
Remove filter frame with dust filter.
To inspect or replace the prefilter, open the door Blow out dust filter with compressed air from the
accommodating the prefilter. air-leaving side or wash dust filter. If necessary,
Loosen wing nuts and then remove filter frame and replace dust filter.
the two filter pads. Reinsert filter frame with clean dust filter into the
A slightly contaminated coarse filter can be cleaned dryer, making sure that the filter frame joint is in
by beating or blown out with compressed air from the bottom center position.
the air-leaving side. The fine filter can be reused if Refit connection branch and turn it clockwise
in proper condition. before tightening the screws.
In case of more severe contamination, both filter After replacement of both dust filters, properly
pads should be replaced. restore all connections.
For reassembly of the filter, follow the same Close door and energize exciter dryer.
procedure in reverse order. The exciter dryer is ready for further operation.

1111E
Ventillation and
Maintenance Make-Up Air Filter of Exciter
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check make-up air filters in exciter enclosure ×
Perform functional check of exciter drying system and clean filters, if necessary. ×
1 Make-up Air Filters in Exciter Enclosure 2 Exciter Drying System

The make-up air filters in the exciter enclosure are Slightly contaminated filter pads should be blown out
contaminated by the continuous addition of the air in with clean compressed air from the clean air side or
the exciter cooling circuit. They should be checked at washed in a water bath at a water temperature of ap-
regular intervals and replaced, if required. proximately 30oC, adding a neutral detergent.
Depending on the operating conditions, the ball bear-
ing of the ventilator and the generator should be filled
with new grease every two to three years.
BHEL, Haridwar 2 .4-4930-0600/1

1111E
Turbogenerators
Maintenance of Exciter Coolers
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check exciter cooler vents ×
1 General
2 Exciter Coolers
Special measures should be taken to prevent corro-
During normal operation, the cooling water flows
sion damage to the cooler[1]. Cooler sections having no
through the cooler sections. Since the coolers are de-
cooling water flows for some time may be subject to
signed for 100% capacity at maximum cooling water
standstill corrosion. In addition to many other corrosive
temperature, the condition may arise that the coolers
influence, such as the different elements of the cooling
are supplied with smaller cooling water flows for long
water, locally differing deposits, raw materials, etc. there
periods. Depending on the purity of the cooling wa-
exists the danger that micro-organisms on the tube walls
ter, this may result in deposits due to the lower water
may die an decay due to a loss of fresh water supply
velocity in the cooler. To prevent cooler damage, it is
(lack of oxygen). Ammonia is formed from such decay
therefore recommended to rinse the coolers with the
which may lead to stress corrosion cracking. Corrosion
full water flow during short outages. In addition, the
damage can only be properly prevented if the cooler is
coolers should be frequently cleaned with brushes.
drained on the water side, cleaning completely dried and
For heavy cooler contamination and if operational
maintained in a dry condition. With the generator in com-
restrictions and shutdowns are undesirable, it is rec-
mercial operation, such measures are often unfeasible,
ommended to install a continuous cooler water purifi-
particularly in cases of short outages. In such cases,
cation system.
special measures should be taken.

[1] 2.3-5003 Hints for Cooler Operation
BHEL, Haridwar 2 .4-4940-0600/1

1111E
Turbogenerators
Maintenance of Ground Fault Detection System
Every 3 Months
Every 6 Months
Work required
Annualy
Monthly
Weekly
Daily
Check carbon brushes of ground fault detection system ×
1 Ground Fault Detection System

The ground fault detection system runs continuously.
On occurrence of a ground fault between the winding
and ground an alarm is activated and indicated on the
danger alarm panel.
If a ground fault is indicated, the cause of the ground
fault alarm must be investigated at once. To do this, the
insulation resistance should be measured with a 500V
megger. The ground fault detection system should be
disconnected at the brush gear or isolated if a
changeover switch is provided.
Caution: If, as described below, the measurement is
performed with the generator running and excited, handle
sliprings and brush gear with extreme care since at the
worst the full field voltage may be applied to the slipring
connected to the exciter circuit.
If the insulation resistance drops during the
measurement, exchange polarities at the megger for
checking purposes and repeat measurement.
If insulation resistance measured is not sufficient,
operation of the generator should be continued only after
consultation with the manufacturer to avoid major
consequential damage.
2 Carbon Brushes of Ground Fault Detection

System
The carbon brushes should be checked at regular
intervals. During operation, the useful length of each
carbon brush can be determined without removing the 1 2 3 4 5
brush holder by inserting a gauge stick of insulating 1. Terminal board
material into the bore of the brush holder. 2. Bore for gage stick
If a carbon brush must be replaced, the brush holder 3. Plug-in brush holder
4. Brush carrier segment
should be released from its lock and a new carbon brush 5. Slipring
fitted, making sure that the carbon layer comes before
Fig.1 Brush Holder for Ground Fault Detection
the silver layer in direction of rotation and that the new
brush has a contact face which matches the slipring
contour. Grinding of the new brushes to the required
contour should be done using a model of the ring contour Note: Remove only one brush holder at a time in order
or by grinding to size at the slipring when the unit is at not to disturb proper operation of the ground fault
rest. Carbon brush wear depends on several factors. The detection system. When inserting a new double-layer
normal service life of a set of carbon brushes may be carbon brush, make sure that silver layer comes after
determined by keeping a record of brush replacements carbon layer in direction of rotation
over a period of several years.
BHEL, Haridwar 2 .4-4990-0600/1

1111E
Turbogenerators
Introduction
Inspection
Reliable operation of the turbogenerator will be ensured periods of turbogenerators may thus result in a latent hazard
only if inspections and overhauls are carried out at regular to components which are made of a material sensitive to
intervals so that any faults can be detected and corrected stress corrosion. Endangered parts of the turbogenerator
before they result in costly failures. Following each are, for instance, the rotor retaining rings which consist of
inspection or overhaul, the next inspection should be high-tensile austenitic steel. This latent hazard can only be
scheduled. positively avoided by taking all preventive measures
Provided that commercial tools can be used and that no required to fully protect those components of the
special skills are required for the dismantling and erection turbogenerator which may be affected by stress corrosion
work, the inspections can be performed by skilled power against the effects of moisture [1].
station staff. In all other cases, however, such as for the The shutdown of a turbogenerator for inspection should
inspection of the shaft seals and their auxiliaries, the be made in exactly the reverse order as during
services of the manufacturer’s product service personnel commissioning. It should be noted in particular that the
will be required. hydrogen must be removed from the generator housing
During an inspection, special attention should be given with carbon dioxide only. Should opening of the gas system
to avoiding the effects of moisture on austenitic retaining or of the generator proper be required during an inspection,
ring materials as a preventive measure against stress it is required to replace the carbon dioxide with air.
corrosion. In the event the manufacturer’s personnel are required
According to the conventional interpretation, the for a scheduled inspection or overhaul, it is recommended
conditions for stress corrosion to occur are given by the to notify the manufacturer well in advance. The estimated
combination of sufficiently high tensile stresses and a duration of the inspection or overhaul should also be stated.
sensitive material/corrosion medium system. In high- The spare parts stored for repairs and overhauls
tensile steel, this sensitive system already develops when should be checked at regular intervals. Components packed
the material is exposed to the moisture in the air. Extended in plastic sheeting mostly contain a desiccant which must
storage until startup and extended shutdown or stand-by be replaced or reactivated from time to time.
[1] 2.5-1003 Measures to Prevent Corrosion During

Inspections

1111E
Turbogenerators
Determination of
Inspection Dewpoint Temperature
Relative humidity in %
Example: Relative humidity of ambient air = 50 % and room temperature = +20oC result in a
dew point temperature (DT) of + 9oC, corresponding to an absolute humidity of 8.6 g/m3

1111E
Turbogenerators
Packing, Transport and Storage
Inspection of Generator Rotors
Note
Generator rotors are high-grade components which endangered by stress corrosion and for protection against
are sensitive to moisture. For this reason, they must be mechanical damage during transport and transshipment
protected against corrosion and mechanical damage during procedures.
transport and storage. For protection against the effects of moisture, the rotor
The packing precautions and the organizational retaining rings and the rotor body are packed in sealed
measures for protection during transport and storage are plastic sheeting covers, adding materials for moisture
described below and summarized in [1]. This description absorption. This sealed packing is protected with a second
contains all details required for restoring the standard plastic sheeting cover. In the case of sea transport, a third
packing provided by BHEL for delivery of the rotor. If a plastic sheeting cover is provided for the rotor retaining
rotor is to be returned to the manufacturer’s works for rings and the rotor body. This cover forms a second
overhaul or in the case of a prolonged outage of the additional barrier against the diffusion of moisture into the
generator involving a separate storage of the rotor, the innermost plastic sheeting cover.
requirements specified in the following must be met for The metallically bright shaft ends (shaft journals and
protection of the rotor. couplings) are protected with a hard wax coating.
Any deviations from the standard packing due to special The rotor is then placed on a skid with closed bottom
circumstances shall be subject to the approval of BHEL. and secured in position for protection against mechanical
damage. For land transport not exceeding one month, this
Contents unit is protected against external influences by a wooden
enclosure resting on the bottom frame of the skid. This
1. Basic Makeup of Packing
enclosure must be removed prior to each transshipment to
2. Definitions hitch the rotor with a lath grid in place at the middle of the
rotor body.
3. Summary of Rotor Packing Requirements In the case of land transport exceeding one month and
with sea transport, the enclosure forms an integral part of
4. Sealed Packing
the skid. The hitch should then be taken directly at the skid.
4.1 Production Appliances and Packing Materials
The complete cargo is covered with tarpaulins for
4.2 Protection of Metallically Bright Shaft Ends
protection from the elements.
4.3 Providing the Plastic Sheeting Covers
Rotors with water-cooled windings are protected
4.4 Desiccant
against corrosion by filling the water passages with pure
nitrogen after drying to a gauge pressure of 0.5 to 1 bar
5. Skid and Outer Protection
via a cover at the exciter end. The pressure can be read
5.1 Land Transport
on a permanently installed pressure gauge.
(Less Than One Month)
5.2 Land Transport or Sea Transport
2 Definitions
or Longer Duration
2.1 Land Transport

6. Protection of Packing During Transit
The packing provided for this mode of shipment affords
6.1 Organizational Measures
sufficient protection for land transport under moderate
6.2 Loading
climatic conditions and for a scheduled transit period of
6.3 Receiving Inspection
not more than one month. This provides a reliable protection
for short-distance transport (from BHEL, Haridwar to
7. Storage
destinations in India ).
7.1 Storage Area
This type of packing also ensures sufficient protection
7.2 Checks During Storage Period
during subsequent storage in a covered hall, e.g.
7.3 Removal From Storage
powerhouse. Following the receiving inspection, the
insulation resistance of the rotor winding and the condition
1. Basic Makeup of Packing
of the desiccant should be checked at intervals of one
The packing precautions and organizational measures
month and the desiccant reactivated, if necessary.
during transport and storage are intended for reliably
2.2 Sea Transport
preventing the effects of moisture on the rotor and
The packing provided for this mode of shipment
especially on the rotor retaining rings which may be

1111E
affords protection during shipment by sea, during 4.1 Production Appliances and Packing Material
unavoidable outdoor storage and for transport periods and In addition to the standard tools, such as scissors,
under conditions exceeding those under item 2.1. The knife, etc., special appliances are required for obtaining a
additional packing, as compared to land transport, consists packing affording corrosion protection.
of a third plastic sheeting cover and a closed, seaworthy
outer packing. The desiccant included in the plastic sheeting Q Heat-impulse fixture for heat sealing of polyethylene
covers is sufficient for the scheduled transport period, plastic sheeting, consisting of:
but for not more than six months. heat – impulse generator and
The inspections required during storage are the same heat – sealing tongs for a minimum seam length of 200
as specified for land transport under item 2.1. mm,
Q Heated plate to melt wax-coated sheeting for bonding
3 Summary of Rotor Packing Requirements (e.g. electric iron).
· Blower with small delivery rating for checking the plastic
This summary [1] contains information on the makeup sheeting cover for tightness and for extracting the test
of the packing and on the procedures required to maintain air (e.g. vacuum cleaner).
the packing in sealed condition. A detailed description is Q Air dryer for any required drying of rotor end windings
given in the following section. prior to packing.
4 Sealed Packing
The following packing materials are used, which are
The obtain a reliable and long-lasting corrosion available from BHEL, HARIDWAR on request:
protection, both suitable production appliances and
Q Polyethylene sheeting, 0.2 mm thick, endless, preferred
materials and appropriate methods of packing are required.
width 6000 mm
The basic prerequisites are:
Q Rubber board with canvas reinforcement, 3 mm thick,
minimum width 1000 mm
Q Dry Condition of Rotor Prior to Packing
Q Wax-coated linen binding with 1 mm wax coating, 100
The rotor must be dried if it is expected to be in a wet
mm wide (e.g. Denso binding)
condition due to operational faults. To do this, the rotor
Q Hard wax for application by brush (e.g. Tectyl 506)
and especially the rotor retaining rings and end winding
Q Cold degreasing agent
portions should be dried with dry air by means of an air
Q Wax-coated aluminum foil
dryer (e.g.. Munters dryer).
Q Adhesive for plastic sheeting
Q Adhesive tape for plastic sheeting
Q Water-Cooled Rotor Winding
Q Foam material, which does not absorb water, 5 to 10
Drying the cooling water circuit of the rotor winding
mm thick (e.g. polyurethane)
should be performed with a vacuum pump, heating the
Q Silica gel in linen pouches as desiccant
winding with direct current to approximately 60 to 70°C.
Q Moisture indicators for functional checking of desiccant
Drying can be terminated when a pressure of less than
(color indicators for 30%, 40% and 50% relative
5 torr has been maintained on the hot rotor for a period
humidity)
of five hours. Following this, the rotor winding should
Q Hemp rope, 2 mm thick, for attaching desiccant pouches
be filled with pure nitrogen to a gauge pressure of 0.5
Q Fabric tape, 20 mm, endless
bar via the end cover at the exciter end.
Q Steel band, 1 mm thick, 30 mm wide, with turnbuckle
The equipment and power sources required for vacuum
and tensioning device
drying should be obtained by the user in due time. The
Q Lath grid for taking a hitch at the rotor body consisting
mechanical data required for the procurement of the
of hardwood laths 50x80x3000mm, nailed to 5mm thick
equipment are available from the manufacturer on
fabric mat.
request.
4.2 Protection of Metallically Bright Shaft Ends

Q Weather-Protected Packing Area
The metallically bright shaft ends should be cleaned
Packing and unpacking is only permissible in a weather-
and degreased and protected with a hard wax coating
protected area, preferably in a hall.
(e.g. Tectyl 506) of sufficient thickness (dark-brown). In
addition, the areas of support in the skid should be wrapped
Q No Delays in Packing Procedure
with two layers of wax-coated bindings (e.g. Denso
Care must be taken to ensure that after its removal the
binding) and a 3 mm thick canvas-reinforced rubber mat.
rotor will not suffer any moisture condensation or
All other areas contacting the skid should also be covered
accidental wetting. Packing the rotor should therefore
with 3 mm thick rubber board.
be performed immediately after withdrawal of the rotor
and any required drying in order to minimise any
4.3 Providing the Plastic Sheeting Covers
uncontrolled phases.
The polyethylene sheeting covers are made directly
2.5-0030-0600/2
on the components to be protected. To protect the plastic approximately 150 mm wider at each end of the rotor. The
Turbogenerators
sheeting cover from damage, any contact with sharp edges range between the free shaft portion protected with hard
must be avoided. Edges should be padded with layers of
Inspection wax and the end of the rotor body should then be wrapped
rubber board or foam rubber. The use of excelsior, with polyethylene sheeting which is to be sealed tightly
corrugated cardboard, felt or other hygroscopic materials with wax-coated canvas bindings at the rotor body and
is not permissible. Care should be taken to ensure that the free shaft portion.
plastic sheeting cover remains intact during the subsequent Experience has shown that in the case of larger
packing procedures. Even pinpricks and minute tears in rotor body diameters (>1300 mm), the aluminum foil cannot
the plastic sheeting will render tight sealing ineffective. be wrapped around the rotor with sufficient tightness and
Within the range of rotor support in the skid and of other may thus be omitted. In such cases, the above mentioned
contact points (upper shipping saddles), the polyethylene polyethylene sheeting should extend beyond the rubber
sheeting should be inserted between two rubber boards mat at the middle of the rotor body and should be sealed
of sufficient size for protection against damage. At the tightly with wax-coated canvas bindings at these points.
end winding, each plastic sheeting cover is provided with The precautionary measures specified under Items
a 500 mm dia. opening for connection of a plastic sheeting 4.2 to 4.3.1 provide for the minimum packing requirements
hose having the same diameter and a length of and are sufficient for land transport not exceeding 20
approximately 1m. After checking the cover for tight sealing, hours. In the case of rotors provided with aluminum foil
the desiccant is added via this hose, which is then closed within the range of the rotor body, sealing of the rubber
by heat-sealing. mat at the middle of the rotor body will not be required for
To maintain the sealed range in a dry condition short-distance transport.
desiccant (see Item 4.4) is added to each plastic sheeting
cover. 4.3.2 Second Plastic Sheeting Cover
After heat-sealing and tight wrapping with wax- In addition to the first plastic sheeting cover described
coated bindings, each plastic sheeting cover should be under Item 4.3.1, a second polyethylene sheeting cover of
checked for tight sealing. To do this, one corner of the the same type should be provided between the shaft ends
plastic sheeting hose should be cut for insertion of a and the rubber mat at the middle of the rotor body. To
vacuum cleaner hose (discharge end) and tightly sealed separate the two plastic sheeting covers, a 5 to 10 mm
with a binding. If the cover remains inflated during the thick layer of foam material should be placed over the top
following two hours, the cover is properly sealed. Following half circumference of the rotor retaining rings and rotor
this check, the air should be drawn off. body.
Two plastic sheeting covers are required for land
4.3.1 First Plastic Sheeting Cover transport and storage as defined under Item 2.1.
As a first step, the entire rotor body should be
wrapped with wax-coated aluminum foil with 50 to 70 mm 4.3.3 Third Plastic Sheeting Cover
overlap, with the wax coating facing the rotor body. Seams For sea transport and outdoor storage as defined
and overlapping portions should be sealed airtight by melting under Item 2.2, an additional diffusion barrier is provided.
the wax coating with an electric iron. This third polyethylene sheeting cover protects the entire
To protect the aluminum foil from being damaged by range of the rotor between the shaft journals at either
the handling ropes, a canvas-reinforced rubber mat, 3 mm end. It is placed over the plastic sheeting covers according
thick and approximately 2500 to 3000 mm wide (dependent to Items 4.3.1 and 4.3.2 and is to be made in the same
on overall length of rotor) should be placed around the manner.
center of gravity of the rotor. This rubber mat consists of The plastic sheeting is placed over the rotor before the
individual sections, each having a length corresponding to rotor is supported on the skid. Within the range of rotor
the rotor body diameter + 100 mm and arranged with an support the plastic sheeting is inserted between two rubber
overlap of not less than 100 mm. All overlap seams are mats of 3 mm thickness each. After the rotor has been
sealed with wax-coated canvas bindings. Axial overlap supported on the skid, its upper half portion (rotor body
seams are additionally secured with steel bands. The and retaining rings) should be covered with a 5 to 10 mm
overlap seam at the top on the circumference is secured in thick layer of foam material outside the lath grid area, and
axial direction by wooden lath, 80x40 mm, which is also then the plastic sheeting cover should be heat-sealed.
held in place with steel bands.
Finally, a lath grid (hardwood laths attached to fabric 4.4 Desiccant
mat or fabric tape) should be placed in position for hitching. 4.4.1 Type and Application
The grid should cover not less than the lower half two- The desiccant consists of silica gel in dust-free and
thirds of the rotor body circumference and be adequately air-permeable pouches. It should be inserted into each
secured with steel bands. The wooden laths must be on plastic sheeting cover via the plastic sheeting hoses at the
the outside and arranged so that the rubber mat is end windings. The desiccant must be placed so that it can

2.5-0030-0600/4
be easily replaced when this becomes necessary and that are to be closed and reinserted into the plastic sheeting
Turbogenerators
it does not come into contact with steel or winding covers as quickly as possible. Care should be taken to
components (danger of corrosion). If necessary, cover
Inspection ensure that the pouches do not come into contact with
contact area with polyethylene or rubber sheeting. metal parts. The opening in the plastic sheeting cover should
All pouches must be tied together with a hemp rope, then be resealed with a heat-sealing unit.
and, when used, they must be in an active, i.e. absolutely
dry condition 5 Skid and Outer Protection
4.4.2 Desiccant Quantities BHEL, HARIDWAR generator rotors are delivered in

The desiccant quantities [1] are proportioned to box type shipping containers, consisting of a skid and an
accommodate highly adverse climatic conditions. The enclosure. Figs. 4 and 5 depict typical examples. It is
maximum quantity is sufficient for a shipping time not recommended to keep this shipping container for future
exceeding six-month. needs, unless an adjustable universal skid is used for land
transport which is available from BHEL, HARIDWAR, if
4.4.3 Checking and Reactivation requested in due time. The information given in the following
The moisture absorption capacity of the desiccant relates to the remounting of the rotor in sealed packing on
must be checked after completion of shipment, after the skid and to the provision of the outer protection.
interruptions in transit involving a storage period of more
than one month and during normal storage at the site (see 5.1 Land Transport (Less Than One Month)
Item 7.2). To do this, use the moisture indicators (Fig. 3) For land Transport, the rotor should be supported on a
inserted in the plastic sheeting covers at a distance of not skid similar to Fig. 4. The points of support should be padded
less than 5 cm from the sheeting. The moisture indicators with rubber mats for protection of the plastic sheeting
are marked with their respective location identifications as covers. At the shaft ends, the rotor should be attached to
illustrated in Fig. 2 and show the relative humidity inside the skid by means of upper saddles and secured in axial
the cover in three ranges (>30%, >40% and >50%). With direction.
the packing in dry condition, all circles are blue. A change For loading operations, the hitch should be taken either at
in color to pink in the respective circle indicates the relative the middle of the rotor body (lath grid) or at the rotor ends.
humidity in percent. As soon as the 40% indicator changes During transit, the rotor should be protected against external
to the pink color, the desiccant must be removed and influences by a wooden enclosure resting on the bottom
replaced or reactivated by drying. frame of the skid. Both long sides of this protective
enclosure should be clearly stencil-marked with the
following note.
All circles pink: danger of corrosion 50 Caution: Remove protective enclosure for rotor
transshipment.
The complete cargo should be covered with a lashed
tarpaulin.
Two circles pink: replace desiccant 40
5.2 Land Transport or Sea Transport of Longer

Duration
One circle pink: warning 30 For land transport exceeding one month and for sea
transport, the rotor should be packed in a closed, self-
supporting container. The setup for two-pole rotors
Fig. 3 Moisture Indicator corresponds to Fig. 2. The container bottom should have
openings with perforated–plate covers for ventilation and
Make sure that sufficient replacement desiccant or
to prevent the accumulation of water. In addition, inspection
the necessary drying facility for reactivation is available.
openings with covers should be provided on the long sides
After opening, the plastic sheeting cover should be
for access to the desiccant pouches via the plastic sheeting
provisionally resealed, but must not be left in this condition
hoses. An inspection opening at the exciter end should
for more than 20 hours.
provide access to the contact pins on the exciter-end end
For reactivation, the pouches should be dried in a
cover of the rotor for measurement of the insulation
drying oven at a temperature of 110°C for 12 hours. If a
resistance of the rotor winding.
drying oven is not available, the desiccant should be
Prior to closing the container, the rotor should be
removed from the pouch, spread out in a thin layer on a
covered with 3 mm thick pressboard panels and
metal plate and dried at 110 to 130°C for several hours until
polyethylene sheeting, taking care to avoid the formation
the weight of the desiccant remains constant. The
of troughs in which water might accumulate. The container
desiccant should then be filled back into the pouches which
lid should be covered with tar board sanded on one side

and folding down over the edges not less than 200 mm. should be checked. In the case of a water-cooled rotor
The total weight and the dimensions of the cargo should winding the pressure of the nitrogen blanket should also
be marked on the container. In addition the hitching range be checked. The date of the receiving inspection should
should be color-marked. The complete cargo should be be entered in the respective section on the inspection hole
covered with a tarpaulin for protection against the elements. covers. The results of the receiving inspection should be
recorded in the check lists [2], [3], copies of which should
6 Protection of Packing During Transit : be forwarded to the consignor.
6.1 Organizational Measures : If the packing is found in damaged condition, it should
Proper packing of the rotor will prevent both the ingress be resealed as soon as possible. The same requirement
and the condensation of moisture during transit, unless applies if the seals were opened by the customs authorities.
the sealed packing is damaged by improper loading If the moisture absorption capacity of the desiccant is
procedures or customs inspections. This should be avoided no longer sufficient (40 % indicator is pink), the desiccant
by suitable precautions, enabling a quick restoration of the should be removed from the plastic sheeting cover, with
dry condition of any damaged sealed packing. These the shipping container protected from the environment, and
measures include : reactivated (see Item 4.4.3). If the rotor is unpacked
immediately after delivery, it may become necessary to
On the Cargo: bring it to ambient temperature level for protection against
moisture condensation. If the rotor temperature is equal to
Q Instructions for correct handling. or higher than the room temperature, there will be no need
Q Reference to “Sealed Packing” on shipping container. for raising the temperature of the rotor to the level of the
Q Indication of desiccant quantity inserted into each ambient temperature. The rotor temperature can be
individual plastic sheeting cover behind inspection hole measured at the accessible rotor ends using a temperature
cover. measuring instrument. If the rotor temperature is lower
Q Attaching this instruction 2.5 – 0030. than the ambient temperature, steps must be taken to
ensure that the rotor temperature will be 5 degC (safety
In the Accompanying Documents: margin) higher than the dew point temperature of the
Q Reference to “Sealed Packing”. ambient air [4].
Q Reference to arrangements for customs clearance at In the case of outdoor units, the rotor installation phase
place of installation. should be timed so that the unpacked rotor will not be
Q Request for immediate drying in case of transport exposed to extreme changes in temperature as this will
damage with moisture penetration. involve the risk of moisture condensation.
Q Check list relating to condition of desiccant [2].
Q Checklist relating to insulation resistance of rotor 7 Storage
winding [3].
The preventive measures during storage provide for
6.2 Loading maintaining the dry condition of the rotor in the sealed
If a flatcar is used for transport, the cargo should be packing without any interruptions until commencement of
loaded so that it can slide on the car, i.e., the skid must not the installation.
be secured in position and must be free to move in both To this end, certain minimum requirements must be
directions of running. Provision should be made for a sliding observed, which are dependent on the condition of the
distance of approximately 1.5m at either end. storage area. In addition, the condition of the packing and
Planks , approximately 50 mm thick, should be nailed to of the desiccant contained in the packing must be checked
the long sides adjacent to the battens. at regular intervals. To obtain additional verification, the
If a deep well wagon is used for transport, the skid- insulation resistance of the rotor winding should be
mounted rotor should be secured in position at both ends measured.
of the loading bridge. The bridge through should be sealed As long as the nitrogen pressure is still slightly above
with boards for protection against stones. atmosphere, it will normally not be necessary to recharge
During shunting operations, the car must never be a water-cooled rotor winding with nitrogen. If the nitrogen
allowed to pass over a hump. A corresponding note should pressure has dropped to zero, the winding should be filled
be included in the waybill and affixed to the car in a well with pure nitrogen to a gauge pressure of 0.5 bar from the
visible location. nitrogen bottle permanently installed in the shipping
container.
6.3 Receiving Inspection
After arrival of the rotor, the consignee should examine 7.1 Storage Area
the packing for external damage. The condition of the Sufficiently ventilated and dry storage rooms for stable
desiccant can be ascertained at the moisture indicators. In support of the parts in a fully accessible location are
addition, the insulation resistance of the rotor winding favorable preconditions for storage. If outdoor storage
2.5-0030-0600/6
cannot be avoided, a heavy-duty outer packing of the The dates of the repeat checks should be recorded on the
Turbogenerators
seaworthy type must be provided. The outdoor storage outer packing below the date of the receiving inspection
facility must beInspection
set up in such a way that the stored item is and in the check lists [2],[3].
protected against rainfall and moisture from the ground.
This would include placing a waterproof shelter over the 7.3 Removal from Storage
shipping container which affords sufficient ventilation. In If the storage area and the place of installation are not
addition, the stored item should be blocked up on the solid located in the same room (power house or workshop), the
ground for protection against moisture. Enough space must rotor temperature may be below the dew point level on
be left between the boxes to permit inspections and checks. transfer of the rotor from a cold storage area to a warm
power house. To protect the rotor from moisture
7.2 Checks During Storage Period condensation, it should be left in its sealed packing for
Following the receiving inspection, surveillance of the several days and allowed to assume the ambient
equipment should be conducted by repeat checks at temperature prior to removing the packing for immediate
intervals of four weeks. The checks required are the same installation.
as specified for the receiving inspection under Item 6.3.
[1] 2.5-0031 Preventive Measures for Transport and [3] 2.5-0033 Insulation Resistance Measurements on
Storage of Generator Rotors (Summary) Rotor and Exciter Windings During Storage
[2] 2.5-0032 Checking Desiccant in Generator Rotor (Test Report)
Packing [4] 2.5-0019 Determination of Dewpoint Temperature

Turbogenerators Preventive Measures for Transport and
Storage of Generator Rotors
Inspection Summary
Protective Materials and Setup
Prev. Measure
Land Transport Sea Transport
Purpose/ Component Short-Distance Shipment by Sea or
Phase Transport Period Less Transport Period More
Than One Month Than One Month
A
Corrosion Shaft journals 1 Hard wax coating (e.g. Tectyl 506) of sufficient thickness (dark-brown color).
Protection Couplings Additionally protect areas of support in skid with two layers of wax-coated
of shaft bindings and one layer of 3 mm canvas-reinforced rubber mat.
ends
B
Corrosion Water- 2 Fill dried rotor winding with pure nitrogen to a gauge pressure of 0.3 to 0.5 bar
Protection cooled through cover at exciter end.
of rotor rotor
winding winding
C
First packing Rotor 3 Place wax-coated aluminum foil over entire range of rotor body (only for rotor body
of rotor Body diameters < 1300 mm, due to difficult handling)
retaining
Place 3 mm canvas-reinforced rubber mat, 2500 to 3600 mm wide (dependent on
rings and 4
length of rotor) around center of gravity; seal overlap seams with wax-coated bindings
rotor body
and steel bands; secure axial overlap seam with wooden lath.
in plastic
sheeting Place lath grid on fabric mat, about 300 mm narrower than 4 , around two-thirds of
cover 5
rotor circumference and secure at top.
Retaining 6 Place 0.2 mm polythene sheeting between shaft ends 1 and body ends 3 and
rings rubber mat 4 , respectively, seal joints with wax-coated bindings at both ends,
Fans heat-seal seams
(water boxes)
(sufficient Check plastic sheeting cover for tight sealing by inflation with air and recheck after
7
for short- two hours.
distance
transport up 8 Add desiccant per m2 of sheeting surface shipping time up to 1 month: 500 g; up to
to 20 hours 3 months : 1000 g; up to 6 months: 1500 g. Plus 280 g for each Kg of wood and 35 g
and imme- for each Kg of foam material within plastic cover. Moisture indicators for relative
diate instal- humidity > 30%, > 40%, > 50%.
lation)
D
Protection Rotor body 9 Place 0.2 mm polythene sheeting between shaft ends 1 and rubber mat 4 over a
of first and 5 to 10 mm foam mat around top half circumference of rotor retaining rings and rotor
packing retaining body.
C by rings Check heat-sealed and tightly wrapped plastic cover 9 for tight sealing as
second 10
under 7
plastic sheet-
ing cover 11 Add desiccant and moisture indicators as under 8 .
E
Protection Rotor body 12 Not required for land transport. foam mat and cover entire rotor between shaft ends
of packings and as under 9 . With four-pole rotors, foam mat is split
C and D by retaining within range of lath grid; insert plastic sheeting
third plastic rings between 3mm rubber boards. Check for tight seal-
sheeting ing as under 7 . Add desiccant as under 8 .
cover

1111E
Protective Materials and Setup
Prev. Measure
Land Transport Sea Transport
Purpose/ Component Short-Distance Shipment by Sea or
Phase Transport Period Less Than One Month Transport Period More Than One Month
One Month
F
Transit Tightly 13 Tightly sealed rotor 1 to 11 on skid Tightly sealed rotor 1 to 11 in closed
protection sealed rotor with closed bottom under enclosure and self-supporting shipping container Under
tarpaulin tarpaulin.
G
Loading Complete 14 Hitch point on rotor at lath grid in center Hitch point on shipping container; in the
cargo of gravity after removal of enclosure. case of four-pole rotors on Steel sleeve
at mid-length of skid.
H
Receiving Complete 15 Check outer packing and relative humidity inside plastic sheeting at moisture indicators.
of cargo packing Replace desiccant when relative humidity is higher than 40 %. Return check list with
and rotor details on condition of packing and insulation resistances of rotor winding
winding to consignor.
16 Prior to unpacking the rotor in a weather-protected location, a cold rotor must have
ambient or dewpoint temperature plus 5 K safety margin to prevent moisture condensation.
J Storage area 17 With packing for land transport, only in a hall kept at a moderate temperature. For
Storage outdoor storage, seaworthy packing plus additional precautions are required: storage
on well tamped and suitably reinforced ground and set on blocks for protection against
moisture, case under protective roof.
Complete 18 During storage (including interruptions in transit), check outer packing for damage and
packing tight sealing, insulation resistance of rotor winding and, if applicable, nitrogen blanket at
and rotor intervals of four weeks.
winding
K
Removal Rotor 19 Maintain tight sealing of packing as long as possible until rotor is installed. Protection
from storage against condensation hazard by preventive measure 16
2.5-0031-0600/2
Turbogenerators Checking Desiccant in
Packing of Components
Inspection
Desiccant Checking Requirements The results should be recorded in the table below. The
The absorbent capacity of the desiccant must be desiccant must be removed and replaced or reactivated
checked after shipment has been completed and at inter- by drying when a change in the color of the 40% moisture
vals of one month during any subsequent storage period. indicator is observed.
Job name: Sl. No.: Type:
Shipping Location Moisture indicator Weight of Replacement or

of compotent
Storage area
Condition of
or identification blue or pink? desiccant reactivation

Company
storage of moisture Bottom Center Top in packing of desiccant

packing
phase indicator circle circle circle in Kg

Name
outer
Date
(30%) (40%) (50%)
Prior to TE 1
shipment TE 2
TE 3
EE 1
EE 2
EE 3
TE 1
TE 2
TE 3
EE 1
EE 2
EE 3
TE 1
TE 2
TE 3
EE 1
EE 2
EE 3
TE 1
TE 2
TE 3
EE 1
EE 2
EE 3
TE 1
TE 2
TE 3
EE 1
EE 2
EE 3

1111E
Turbogenerators Insulation Resistance Measurements
on Rotor and Exciter Windings
Inspection Test Report
Checking the Insulation Resistances be checked after shipment has been completed and at
of Rotor Windings in Sealed Packing intervals of one month during any subsequent storage
The insulation resistance of the rotor winding should period. The results should be recorded in the table below.
Job name : Sl No.: Type : Component :
Shipping or Prior to
storage phase shipment
Date
Name
Company
Storage area
Temperature in
Storage area in °C
Rel. humidity of ambient

Air in storage area in %.
Rotor temperature
in °C
Moisture 50
Indicator TE1 40
in packing 30
blue or 50
pink? TE1 40
30
Pressure of Nitrogen
blanket in bar
Applied voltage in V
15 s
30 s
45 s
Inaulation Resistance in M ohm
1 min
2 min
3 min
4 min
5 min
6 min
7 min
8 min
9 min
10 min
Notes: 3 The connection to the rotor winding should be made at

1 The insulation resistance should be measured with an a specially identified bolt on the exciter-end end cover.
insulation measuring device, applying a voltage of 100 4 The connection to the rotor body should be made at a
V, but not more than 250 V. specially identified bolt on the exciter-end end cover.
2 Prior to each measurement, any static charges should 5 After each measurement, any static charges should
be removed by grounding the windings as a precau- be removed by short-circuiting the winding through
tionary measure (10 minutes). the rotor body (not less than 20 minutes).

1111E
Turbogenerators Preparation of Machinery Parts
Inspection
1 General plug-in contact assembly of the exciter rotor will

not come into contact with any solvent.
The machinery parts to be assembled are delivered
ready for mounting, unless certain portions must be Cleaning of internal and external threads should be
protected during transport against corrosion or damage. done by chasing, using suitable taps or cutting dies. The
In case of orders for delivery to other countries, all dimensions of the external and internal threads may be
sensitive portions of the machinery parts, e.g., journals, taken from the respective drawings. Use dry compressed
are provided with a protective coating and protected against air to blow out the re-tapped holes.
damage. Where no taps are available cleaning of the tapped
In case of orders for delivery to overseas countries, holes may also be carried out with the aid of the original
all machined surfaces are provided with a protective screws. At first, the screws should be cleaned by means
coating. In addition, complete assemblies are sealed in of solvent and a brush. The cleaned screws should then
plastic sheeting. be dipped into a solvent and immediately afterwards be
screwed into the holes for thread cleaning.
2 Removal of Protective Coating If required, this procedure should be repeated several
times until the threads are free from protective coating.
The protective coating applied at the manufacturer’s
works should be carefully removed prior to assembly. The 3 Remedying Minor Damage
surfaces to be cleaned should be washed with petroleum
or a similar agent. When using trichlorethylene, the cleaned Damaged machinery parts should be reconditioned as
surfaces should be carefully dried and afterwards a thin dictated by the extent of the damage and the operational
oil film should be applied. Non-observance of this requirements unless the nature of the damage does not
requirement implies the danger of corrosion. warrant such remedying.
Particularly thick layers of protective coating should be Seriously damaged parts should be returned to the
softened by applying one of the above-mentioned cleaning manufacturer’s works together with a damage or failure
agents and then be removed by means of a hardwood report.
board (approximately 10 cm x 10 cm x 1 cm). The machinery parts and the fixing and locating
Caution: Never use scrapers, finishing trowels or elements should be checked for burrs and compression
sheet metal strips for removing the protective marks, and such imperfections should be removed by
coating from highly sensitive machinery parts means of a smooth-cut file. Fine –finished surfaces should
(journals, etc.) only be polished by means of an oilstone.
The covers protecting the components of the DC plug- Caution: Burrs and compression marks on bearing
in contact assembly should be removed shortly before metal surfaces should only be removed by means of
coupling the rotors. a spoon scraper or flat scraper.
Make sure that the sleeves and bolts of the DC.

1111E
Turbogenerators Checking the Bearing and Seal Insulation
Inspection
1 General the total resistance will likewise be lower than the lowest
During operation of a generator, voltages are set up along individual resistance measured before.
the rotor due to magnetic unbalances and ring excitation.
This shaft voltage would cause a destructive current to flow 2.4 Pedestal Bearing of Exciter
through the bearing, shaft seal and other components if the The insulation resistance between the bearing pedestal
rotor were not insulated from ground at least at the exciter and base frame should be measured immediately after
end. For reasons of interchangeability, all stator components mounting of the pedestal.
coming into contact with the generator rotor are insulated. At With satisfactory insulation, a value in excess of 10
the exciter, all bearings or the complete exciter are insulated. megohms is to be expected. Following this, bolt the associated
oil pipe to the bearing pedestal being careful to insulate it. It is
2 Checking the Shaft Seal and Bearing Insulation
also recommended to repeat the insulation resistance
During Installation
measurement after fitting of each individual pipe. If a sufficiently
2.1 Bearing Saddle high resistance value is measured (five megohms) proceed
Prior to inserting the rotor and supporting it on the with fitting of the next pipe. Finally, measure the insulation
bearings, the insulation resistance of the built-in bearing saddle resistance to the base frame of the bearing pedestal with the
should be measured separately by means of a 100 V megger connected pipe work. If this value is higher than three
applied between the bearing saddle and the lower part of the megohms , proceed with mounting of the exciter rotor.
stator frame. The values measured should be recorded.
With satisfactory insulation, a value in excess of 10 2.5 Final Checking
megohms is to be expected. If an insulation resistance value After the exciter rotor has been coupled to the generator
below three megohms is measured, the insulating parts should rotor and insulated from the bearing pedestal, a final insulation
be checked for moisture, contamination or metallic contacts. check should be performed. The total insulation resistance
If required, the insulation should be dried at 80°C maximum. must not be less than one megohm. Due to contact with the
The measurement should be repeated immediately after shaft, the measuring circuit covers in parallel.
the rotor has been supported on the bearings.
Caution: With this measurement and the following TE/EE bearings
checks both rotor bearings must be insulated, and the TE/EE shaft seals
generator rotor must not come into contact with the Exciter bearing pedestal with pipe work
turbine shaft through measuring devices or similar
parts, to prevent the generator rotor from being 3 Checking the Shaft Seal and Bearing Insulation of
grounded. the Assembled Unit
Since, with the rotor inserted, all individual Checking the shaft seal and bearing insulation during
resistances measured previously are now in parallel operation may be done by way of the shaft voltage prevailing
in the measuring circuit, the total resistance will be with the generator running in an excited condition. For this
slightly lower than the lowest individual resistance purpose, the potential of the insulated shaft seals and bearings
value measured before. is accessible external to the generator. With the generator
running, the components coming into contact with the shaft
2.2 Inner and Outer Labyrinth Rings are separated from the shaft by an oil film, which has insulating
Inner and outer labyrinth rings are insulated from other properties. Consequently, a non-defined resistance value is
components. The insulation resistance of each individual set up at the potential measuring points of the shaft seals
labyrinth ring should be measured after installation in order to and bearing sleeves which is dictated by the magnitude of
preclude any lengthy search for faulty mounting on the resistances of the oil film and insulating parts. The
measurement of a poor insulation resistance. Proceed with following method permits the insulation to be checked without
mounting of the next component only after having identified disassembly of components being required.
and removed the cause of a poor insulation resistance. After Useful results are, however, to be expected only if the
installation of all insulated components the total resistance turbine end of generator rotor and the turbine shaft are
will be slightly lower than the lowest individual resistance grounded properly as defined during the measurements.
value measured before. Grounding must be maintained to discharge to ground any
static charges occurring continuously during operation due
2.3 Shaft Seals to steam and oil film friction.
Both shaft seals are mounted such they are insulated.
To check the insulation resistance, follow the same procedure 3.1 Checking the Insulation with the Generator in an
as outlined for the labyrinth rings. It is also be expected that Excited Condition

1111E
Due to the rotor grounding arrangement at the turbine reduction of the original shaft voltage or in its complete
end, the shaft voltage should be measured at the exciter end. collapse.
Since the result depends, however, on the function of the
rotor grounding system (carbon brush sliding on shaft), the
shaft voltage should first be measured according to Fig.1
with the generator running and excited. Normally, this will be
an AC voltage of a few volts on which a small dc component
is superimposed.
1 Voltmeter (AC range) 2 Ammeter
Fig. 3 Measurement of Shaft Current With the

1 Voltmeter (AC range)
Generator in Excited Condition
Fig.1 Measurement of Shaft Voltage With the
Generator in Excited Condition The resulting current can be measured for a brief moment
by means of an ammeter connected into the circuit between
Measurement should be performed by means of an AVO-
the measuring brush and the potential measuring terminal.
meter in the AC range. The voltage should be picked off the
shaft through a sliding contact with an insulated handle, which 3.2 Checking the Insulation With the Generator in Non-
is connected to the meter by a circle. Excited Condition
The shaft voltage measured in this way should then be If the previous tests are inconclusive, additional tests
compared with the voltage according to Fig. 2. If the two may be performed in consultation with the manufacturer
1 Voltmeter (AC range) 1 Measuring Bridge

Fig. 4 Measurement of Insulation Resistance With the Unit in
Fig. 2 Measurement of Shaft Voltage at Exciter End Non-Excited Condition
With the Generator in Exciter Condition
readings are not identical, the rotor grounding system should to locate insulation defects with the generator running and in
be rectified first before taking any further readings to check non-excited condition. A bridge instrument must be used. To
the insulation for shaft currents. measure the resistance of the insulated component with
If the shaft voltage can be exactly measured according respect to the shaft and ground, the bridge instrument should
to Fig.2, the measuring brush on the shaft should first be be connected between this component and ground.
connected to the potential measuring terminal of the insulated The resistance (Roil and Rins in series) of the parts in contact
component (bearing sleeve or shaft seal) at the exciter end with the shaft are then connected in parallel with the
by means of a cable. The oil film of the component is thus measuring voltage. This measurement is not practicable with
bridged, with the component assuming the shaft potential. the generator at standstill, since a stable oil film providing for
With satisfactory insulation, the instrument will continue to full insulation can be formed above a speed of approximately
indicate a shaft voltage of the original magnitude. In the event 3.33 to 6.66 s-1.
of insufficient insulation resistance, a current will flow In case of a low insulation resistance, it must be assumed
through the insulation, which may be read at the ammeter that the insulation is defective, requiring detailed checking of
connected into the circuit. Bridging of the oil film results in a the insulating parts. (Contact the manufacturer).
2.5-0300-0600/2
Turbogenerators Test Norms During Overhaul
Inspection
1 Hydraulic pressure test of hydrogen gas coolers. 8 bar for 30 mts

(No leakage is allowed)
2 Hydraulic pressure test for brushless exciter coolers 8 bar for 30 mts
3 Gas tightness test of TG Rotor. (No visual leakage 6 bar for 6 hrs.
is allowed. The test is to be conducted either with Press. drop not
nitrogen or helium). more than 0.5 bar
4 Gas tightness test of exciter rotor. (Condition of ——do——-

testing same as a Sl. 3 above)
5 Hydraulic test for stator winding and primary water system. 6 bar for 48 hours
(No visual leakage is allowed) by N 2 cushion
6 Hydraulic test pressure for seal oil and ring relief oil 10 bar for 15 mts
inlet pipeline in the end shield
(No leakage and pressure drop is allowed)
7 Pneumatic test for seal oil and ring relief oil inlet 6 bar for 30 mts
pipeline. (No leakage & pressure drop is allowed).
8 Hydraulic test of seal oil cooler

i) Shell side 10 Kg for 30 mts
ii) Tube side 10 Kg for 30 mts
9 Hydraulic test of stator water coolers

i) Shell side 10 Kg for 30 mts
ii) Tube side 10 Kg for 30 mts
10 Test on diodes for reverse blocking capability IR > 5 Mega ohms

(by 1KV megger with two diodes in parallel circuit)
11 Measurement of fuse resistance on the diode wheel 155+6% Micro ohm

by passing 10 Amps regulated D.C. current at 20 deg. C
(Fuse Type 800V/800Amp)
12 IR measurement of heat sinks. Min. 10 Mega ohms.

(By 500V megger)

1111E
Turbogenerators
Leakage Tests of Generator and
Inspection Gas System
To ensure trouble free operation, all systems should be z = duration of leakage test, hrs
checked and operated strictly in accordance with sound, VG = generator volume, m3 (see Mechanical
safe and accepted practice. Data)
p1 = gauge pressure within the system at
1 Leakage Test of Primary Water Circuit
beginning of leakage test, mbar
The primary water circuit must be filled with water for p2 = gauge pressure within the system at end
leakage testing. The pressure gauge in the waste gas pipe of leakage test, mbar
should be replaced for the duration of the test with a pres- p B1 = barometer reading at beginning of leakage
sure gauge having a range of not less than 6 bar. A nitro- test, mbar
gen cushion at a gauge pressure of 6 bar is to be provided p B2 = barometer reading at end of leakage test,
on the water level in the primary water tank and main- mbar
tained for a test period of not less than 48 hours. During t1 = temperature of the gaseous atmosphere at
the test, the entire circuit should be carefully checked for beginning of leakage test, °C
leakage. Any leaks detected should be repaired, and the t2 = temperature of the gaseous atmosphere at
leakage test repeated. end of leakage test, °C
2 Leakage Test of H2 Gas System Using Air

If an air loss higher than 2.4 m3 (s.t.p.)*/24 hrs results,
After assembling the generator and placing the seal oil a search for the leak must be made. The likely location of
system into operation, the generator, including the con- leaks, such as
nected gas system, must be leak tested using compressed
air. A special connection is provided for this purpose. Q flange connections,
The test pressure should be equal to the generator Q joints,
operating pressure. A class 0.6 precision pressure gauge Q screw couplings,
should be used for pressure measurement. Q welds,
The duration of the leakage test should be at least 48 Q bushings, etc.,
hours.
During this test the stator winding should be filled with should be examined thoroughly. Suspected areas should
water. The primary water tank should be at atmosphere be brushed with Diprol or other foaming solution. The
pressure and the waste gas pipes closed. Though the formation of bubbles (foam) indicates a leak.
primary water circuit has already been leak tested, the If a satisfactory tightness is established the generator
internal primary water circuit should be included in the may be filled with CO2, and subsequently with H2.
leakage test of H2 gas system. For this purpose, the pres- If, as an exception, a leakage test using hydrogen is
sure gauge in the waste gas pipe of the primary water performed, the leakage rate may be four times as high as
tank should be replaced by a U-tube gauge, permitting even during a leakage using air. Leak detection during this test
small pressure increases to be measured. Should a pres- should be performed by means of a gas leak detection.
sure increase be observed in the primary water tank, a
leak of the primary water system within the generator 3 Leakage Control of H 2 System During Actual
would be expected and must be located and repaired. Operation
The H2 gas system may be considered sufficiently tight
if the loss of air is below 1.5 m3/24 hrs = 100 dm 3/hr During operation, the loss of H2 gas must be monitored
(s.t.p.)* at this test. continuously on the basis of H2 consumption. The quantity
The loss of air is determined as follows : of hydrogen leaking uncontrolled may amount to 12 m3
(s.t.p.)*/24 hrs. Note that only the quantity of gas leaving
0.2694 x 24 p1 + pB1 p2 + pB2
V = ——————— . VG ( ————— - ————— ) uncontrolled should be used for evaluating the tightness.
Z 273 + t1 273 + t2
Losses such as the steady controlled gas loss occurring
Where at the electrical purity meter system and the gas removed
V = loss of air in m 3 (s.t.p.)* per 24 hour periods from the generator through the seal oil should not be
counted.
273°K
0.2694 = ———————
1013.25 mbar

1111E
4 Leak Detection by Means of a Gas Leak Detector practical manner. The pistol form allows one-hand
operation. The overall dimensions of the equipment are
If an undue loss of gas occurs on the unit, the 150 x 160 x 65 mm. The Handy-Tector is supplied in a
location of the leak must be determined. To do this, we portable leather case.
recommend a leak detector of the Handy-Tector type
with battery charger (product of Edwards Hochvacuum 4.2 Handling the Handy-Tector
GmbH, Frankfurt/Main, West Germany). The sniffer probe of the Handy-Tector should be
led over the surface of the test object as slowly as
4.1 Description of the Handy-Tector possible. Note that with a leakage gas lighter than air
The equipment consists of a battery driven manually the leak detection should be carried out above the object,
operated leak detector with two sniffler probes (made and with gases heavier than air underneath of the test
of stainless steel and plastic) and a battery charger. object.
The Handy-Tector is accommodated in a handy
case and is provided with a pistol grip. It weighs about
0.5 Kg and enable access to all components of the unit
even when locations are obstructed. Equipped with a
thermistor bridge as a sensing element it detects leaks
from which, for instance, H2 gas escapes by initiating
the difference in thermal conductivity of the gas and
the ambient atmosphere (normally air). The sensing
element is not subject to wear and cannot be overloaded,
damaged or contaminated by too high a gas
accumulation. All operating elements, e.g. indicators
(measuring range 0 to 5 with adjustment mark for battery
testing), switch for polarity reversal, On-Off switch,
key for battery voltage testing, and a potentiometer by
zero setting, are arranged in an easily surveyed and Fig.1 Handy-Tector
* s.t.p. = Standard temperature and pressure, 0oC and

1.013 bar
2.5-0310-0600/2
Turbogenerators Flushing the Oil Piping
Inspection
1 Measures to be Taken at Inspections, Repairs

or Checks
When opening parts of the oil systems for inspection,

repair or checking, make sure that no dirt is introduced into
the oil circuits. In the event of a contamination being
unavoidable due to the work to be performed, take care to
reduce such contamination to a minimum and perform a
thorough cleaning afterwards.
In case of more extensive inspections, it is
recommended to drain the oil, to clean the oil coolers, the
oil tank and the bearing compartments in the same way as
for initial operation of new plant, and refill the oil via filters.
After each inspection, the oil system should be subjected
to a short flush. It is recommended to install screens in the
throttle valves and to perform flushing for 12 hours. On
completion of this flushing procedure, all filters and screens
should be cleaned again. 1 2 3 4
If the oil piping must be flushed the following procedure
1 Oil drain
should be used.
2 Bearing saddle
3 Seal
4 Bearing sleeve
2 Preparation of Bearing Compartments
Fig. 1 Oil Drain at Generator Bearing
Prior to commencement of the flushing procedure, the
bearing compartments should be cleaned carefully. If any and oil supplier as laid down in the generator manufacturer’s
reworking has been done in the bearing compartments oil specification. In this connection, it may become necessary
(e.g. drilling), the chips should be removed by means of a to consult the turbine manufacturer too.
magnet. In addition, the bearing compartments should be The following methods are possible :
cleaned with lint-free rags (never use cotton waste). The
cleaning agents used should leave no residue. After Q Use of the same oil grade for both flushing and
cleaning, the bearing compartments should be subjected operation. On completion of the flushing procedure, oil
to a thorough visual inspection. samples should be taken and analyzed to decide
whether the flushing oil charge can be used as service
3 Preparing the Lube Oil System for Flushing oil change after treatment by the oil supplier.
Q Use of an oil grade intended for use as flushing oil
During flushing, the highest possible oil velocity is to only. Its properties, particularly its viscosity, are
be maintained in the pipes. matched to the special application. The oil charge is
When the bearings are installed, make sure that no completely drained on completion of the flushing
contaminated oil is introduced between shaft and babbit. procedure and replaced by a new service oil charge.
To do this, remove the upper half bearing sleeves and fit The properties of the service oil and flushing oil must
temporary oil drain pipes to the inlet openings of the lower be suitably matched.
half sleeves. Remove the valve cones from the permanently
adjustable throttle valves before the bearings and insert 5 Flushing Procedure
the flushing screens supplied with the throttle valves. Make
sure that the hoses of the shaft lift oil system are not Flushing all bearing oil lines and all shaft lift oil pipes
connected to the bearings, as otherwise contaminated oil of the generator should be performed in conjunction
will be admitted to the bearing journal. with the turbine according to the instructions issued for
the turbine.
4 Flushing Oil During flushing, the oil lines should be hammered
regularly to remove dirt particles from the walls. During
The oil used for flushing must be provided by the user the last third of the entire flushing period, the screens

1111E
should be temporarily installed in the throttle valves checked for tightness.
upstream of the bearings for checking the dirt
accumulation. 6 Supervision of Oil Circuits
After draining of the flushing oil, remove any left dirt
deposits from the bearing compartments. Remove all After recommissioning, all screens and filters should
bypasses, orifice plates or blank flanges as well as the be replaced and/or cleaned as frequently as possible.
additionally installed filters. Refit the valve cones in the During commissioning, the oil should be checked for
throttle valves before the bearings. Assemble the contamination, e.g. via vent ports. In case of an extremely
bearings ready for operation. The hoses of the shaft lift high dirt content due to carbon dust, construction work,
oil system should be connected to the bearings and etc., special precautionary measures should be taken.
2.5-0320-0600/2
Turbogenerators Measures to Prevent Corrosion
During Inspections
Inspection
dissipated by the pump or the output of the primary water

During an inspection, the individual components of the heater is sufficient to maintain the temperature of the
generator are exposed to the ambient conditions which primary water and the stator winding above ambient
may result in hazards to these components. It is therefore temperature.
strongly recommended to take suitable measures for The cooling water should be drained from the Hydrogen
preventing any exposure to moisture, especially rain, snow, and the Seal oil coolers and the secondary cooling water
liquids of any kind and condensation., Covering the should be drained from the primary water coolers. The
components will not afford sufficient protection. coolers should be cleaned, dried and maintained in dry
To avoid the above-mentioned hazards, the assembly condition by suitable measures.
work during an inspection should be accomplished under During inspection work on the exciter unit , it should be
protection from weather conditions. The generator should noted that the devices installed as a precautionary
only be opened if an uninterrupted execution of the work measure, such as anticondensation heating system and
will be ensured and provided that the necessary protective air dryer will no longer be effective after removal of the
measures can be taken. After opening of the unit and exciter enclosure. Be sure to take appropriate measures
withdrawal of the rotor, the stator openings should be (cover,portable air dryers or hot air fans) to keep the exciter
promptly reclosed. The stator should be dried by means of above ambient temperature to avoid condensation.
a portable air dryer or fan-forced heater and kept above Normally, a condensation hazard can be recognized
ambient temperature level. The air dryer or fan-forced with the help of dewpoint measuring device. In case of
heater should be arranged so that the air will circulate doubt, however, it is recommended to dry the components
through the stator interior in a closed circuit for ventilation on a continuous basis in order to achieve a markedly low
of the entire internal space . dewpoint temperature on these components, i.e. to maintain
The rotor should be protected in such a manner that their temperature above ambient temperature level.
especially the retaining ring area can be kept dry and above
ambient temperature level. The air dryer or fan forced
heater should be arranged so that the air will circulate in a
closed circuit.
Primary water circulation should be maintained also
during the inspection work, as far as possible. The heat

1111E
Turbogenerators Preventive Measures to Avoid Stress
Corrosion
Inspection
Survey
Phase Keyword Precautionary Measure and Checks
Transport Packing: 1 Dry rotor retaining rings and RR* wheels by blowing dry air into rotor end
windings and RR * wheels portable air dryersshortly before packing. Multiple dry
packing in sheetings with desiccant added:
Accompanying 2 Reference to special packing and request for restoration after opening due to
documents: customs or in-transit damage.
Damage to 3 Restore proper condition of dry packing immediately. For details, see description
Packing: accompanying the cargo.
Receiving: 4 Check effectiveness of dry packing and desiccant. Record condition in checklist.
Request for repeat checks according to checklist during subsequent storage.
Storage Condition: 5 Maintain dry packing until immediately before assembly.
Check: 6 Monthly functional check of dry packing and desiccant according to checklist.
Storage area: 7 Indoor storage in dry building; outdoor storage in seaworthy packing, under shelter
protected against precipitation/ground moisture.
Installation Outdoor 8 Transport to job site in dry packing. Acclimatization in dry packing to avoid conden-
installation: sation after unpacking.
9 Installation under shelter. Removal of dry packing from retaining rings (1 st layer) as
late as possible.
Open generator 10 With danger of condensation (outdoor installations and open power house), blow
rotor installed: dry air from portable air dryers into rotor end windings and RR * wheels
Ready for Generator closed, 11 H2 –cooled generators:

Operation filled with Pass small cooling water flow through H2 cooler to ensure that cooler is coldest
(standstill H2 gas: component in the generator (condensation hazard!).
or turning
gear Exciter unit 12 RR* exciter units:
operation) in enclosure Drying process with stationary or mobile air dryer.
Sched. 13 Generator closed: Measures as under “Ready for operation”

Outdoor
mainten.
installation: 14 Generator open: Shelters must prevent precipitation from entering the generator;
Without
the retaining ring areas must be covered and kept dry by supplying dry air.rotor
removal
Sched. Indoor 15 If rotor is set down in dry power house with even temperature, it is sufficient if the
mainten. installation: entire rotor is covered against dirt and wetness. If danger of condensation, the rotor
with areas between the bearing journals must be provided with dry packing.
rotor
Outdoor 16 Set down rotor under shelter and provide rotor areas between bearing journals with
removal
installation: dry packing
* RR = Rotating rectifier

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Turbogenerators Inspection Schedule
Foreword
Inspection
Preventive maintenance of generators serves to 2 Influences

avoid major problems or damage while the unit is in Scheduling of the initial inspection and of the
service. subsequent inspections mainly depends on the number of
Apart from its scope, the timing of an inspection is operating hours and on the number of starts and the turning
important. To account for the deterioration and stresses times. The influences are considered according VDEW
due to different modes of operation, both the number Recommendation for
of operating hours and the number of starts are used an equivalent operation time under considerations of the
as criteria determining the intervals between the machine output in four perfoormance groups.
inspections.
The intervals recommended in the following are the Tequiv =K T + K .T + n.T
1 1 2 2 3
same as those indicated in the VDEW Recommendations where
for intervals between Generator Inspections (published
by Vereinigung Deutscher Elektrizitatswerke – VDEW Tequiv T equiv = equivalent operating hours
t , r
– e.V. in 1980). This Foreword contains a large number K = Weighting factor for stress impact
1
of extracts from the VDE Recommendations. during normal operation
The guiding values given in the VDEW T1 ,t1 = Opearting time in hours
t r
Recommendations are to assist the power plant
owners/operators in scheduling inspections, taking into K2 = Weighting factor for turning gear
account also own experience on the performance of operation.
their generators and that of sister machines. T2 ,t2 = Turning gear operation time in hours
t r
1 Types of Inspections n ,n = Munber of Starts

t r
T = Weighted time equivalent in hours per

Depending on the scope ,date and duration of the 3
start
inspections,a differentiation is made between
Initial inspection ing (II)
Where
Short inspection (SI) (or Minor
Subscript t refers to total operational hours since initial
Inspection)
commissioning
Intermediate inspection (InI) (or Medium
Subscript r refers to total operational hours between
Inspection)
two main inspections.
Main inspection. (MI) (or Major
Inspection)
Table 2 : Weighting Factors for the Different Power
Type Feature Duration output Ranges.
Power Rating K1 K2 T3
II Maximal as Upto several
Main Inspection Weeks
SI Checks and Measures required
1 SN>600MVA 1.0 0.5 20
based on observation during Days 2 250<SN<600 MVA 0.9 0.3 10
Operation and Checks. 3 50<SN<250 MVA 0.8 0.1 10
InI Like Short Inspections including few Weeks
4 SN<50 MVA 0.7 0.1 5
Partial disassembly but without
removal of rotor
MI Like Intermediate Inspection but Several weeks The recommendations given in the following apply to
with removal of rotor normal operation without major disturbances. Abnormal
Table 1 Types of Inspection,Features and Dura- disturbances, such as close-in system faults, faulty
tion. synchronizing, asynchronous running and inadmissibly high
unbalanced load, may necessitate shortening of the
The initial inspection is the first major inspection of the respective inspection interval or an immediate check.
generator involving the removal of the rotor and is an When scheduling inspections, also consider the
essential prerequisite for assuring high reliability on a long- following factors :
term basis. The scope of work and checks to be performed
should be agreed upon with the manufacturer in good Q Wear and deterioration of components.
time. The date of the initial inspection should be determined Q Deterioration of running behaviour.
under due consideration of changes that are likely to occur Q Frequency of load rejections associated with overspeed.
after a relatively short service period. Q Earth faults or interturn faults in generator field circuit.
The time periods given are guiding values. Depending Q Hydrogen, water or cooler leaks.
on the scope of the planned work of inspection findings, Q Change in coolant flow rates.
the inspection period is either shortened or lengthened. Q Fouling of air-cooled genera

1111E
Q Deterioration of shaft insulation. Examples of the equivalent opearting hours in a calendar
Q Type Specific experience year for each of the five typical operating modes are shown
in table 4 for the four power output ranges.The turning gear
With proper performance of the generator and provided time in the table has been taken as 50 hours per shutdown,
that the inspection findings obtained by the preceeding but subject to an annual maximum of the difference between
inspection(s) have been favourable, the intervals between 8500 hr/year and the opearting time.In some circumstances
inspections may be lengthened within reasonable limits. this may result in shutdown times of 1000 hrs per year for
opearting modes A,B and E.
3 Recommendations for Inspections Intervals The recommendations of a generally binding inspection
The initial inspection (II) after an equivalent operation time interval of 40,000 to 60,000 equivalent opearting hours
between Main inspections for a medium sized
10,000 h < Tequiv t < 20,000 h turbogenerator (power output range 2 ) at peak load
(opearting mode D) will result in an interval of 6 to 10 years.
The Main Inspection (MI) after an equivalent opearting
time Table 4: Determination of the equivalent Operating Hours for
One calendar year with differing operating Modes and
40,000 h < Tequiv r < 60,000 h Ratings
It is recommended that one or more Short and Intermediate Power Output 1 SN> 600 MVA
Inspections are performed between Main inspections.This Operat T1 T2 n T1xK1 T2xK2 NxT3 Tequiv
resilt in a sequence of Short,Intermediate and Main Inspectins mode
which can be selected flexibly at different intervals. A+E 7000 500 10 7000 250 200 7450
This point of time is not dependent to the technical B 5000 2500 50 5000 1250 1000 7250
requirements of the generator,but also to the most C 3000 5500 150 3000 2750 3000 8750
generator dependent moments of shut down periods of D 1000 7500 300 1000 3750 6000 10750
the machine set.
Recommendations Power Output 2 250 MVA < SN<600 MVA

By the mathematical calculation of inspection intervals Operat T1 T2 n T1xK1 T2xK2 NxT3 Tequiv
based on the equivalent opearting time mode
T equiv =K T + K .T + n.T (from Table 2) A+E 7000 500 10 6300 150 100 6550
1 1 2 2 3
B 5000 2500 50 4500 750 500 5250
will be included the turning gear opeartion hours in addition C 3000 5500 150 2700 1650 1500 5850
to the number of starts and by classifying four groups of D 1000 7500 300 900 2250 3000 6150
power output ranges with different weighting factors.
In this way an equivalent opearting time is
determined for the various opearting modes.It reflects the
Power Output 3 50 MVA < SN<250MVA
diverse opearting influence and corresponds well with
experience.The equivalent operating times are determined Operat T1 T2 n T1xK1 T2xK2 NxT3 Tequiv
and compared for one calendar year considering different mode
operational modes in the four power output ranges. A+E 7000 500 10 5600 50 100 5750
Regardless of the four power output ranges,in B 5000 2500 50 4000 250 500 4750
principle five operating modes can typify turbogenerators C 3000 5500 150 2400 550 1500 4450
(Table 3).For each operating mode typical values are given D 1000 7500 300 800 750 3000 4550
for the load ranges,the annual operating time,load variations
and the annual number of starts providing such a
characteristic order. Power Output 4 SN< 50 MVA
Operat T1 T2 n T1xK1 T2xK2 NxT3 Tequiv
Table 3: Typical Operating Modes. mode
A+E 7000 500 10 4900 50 50 5000
Opera Load Annual Load Annual B 5000 2500 50 3500 250 250 4000
ting Ranges Operating Variation No C 3000 5500 150 2100 550 750 3400
Mode Time of starts D 1000 7500 300 700 750 1500 2950
(in Hr)
A Base Load >7000 small 10 The maximum time between two main inspections and also
B lower 4000-6000 large 50 between (SI) & (InI) should not exceed the period specified
medium load below in table 5 because of harmful long term effects.
C Upper 2000-4000 large 100-200 TABLE 5: Maximum Total Time for Inspection
medium load Intervals
D Peak load <2000 small 300
E Operation in >7000 large 10 Power output range 1 + 2 Power output Range 3+4
industrial SI 2 years 3 years
power plants InI 5 years 6 years
MI 10 years 12years
2.5-1010-0600/2
Inspection Stator
Minor Inspection
Major inspection
Initial inspection
work required
Measure insulation resistance of stator winding x x x
Stator winding insulation x x
Dismantle stator end shield and replace gaskets x x
Dismantle bushing compartment and replace all gaskets x*
Dismantle bushings and replace gaskets x*
Check condition of stator core x x
Check slot wedging system and end winding support structure x x
Check coil connections (preloading, voltage drop) x x*
Replace all generator flange gaskets x x
Replace all gaskets on water-carrying parts x*
Replace seals on teflon hoses of primary water system x*
Replace all gaskets of casing penetrations x*
Check teflon expansion joints x x
Clean filters in primary water circuit x x x
Check balancing orifices in phase connector x*
Check strainers at phase connector flanges x*
Leakage test of primary water system x x x
Leakage test of H2 system x x x
* Normally required only at every second major overhaul

1) Dissipation factor measurement, charging and leakage current measurement, and, in particular cases, high potential test.

1111E
Inspection Rotor
Minor Inspection
Major inspection
First Inspection
Work required
Perform runout check x x
Withdraw and check rotor x x
Perform ultrasonic testing of rotor retaining rings x x
Check rotor wedges and retaining rings x x
Check end windings and gas outlet ducts x x
Measure insulation resistance of rotor winding x x x
Check bearing surfaces x x
Check shaft seal contact faces x x
Check rotor fan x x
Check coupling flanges x x
Check rotor alignment x x

1111E
Inspection Coolers
Minor Inspection
Major Inspection
Initial Inspection
Work required
General
Check cooling water inlet and outlet pipes, vent pipes, drain pipes and mountings of all coolers x x x
Check condition and performance of temperature and pressure measuring devices at all coolers x x x
Hydrogen Cooler
Clean H2 cooler on water side x x x
Check condition and, if required, recondition H2 cooler water channels x x x
Dismantle H2 cooler, check on water and gas sides, clean, if required, replace gaskets x
and perform pressure tests
Exciter Cooler
Clean Exciter coolers on water side x x x
Check condition and, if required, recondition Exciter cooler water channels x x x
Dismantle Exciter cooler, check on water and gas sides, clean, if required, replace gaskets x
and perform pressure tests
Seal Oil Cooler

Remove seal oil cooler,check for fouling and clean if necessary. x x x
Replace any gaskets if damaged and perform pressure test following re-assembly x x x
Primary Water Cooler

Remove primary water cooler,check for fouling and clean if necessary. x x x
Replace any gaskets if damaged and perform pressure test following re-assembly x x x

1111E
Inspection Bearings
Minor Inspection
Major inspection
First Inspection
Work required
Check and , if required, replace bearing insulation x x
Check bearing surfaces and babbitt bonding x x
Check bearing clearances x x
Check seating of bearing sleeves on bearing saddles x x
Check labyrinth rings and, if required, replace seal strips x x
Check condition and performance of bearing temperature monitoring system x x
Check condition and performance of shaft lift oil system x x

1111E
Inspection Shaft Seals
Minor Inspection
Major inspection
First Inspection
Work required
Check shaft seal insulation x x
Replace shaft seal insulation and gaskets x x
Check sliding contact faces of seal rings and seal ring carriers x x
Check contact faces of seal rings x x
Check seal rings clearances x x
Check inner labyrinth rings and, if required, replace seal strips x x

1111E
Inspection Seal Oil System
Minor Inspection
Major inspection
Initial inspection
Work required
Perform functional check × × ×
Seal oil pumps Check coupling × × ×
and Regrease bearings of drive motors (1)

× ×
drive motors Replace bearing of drive motors ×
Replace gaskets of seal oil pumps ×
Replace antivibration pads ×*
Check control and safety valves (including float valves) x x x
Replace control valve bellows x x x
Check all valves x x x
Replace valve inserts x
Replace gaskets in and at valves x
Replace complete flange gaskets ×*
Check and clean seal oil filters, replace gaskets x x x
Check condition and performance of measuring devices x x x
Check condition and performance of level monitoring system (oil level); check sight glasses x x x
Perform functional check of complete seal oil system x x x
Check seal oil flows of individual shaft seals (at rated gas pressure and n=50 s-1 and n=0 s-1) x x x
Overhaul Vacuum Pump x x x
* Normally required only at every second major inspection

1111E
Inspection Gas System
Minor Inspection
Major inspection
First Inspection
Work required
Check condition and performance of all pressure reducers x x x
Check performance of all valves (leakage, operation) x x x
Replace valve gaskets and inserts x
Replace flange gaskets x*
Replace gaskets and coating of CO2 flash evaporator x
Check condition and performance of CO2 flash evaporator x x x
Check complete gas system for leakages x x x

1111E
Inspection Primary Water System
Minor Inspection
Major inspection
Initial inspection
Work required
Functional check × × ×
Check coupling × × ×
Change bearing oil in pump casings 1) × × ×
Primary water pumps Regrease bearing of drive motor 2) × ×
Check and, if required, replace bearing of drive motors and pumps × ×
Replace bearings and oil seal rings of drive motors and pumps ×
Replace sliding-ring glands of pumps x x
Check and clean main filter x x
Perform functional check of ion exchangers (replace resins, if required) x x x
Perform functional check of fine filter x x x
Replace Micro-Clean cartridges in fine filter x x x
Check shutoff valves and non-return flaps for leakage x x x
Perform functional test of valves and, if required, replace wearing parts x
Replace valve stuffing boxes x*
Check condition and performance of all measuring and supervisory devices x x x
Replace all flange gaskets x*
Check complete primary water system for leakage x x x
Inspect and, if required, clean NaOH tank in alkalizer unit x x x
Check feed valve in alkalizer unit for tight shutoff x x x
Check cable and pipe conduits in NaOH tank for firm attachment x x x
Replace diaphragm of diaphragm pump x

1) The intervals (operating hours ) are specified in the supplier’s documentation

1111E
Waste Gas system
Operation

1111E
Inspection Generator Suppervisory Equipment
Minor Inspection
Major inspection
First Inspection
Work required
Check condition and performance of temperature gauges and alarms x x x
Replace gaskets at temperature measuring points x*
Check condition and performance of level meter system (liquid level alarm switches) x x x
Check condition and performance of grounding brush x x x

1111E
Inspection Excitation System
Minor Inspection
Major inspection
Initial inspection
Work required
Dismantle exciter x x
Check insulation resistances of windings x x x
Replace fuses x
Check condition and performance of rectifier wheels; check stator and rotor windings x x
Check coupling flange x x
Replace Multicontact-strip x x
Check alignment x x
Check bearing and pipe insulation x x
Replace bearing and pipe insulation x*
Check bearing surface and babbitt bonding x x
Check bearing clearances x x
Check seating of spherical portions of bearings x x
Check labyrinth rings and, if required, replace seal strips x x
Check air filter and, if required, replace air filter x x x
Check condition and performance of ground fault detection system x x x
Clean prefilter for exciter dryer and replace if required x x x
Clean measuring sliprings and insulating components of ground fault detection ststem x x x
* Normally required only at every second major inspection.

1111E
Turbogenerators Measures for Preservation of Generator
Inspection During Standstill
Preservation measures will have to be taken when a 3 Coolers

water-cooled generator is to be shut down. All coolers should be drained on their water sides
The scope of the preservation work required depends and dried by suitable measures. During the outage, the
on the duration of the shutdown, on the overall conditions drains and vents should be kept open.
in the vicinity of the unit and on the extent to which checks Caution : Never leave water-filled coolers standing
and inspections are possible during such period. The idle for several weeks.
preservation measures recommended in the following are
sufficient under normal conditions. High relative humidity For cooler drying, hot air or dry ambient air may be
in combination with severe temperature changes involves used which should be admitted by means of blowers
the risk that the temperature of certain surfaces in the via the cooling water inlet/outlet flanges. A fan-forced
generator may drop below the dew point, resulting in the heater with a rating of 1-2 kW has proved satisfactory
possible formation of a moisture film due to condensation for this purpose.
on these generator components. In such a case, special
measures may be required for preservation of the rotor 4 Exciter
retaining rings and rectifier wheels [1]. The exciter should be protected against the
formation of a moisture film due to condensation To do
1 Generator Interior this, the cooler should be drained, dried and maintained
The hydrogen gas should be removed from the in a dry condition, and the exciter drying system should
generator. The stator and rotor windings should then be be kept in operation continuously.
protected against moisture by maintaining the generator The carbon brushes should be lifted off and the
interior at a moderate temperature or in dry condition by sliprings covered with oiled paper.
suitable means. This may, for instance, be achieved by the
provision of a hot air blower or dryer. The generator interior 5 Bright Components
can also be maintained in a sufficiently dry condition by All accessible bright components, e.g. exposed shaft
keeping the primary water system in operation as mentioned portions, should be protected with a suitable corrosion
under Item 7 with activated primary water heating system, inhibiting oil or grease, e.g. Tectyl.
if provided. No additional blowers are then required.
If additional blowers are used for drying, the air should 6 Seal Oil and Gas Systems
be admitted and discharged via branches at the exciter Except for the work already mentioned, no
and turbine end manhole covers preservation measures are required on the coolers of
Prior to recommissioning the generator, the insulation the seal oil system.
resistances of the stator and rotor windings should be During the weekly activation of the seal oil system
measured and the windings dried, if required. for turning the shaft, the system should be inspected
for proper functioning by checking all operating values.
2 Bearing and Shaft Seals All valves in the gas system should be closed. No
No preservation measures are required on the bearings additional measures are required.
of the turbogenerator and exciter and on the H2 shaft seals.
However, the bearing and seal oil systems should be 7 Primary Water System
placed into operation once a week and the entire system After completion of the assembly or following a
adequately flushed with water free oil. After activation of prolonged shutdown of the unit, the primary water
the oil systems, the shaft should be operated on the turning system should be placed into operation or kept in
gear for approximately three to four hours. service, with monitoring and maintenance to be
The supply of water to the bearing oil and seal oil performed in accordance with the information given in
coolers is not required during this period. the turbogenerator manual.

[1] 2.5 – 0030 Packing Transport and Storage of Generator Rotors

1111E
Turbogenerators Stator
Inspection
1 Insulation Resistance Measurement

Caution
After each shutdown, the insulation resistances should
be measured prior to carrying out the inspection [1], [2], Even minimal -size metallic particles left inside after
[3]. work on generator can lead to large scale damages
during generator operation.To prevent such dam-
2 Stator Winding ages to the generator and the stator winding,the
following precautionary measures must be taken.
Depending on the scope of the inspection, the slot
wedges should be checked for tight fit and the end windings 1 Only persons assigned to such work may enter
should be inspected for proper support. the interior of the generator .
After opening the generator, the interior should always
be inspected for contamination of any kind. If contamination 2 Person assigned to such work must be in the
is detected, its cause should be determined and corrected possession of clear work procedures and have
been informed of special features of the work
in order to preclude any new contamination. The generator
scope involved and of associated potential
interior should be cleaned thoroughly.
dangers.
3 Terminal Bushings 3 All persons entering the interior of the generator

The bushings and expansion joints should be inspected must wear clean shoes.
to ensure a proper connection between the bushings and
the phase connectors. The bushings should also be 4 Before entering the generator interior ,all pesons
must empty their pockets and remove all
checked for proper connection to the bus bars arranged
metallic objects worn (such as watches,chains,
external to the generator. earrings etc.)
4 Primary water Tubes and Hoses in st ator 5 Tools required for work inside the generator
All primary water hoses and pipes should be checked. may only be transported within boxes, and must
If possible , this should be performed without draining the be returned to boxes after use.
primary water from the generator.
6 After completion of work inside the generator ,
the completeness of tool kits should be verified
5 Cooler Wells against tool lists and result of this check logged.
When dismantling of the hydrogen cooler sections is
required for inspection, the cooler wells in the cooling 7 All winding areas on which work is to be per-
header should be checked for cleanliness. formed must be covered off carefully before
work is started.
6 Flanged Joints and Metering Connections
8 All parts to be installed or removed should be
All stator flanges should be checked for proper listed ,with details of their exact whereabouts.
alignment and seating. The stator should be checked for
tight anchoring to the foundation. 9 Should a part be dropped despite all the above
All metering connections should be checked for proper precautionary measures, it is imperative that it
mounting and condition as far as practicable. This should be located and removed.Site management
should be informed in the case of any problem in
include both the electrical metering connections and the
this context.
pipe connections to the measuring instruments.
Prior to recommissioning, the insulation resistance of 10 Generator openings should be closed off with
the stator winding should be measured and, if necessary, the original covers for the duration of any work
improved. breaks.
11 The use of the attached check list(2.5-2001) for

works at the generator is strictly required.
[1] 2.5 – 2300 Insulation Resistance Measurement on Stator Table 1: Precautionary measures during W ork inside
Winding the generator.
[2] 2.5 – 3300 Insulation Resistance Measurement on Rotor and
Exciter Windings
[3] 2.5 – 2310 Drying the windings

1111E
Turbogenerators Cementing the Joints of
Inspection Profiled Gaskets
1 Survey of Adhesives
to 40 mm in length for overlapping at the joint. The joint
faces could be cut so that the overlapping portion to be
1.1 Sicomet 50
cemented is approximately 30 to 40 mm long. When cutting
Profiled gaskets should preferably be cemented
take care that the profiles does not suffer any visible
together by means of Sicomet one-component adhesive.
distortion and that the pressure applied after pulling
This adhesive meets all requirements, its only disadvantage
together the part to be mounted is exerted on the area of
being the difficulties encountered in storage.
cut (see arrow in Fig. 1). The faces to be cemented together
Sicomet should be protected from moisture, heat and
should be well roughened.
sunlight and should therefore be stored in a dry, cool and
dark place. To prevent an increase in viscosity and
2.2 Cementing the Joint
discoloring of the adhesive Sicomet is best stored at a
The adhesive should be applied in drops on the joint
temperature of –10°C. If stored under these conditions,
areas to be cemented together, using a plastic or metal
Sicomet has an unlimited working life. Defrost Sicomet
spreader for obtaining a thin film Immediately afterwards
prior to use and bring to room temperature.
the joint faces should be assembled and located in position.
Repeated freezing and defrosting does not affect the
Because of the short curing time of 10 to 30 sec. any
bonding properties. The maximum storage time at room
readjustment will be almost impossible. After curing, any
temperature is six months. The adhesive not used up must
cement residue should be removed from the outer surface
be stored at a temperature of –10°C immediately.
of the bonded joint by means of emery paper.
Warning : Sicomet should only be used in well
1.2 Pattex
ventilated work areas. Care must be taken to avoid
Pattex cannot be used for cementing together gaskets
body contact. In the event of contact with the eye,
because of its low temperature stability (50°C max.) and
rinse immediately with ample amounts of distilled
insufficient oil resistance.
or potable water to dilute the adhesive. The eye
The use of other adhesives, as, for instance, rubber
should then be treated to sooth any inflammation
cement, is likewise not permissible.
and a physician immediately consulted.
2 Preparatory Work and Application of Adhesive

2.3 Breaking the Cemented Joints
Cemented joints which are to be broken should be
2.1 Preparatory Work
placed in a bath of either dimethyl-formamide for a brief
The exact length of profiled gasket is determined by
period or ethylacetate for a longer time, resulting in swelling.
inserting it in the center of the sealing groove, allowing 30
30 to 40 mm
Fig. 1 Cementing of a Profiled Gasket

1111E
Turbogenerators
Sealing Generator End Shield Joints
Inspection
1 General 3 Bonding Agent

The joints of the end shields and their flange Prior to applying the sealing compound, the surfaces to
surfaces toward the generator frame are sealed be sealed should be wiped with a bonding agent using a
gastight with profiled gaskets. Experience has shown clean, lint free cloth.
that an additional sealing compound must be applied in
order to obtain a gastight seal at the Tee-joints of these 4 Mounting the Lower Half End Shield
packings and at the flange surface of the seal ring Prior to attaching the lower half end shield to the
carrier. generator frame, wipe the flange surface with bounding
agent over a width of 100 mm at the location of the agent.
2 Sealing Compound Wipe the mating flange surface of the generator frame
The recommended sealing compound is silicone with bonding agent too. Immediately before mounting the
compound S with hardener TL. respective lower half end shield, silicone compound S
These should be mixed in a ratio of 100 g silicone and hardener TL should be thoroughly mixed using the
compound S to 3g hardener TL. ratio mentioned earlier. A thick coating of the compound
should be brushed on the surfaces previously treated with
2.1 Preparing the Sealing Compound bonding agent. The lower half end shield should then be
Mixing of silicone compound S and hardener TL carefully mounted, paying particular attention to the gasket.
in the above-mentioned ratio should be done in a clean After curing, any surplus seating compound should be
and completely dry container. At a temperature of +20°C, removed with of a knife, scraper or similar device.
the prepared mixture is usable for about 1 to 1½ hours.
Following this period, the sealing compound starts to 5 Mounting the Upper Half End Shield
thicken and will have completely solidified after 3 to 4 Suspend the upper half end shield from the crane and
hours. wipe its flange surface with bonding agent within the range
Fig. 1 Mounting the Upper Half End shield

1111E
of the joint over a width of 100mm at the location of the surfaces of the lower and upper half end shields should
gasket. Wipe the mating flange surface of the generator be wiped with bonding agent within the range of the Tee
frame with bonding agent too. Following this, the joint joint and within the range of the flange surface for the seal
ring carrier over a width of 100 mm.
Apply a thick layer of ready mixed sealing compound
on the surfaces previously treated with bonding
agent.The upper half end shield should then be carefully
1
mounted, paying particular attention to the flange and joint
gaskets.
2 After lowering the upper half end shield, but prior to
bolting the end shield joint, secure the gasket in place with
a flat iron bar to be attached with a 3 mm shim for spacing.
3 If this is not done the gasket will be forced out too far at
the mounting face of the seal ring carrier during bolting of
the end shield joint (see Figs. 2,3 and 4).
The gasket projecting slightly from the joint in this plane
4 as a result of the contact pressure established by bolting
5 the end shield halves together as well as any surplus
sealing compound should be cut flush with the flange
surface with a sharp knife.
1 Upper half end shield

2 Retaining device for gasket
3 Joint bolt
4 Lower half bearing
5 Rotor shaft
Fig. 2 Upper Half End Shield Lowered in Position
1 2 3 4 5 6
1 Lower half end shield

2 Gasket
3 Mounting screw for retaining device
1 2 3 4 5 6 4 Flat iron bar for gasket
5 Lower half bearing
6 Rotor shaft
1 Inner labyrinth ring Fig. 4 Retaining Device for Gasket

2 Gasket
3 Shim, 3 mm
4 Flat iron bar for gasket
5 Mounting screw for retaining device Note : Detaching the flat iron bar and cutting flush the
6 Lower half end shield gasket should be done immediately prior to mounting the
respective seal ring carrier. Experience has shown that
Fig. 3 Gasket in Lower Half Stator End Shield With the gasket will be forced out if seal ring carrier is not
Retaining Device mounted immediately.
Caution : Any spaces coming into contact with turbine

oil must not be contaminated with silicone compound.
Should this happen, the area should be cleaned with
2.5-2160-0600/2 extreme care after the sealing compound has cured.
Turbogenerators Mounting of Inner Labyrinth Rings
Operation
1. General Following this, the flat gaskets and insulating

The inner labyrinth rings are provided to prevent rings should be matched.
the seal oil leaving the shaft seals on the hydrogen
side from entering into the generator interior.
3. Installing Labyrinth Rings
For this reason, the assembly of these
(if labyrinth rings are assembled after rotor insertion)
components should be performed with utmost care.
Place lower half labyrinth rings on rotor in their proper
axial positions for normal operation. If required, use
the crane.
The erection device for protecting the labyrinth

2 ring from dropping when being shifted in position
should be assembled from the lower side. Then shift
the labyrinth ring on the rotor by turning it through 180°.
1
1. Lower half
labyrinth ring
2. Bolted Joint
1. Labyrinth ring
3. Erection device
2. Oil baffle
Fig. 1 Labyrinth Ring and Oil Baffle
Fig.2 Shifting Lower Half Labyrinth Ring in Position

The labyrinth rings must be mounted after
insertion of the generator rotor and installation of Shift the lower half labyrinth ring in axial direction
the lower half bearings, but before to installing the against the flange of the end shield. Attach it provisionally
upper half end shields. At first, the ring should be to the End shield by means of the two bolts at joint level,
attached to the lower half end shield only. After permitting the fitting device to be detatched afterwards.
complete assembly of the upper half end shield, the When placing the upper half labyrinth ring in
inner labyrinth ring should be bolted in position. position, make sure that the joints are not displaced
At this stage, the generator rotor is not yet and the taper pins can be easily inserted.
coupled to the turbine rotor. The joint bolts, nuts and lock washers should then
To avoid contact with the shaft and the resulting be inserted and uniformly tightened.
flow of shaft current the labyrinth rings must be Remove the two bolts provisionally inserted at the
insulated from the end shields at the flanged points. labyrinth ring end shield joint and shift labyrinth ring in
Attention should be given to careful fitting of the axial direction away from the flange up to the collar. With
insulation. After completion of the assembly work, the labyrinth ring in position, insert the gasket and the
the insulation of the labyrinth rings should be insulation.
checked [2]. 4. Mounting Gaskets and Insulation
Prior to assembling the labyrinth ring to the end
2. Preparatory Work shield, the insulation and gasket should be checked,
The labyrinth rings should be cleaned with a replaced (if necessary), and placed in the proper
suitable solvent. Clean the groove for the gasket position .
and all fixing holes and oil drain holes in the lower 5. Assembling Labyrinth Rings
half labyrinth rings with compressed air. Check Shift labyrinth rings upto the flange of the end
flange surfaces facing the end shield and perform shield. Provide mounting bolts with insulating sleeves,
blue matching. Correct any unevenness by local
insulating washers, washers and lock washers. Insert
rescraping.
bolts from the bearing compartment side via the holes
The mating upper and lower half labyrinth rings
of the end shield and screw them into the tapped holes
are marked TE and EE close to the joints and should
of the labyrinth ring.
be mounted accordingly.
Fit the centering devices. Tighten the fixing screws
The labyrinth rings should be provisionally
uniformly and lightly, but do not yet secure the screws.
assembled and the length of the gasket determined
Measure the insulation resistance and compare with
and prepared.
the value measured previously [1].

1111E
6. Checking Labyrinth Ring Clearances 10. Final Assembly of labyrinth Rings
The labyrinth rings are adjusted during assembly After assembly of the labyrinth rings with the
at the manufacturer’s works and located in position by specified clearances, check the insulation and compare
means of insulated centering devices. the results with those of previous measurements. If the
To check the radial clearances, measure the gap results correspond to the specified minimum values,
between the caulked seal strips and the shaft at two place the upper half end shield in position.
opposite points each on the horizontal and vertical Bolt the labyrinth ring to the upper half end shield
centerlines. only after the upper half end shield has been completely
Use air gap gauges or feeler gauges (0.02 mm attached to the stator frame and bolted to the lower half
steps) for making the measurements. The clearances at the joint. When bolting the labyrinth ring, check
measured should be plotted in a coordinate system and insulating sleeves, insulating washers, washers and
compared with the reference dimensions. lock washers for correct location.
See the specific drawing Erection setting Finally, check all flange bolts again for uniform tightening.
clearances for the required labyrinth ring clearances. Then check again the insulation resistance of the
Normally, these dimensions correspond to the labyrinth ring insulation.
clearances in the following configuration: With satisfactory insulation, secure all bolts on the
The actual top clearance is determined by adding circumference as well as the joint bolts and nuts. Check
the measured top and bottom labyrinth ring clearances the insulation resistance again.
and deducting 0.05 mm. The actual lateral clearance is
determined by computing the mean value of the
measured lateral labyrinth ring clearances.
The bottom clearance must always amount to 0.05 mm.
In case the clearance distribution does not
correspond to Fig. 3, a readjustment should be made by
reworking or using centering devices in order to obtain
the specified clearance distribution.
If the actual clearances do not correspond to the
required clearances, reworking of the labyrinth ring will
be necessary. In case of excessive clearances, new seal
strips will have to be fitted [2].
Top clearance -0.05 mm
1/2 Top clearance 1/2 Top clearance
0.05 mm
Fig.3 Distribution of Labyrinth Ring Clearance in

Circumference
7. Readjusting Labyrinth Rings

The centering devices should be removed and
marked for identification of their mounting position. The
mounting bolts of the labyrinth ring should then be slightly
loosened and the labyrinth ring shifted by means of a
mounting iron and wooden block in order to obtain the
specified clearance distribution. When inserting the
mounting iron be sure not to damage any parts.
Retighten the mounting bolts when the specified
clearance distribution has been obtained and check the
clearances again after tightening.
8. Reworking Labyrinth Rings
The labyrinth rings must be removed for performing
this work.
1. Stator end shield

9. Fitting New Seal Strips 2. Inner labyrinth ring
In case of excessive actual clearances, new seal
strips must be fitted. To do this, remove the old seal Fig.4 Assembled Inner Labyrinth Ring
strips and insert new seal strips [2]. New seal strips are
available from BHEL Works. Also refer to the following information
[1] 2.5-0300 Checking the Bearing and Seal insulation
[2] 2.5-2163 Fitting new Seal strips to Labyrinth Rings

Turbogenerators
Fitting New Seal Strips to Labyrinth Rings
Operation
1. General
During initial installation or inspection of the unit
the radial clearances between the caulked-in seal strips
of the labyrinth rings and the shaft should be measured.
For required labyrinth ring clearances, see the binding
drawing Erection and Setting Clearances. If the actual
clearances are excessive, new seal strips should be
fitted to the labyrinth rings. To do this, the old seal strips
should be removed and replaced by new ones. New
seal strips are available from stock at BHEL Works.
2. Tools
The tools shown below are required for removal
and fitting of seal strips.
Fig.2 Driving Out Seal Strip
1. Scraper
2. Sharpening tool
3. Smooth file
Fig.3 Pulling Out Seal Strip
4. Caulking tool
5. Pincers
6. Turn-out tool
7. Drift key
8. Hammer
Fig.1 Tools Required for Fitting New Seal Strips to

Labyrinth Rings
3. Removing Seal Strips

For removal of the old seal strips, a chisel, screw-
driver or similar device should be sharpened so that it
fits into the labyrinth ring groove. Apply auxiliary tool to
the seal strip at the abyrinth ring joint and drive out seal
strip by light hammer bIows until the turn-out tool can be
applied. The machined slot in the turn-out tool should
be pushed over the caulked seal strip ind the seal strip
pulled out by turning the turn-out tool. Fig.4 Seal Strip, Pulled Out

1111E
4. Cutting New Seal Strips to Length
The new seal strips to be fitted are delivered in the
form of a coil approximately 300 mm (11.8in.) in diameter.
From this coil the required length including a sufficient
allowance for one groove of the half labyrinth ring should
be cut by means of pincers. Bend seal strip by hand so
that its diameter matches the diameter of the labyrinth
ring. Cut seal strip to required length with an allowance
of 2 to 3cm (0.8-1.2in.). Using this strip as a sample. the
half rings required for the remaining number of grooves
should be cut from the coil and bent as described above.
5. Caulking New Seal Strips

Insert seal strip into groove at bottom center of
labyrinth ring and gradually drive seal strip into the groove
over its full length by applying light hammer blows to the Fig. 6 Cutting Projecting Seal Strip Ends
caulking tool.
Fig. 7 Finishing Seal Strip Ends by Means of a Smooth

File
Fig. 5 Driving in Seal Strips
Note: Joint surface is super-finished and must not be
damaged.
Note: Never drive home seal strip to slot bottom
After all seal strips have been caulked in and
immediately as this may result In lateral distortions of
finished at the joint, the joint surface should be checked
the seal strip.
by means of a bar for colorprint control and, if required,
Starting again at the bottom center, proceed to drive
reworked with a scraper.
in the seal strip lightly in direction towards the labyrinth
ring joint. It is recommended to move the caulking tool
along the seal strip several times in opposite directions,
applying light hammer blows until the seal strip beds
against the groove bottom. With the strip in this position,
the caulking tool touches the inner diameter of the
labyrinth ring. Avoid hard hammer blows, as otherwise
the caulked-in seal strip will be unduly squeezed. In
addition, this would necessitate remachining of the
groove prior to inserting a new seal strip.
6. Finishing Seal Strips at Labyrinth Ring Joint

After caulking of each seal strip, the strip end
projecting from the joint should be cut by means of
pincers. The remaining 1 to 2 mm (0.04-0.08in.) should
be carefully removed by means of a smooth file after Fig.8 Checking the Joint with a Bar for Color Print
caulking of all seal strips. Control
2.5-2163-0600/2
Fig. 10 Sharpening Seal Strips
8. Sharpening Seal Strips
Fig. 9 Rescraping Joint Surface. Turning the inside diameter of the labyrinth rings
results in blunt seal strips The seal strips must therefore
be sharpened by means of a special sharpening tool
7. Turning Inside Diameter of labyrinth Ring prior to assembly. After completion of this work, the half
After blue matching , the half labyrinth rings should labyrinth rings should be bolted together again.
be assembled according to the marks and then turned
on a lathe to suit the shaft dimensions and clearances
Caution: Wear leather gloves while sharpening the
specified on the drawing Erection and Setting
Clearances. strip to prevent injuries.
2.5-2163-0600/3
Turbogenerators Insulation Resistance Measurements
on Stator Winding
Inspection
During manufacture and transport, the insulation of the the winding temperature prevailing during the measurement
stator winding may have been exposed to moisture which to the above reference temperature can be made using
would reduce the insulation resistance of the windings. the diagram in Fig.1.
The insulation resistance should therefore be measured If the insulation resistance measured is lower than the
prior to initial startup, after prolonged shutdowns and after specified minimum value, the neutral connections must be
work on the windings. If required, the generator should be separated and the insulation resistances of the individual
dried until a sufficient insulation resistance is obtained. winding phases measured. During the test, the other two
phases which are not involved should be grounded. If the
1 Required Insulation Resistance of Stator Winding insulation resistances of the individual phases are likewise
The insulation resistance measured is dependent on lower than the required limit value, drying of the windings
the temperature. To permit a proper assessment, a will be indispensable. Great differences in the insulation
correction to an agreed reference temperature (formerly resistance values are indicative of local contaminations,
75oC) must be made. e.g. insulators at bus duct or terminal bushings. If
An insulation resistance of 1 megohm per each kilovolt practicable, additional connections should be separated.
of rated voltage at 75oC is normally attainable without any If this measure does not result in an improvement, it is
difficulties. recommended to obtain the services of a specialist from
New international standards specify an insulation the manufacturer’s work.
resistance of not less than 1 megohm per each kilovolt of
rated generator voltage at 40oC. 2 Measurement of Insulation Resistance
A correction of the insulation resistance measured at Prior to each measurement, the generator must be de-
excited and any static charges removed by grounding the
windings. The windings should also be grounded after
10000 each measurement for the duration of the recharging
period.
5000
The insulation resistance of the stator is measured
3000
between the winding copper and the stator core.
2000
Prior to primary water filling, the insulation resistances
1000 of the individual stator winding phases with respect to the
steel part should be measured by means of a 2.5 to 5 kV
500
Insulation Resistance R in megohm
megger.
300 During normal operation, the winding bars are
200 electrically connected to the grounded cooling water
manifolds through the water in the water inlet and outlet
100
hoses.
50 Because of the considerably lower resistance in the
30 hoses, a determination of the insulation resistance
20 according to the known methods is no longer practicable.
To enable, nevertheless, a measurement of the
10 insulation resistance, this turbogenerator with water-
cooled stator winding incorporates the following | design
5
features:
3
2
Q The water manifolds for the cooling water are insulated
1 for 5 kV against the frame and connected outside the
0 20 40 60 80 100 120 140 160 generator via cables to the insulated contacts. During
normal operation, these contacts are connected to the
Temperature in oC frame, and thus grounded.
Q The bushing hoses are provided with contact sleeves.
Fig. 1 Diagram for Correction of insulation Resistance
Measured to a Temperature of 40 o C During measurements, the primary cooling water must
be flowing, the required conductivity being < 1 µmho/cm.
2.5-2300-0600/1
BHEL, Haridwar 1111E
To measure the leakage current according to Fig.2, the and recorded, observing the negative sign. The recharging
water manifolds should be disconnected from ground, current is the mean value of the tests performed with
joined to the contact sleeves and connected to the same positive and negative voltage.
power source as the windings. A micro ammeter should be
inserted in the connection to the windings. Since, in addition Individual phases can be tested by a similar procedure.
to the very low leakage current, the power source is now The insulation resistance (R10) is calculated from the applied
required to supply the possibly very high partial currents voltage and the 10 minute recharging current,
via the cooling water connections, batteries are not suitable
U (kV)
for this purpose. The dc voltage should therefore be Ω
R10 = ————— = 103 MΩ
I (mA)
obtained from a stabilized power supply.
Note : When the generator is filled with hydrogen, make
The measuring circuit is shown in Fig.2. sure that the rotor shaft ends are properly grounded during
measurement and discharging.
To determine the insulation resistance of water-cooled During measurement, the movement of ammeter A N is
windings, the currents due to any cells resulting from the connected to the positive pole of the stabilized power
cooling water in the hoses between the winding copper supply (approximately 1000V to ground).
and the water manifolds of steel must be taken into Temperature detectors may be installed in the ring-
consideration. For this reason, the insulation resistance of shaped water manifold. To protect the connected metering
the complete winding should first be measured by applying leads and measuring instruments, the metering leads
a positive voltage. After discharging, the measurement should be disconnected at the generator terminal strip (at
should be repeated with a negative voltage. stator frame) during the above test.
After completion of the measurements the measuring
Note : Current may pass through zero. In such a case, the circuit should be removed.
ammeter should be changed over and the current read
Stator winding connection and terminal arrangement as

shown in the diagram are schematic only and may not match 1 = Stator
exactly with the machine. 2 = Rotor
3 = Terminal Bushing
4 = Water manifold ground contact
5 = Generator ground connection
6 = Hose with contact sleeve
7 = Ground connection for manifolds
G1 = Grounding of generator frame
G2 = Grounding of TE shaft end
G3 = Grounding of EE shaft end
B = Stabilized power supply
UB = Voltmeter
AN = Ammeter
Fig. 2 Circuit Arrangement for Measuring the insulation Resistance R 10 IUVW= Current to winding
S = Switch
Note:
Q The primary water must flow through the winding
during the measurement.
Q After measurement, the water manifolds should
be grounded again via the ground contacts.
2.5-2300-0600/2
Turbogenerators
Drying the Windings
Inspection
The epoxy resin insulation used for the stator windings magnitude.Should this not be the case, the generator will
absorbs practically no moisture. Any reduction of the have to be de-excited and the cause of the non
insulation resistance during transport, erection or a uniformity(e.g poor contact of buses ) removed.
prolonged shutdown is mostly caused by the formation of The stator winding temperature and the hot and cold
a moisture film on the surface of the insulation.To prevent gas temperatures should be brought to the maximum
damage to the insulation , it will be necessary to check the operating values by slowly raising the field current.
insulation resistance of the stator and rotor windings prior During drying ,the Generator should be occasionally
to running up the unit to full voltage .In case of an insufficient de-excited and run down for measurement of the insulation
insulation resistance being detected , a drying procedure resistances.In the event of sufficient insulation resistance
should be performed first. being obtained,short circuit drying may be stopped.
Drying should preferably be carried out with the Remove the short-circuit at the bushings.
generator filled with hydrogen,making sure that the gas Following this,the generator may be run up to full voltage
dryer is in operation .
The stator winding should be short-circuited at the In the event of a prolonged shutdown of the generator
bushing by means of buses.The buses should be fitted so it is preferred that the hydrogen be retained in the generator,
as to permit a measurement of the short-circuit current by thereby eliminating surface moisture on the windings.
means of the current transformer.
Run up the Turbine-generator to rated speed and excite
generator.As a result of this, a current in accordance
with the short-circuit characteristic will flow in the stator
winding.The current in three phases should be of identical

1111E
Turbogenerators Test Instruction for
Stator Slot Support System
Inspection With Top Ripple Springs
1 Function of Slot Support System - compensates for shrinkage (setting) of the slot material
The slot wedging system serves to ensure that the by providing for resilience.
bars are, and remain, tight in the slots and that they are
permanently protected from possible vibrations in order to Bar vibrations are thus permanently suppressed.
avoid damage to the insulation and the bars. Such forced The required preloading force is obtained during
vibration of loose bars can be caused by the pulsating wedging by compressing the springs, except for a small
electromagnetic forces. A slot wedging system using a residual amount of the normal spring deflection of
preloaded corrugated spring of epoxy-glass-laminate, the approximately 2 mm. To achieve this, filler strips of the
so-called top ripple spring (TRS), inserted between the required thickness are used. The force which the preloaded
slot material and the slot wedge- spring exerts on the slot material can be determined by
depressing the slot wedge from outside [1]. The test
- results in preloading forces far in excess of the pressure to be applied for checking must be higher than
pulsating electromagnetic forces, the preloading force. The actual preloading of the TRS can
be accurately determined from the spring characteristic
by way of the spring compression measured. To simplify
this evaluation in practice , limits are specified for the
permissible slot wedge movement which should normally
not be exceeded.
1 2 Test Procedure
2.1 Measuring Points

To permit an assessment of the preloading, it will
normally not be necessary to check all slot wedges,
2 however, the check should cover not less than 20 % of
3
the total number of slot wedges. This means that at least
4-5
every fifth slot wedge must be checked, excluding the
6
bonded end wedges. However, not less than five wedges
must be checked in each slot. The measuring points should
be distributed over the slot length so that a helical
7 configuration is obtained on the stator bore circumference,
with the measuring points not being located side by side
but staggered from slot to slot.
1 2 3 2.2 Test Pressure

The test pressure to be applied to a particular slot
wedge depends on the thickness, number and compressed
area of the springs (approximately slot width x length of
slot wedge). The following versions are possible.
Top Ripple Springs Test Pressure F

Number x Thickness Per Wedge
4 5 6 7 1 x 0.8 mm 10 bar x N B in cm x K L in cm
1 x 0.9 mm 18 bar x N B in cm x K L in cm
1 Stator core F = Test pressure 2 x 0.9 mm 30 bar x N B in cm x K L in cm
2 Slot wedge a = Spring deflection
3 Driving strip N B = Slot width
4 Filler strip (equated with TRS width)
5 Compression strip KL = Length of slot wedge 2.3 Slot Wedges Movement tolerances
6 Top ripple spring (TRS) (equated with TRS length) In order to be able to accomodate the extreme
7 Stator bar
electromagnetic forces occuring in slots of view of large
Fig. 1 Stator Slot Support System Using T op Ripple KWU generators, the Tolerances levels for slot wedge
Spring
movements detailed below are very low.The tolerances

1111E
reliable bar support during the subsequent service period. loading with the electromagnetic force arising in the
particular generator. The remaining deflection determined
Q Slot wedge movement shall not exceed 0.55 mm for not by depressing the slot wedges permits the actual
less than 60 % of all measuring points. condition of the spring to be readily derived from the
Q Slot wedge movement at remaining 40 % of measuring known stress-strain characteristic of the top ripple
points shall not exceed 0.75 mm. spring.
Q If one slot wedge movement of more than 0.75 mm is The test record with the results of the depression
measured in any slot, the number of measuring points check should be forwarded to BHEL for evaluation in
for this particular slot should be doubled. If two each case.
wedges in any slot exhibit movements of more than
0.75 mm, all wedges of this particular slot shall be 2.4 P e r m i s s i b l e S l o t W e d g e M o v e m e n t s A f t e r
checked (except for end wedges) to ensure that Rewedging
not more than two excursions per slot exist. During a rewedging operation [2], the preloading of
Q For slot widths of more than 60 mm, an additional the spring is restored by inserting filler strips of the
slot wedge movement of 0.1 mm is permissible to required thickness. To enable an easier and more reliable
account for the elastic spring action of the slot determination of the thickness of the filler strips, it is
wedges. recommended to measure the movements of all wedges
prior to rewedging. A residual spring deflection is
If the actual slot wedge movements measured during required for elastic compensation of the thermal
the next major overhaul are larger than the above expansion of the bars in the slots. After rewedging of
guiding values, the condition of the slot support system the complete winding, the following slot wedge
will be separately investigated by BHEL, Haridwar who movements are permissible :
will then issue recommendations regarding the need for
rewedging under due consideration of : Q Slot wedge movement shall not be less than 0.1 mm
but not more than 0.3 mm for not less than 75 % of
Q the specific electromagnetic forces and preloading all measuring points.
forces Q Slot wedge movement at remaining 25 % of measuring
Q the specific relaxation due to setting points shall not exceed 0.45 mm.
Q the statistical experience with comparable units
Q customer’s specific requirements in respect of future For test pressure to be applied, see table under item 2.2.
inspection intervals.
The individual assessment of the preloading Note : New top ripples springs must only be fitted
conditions relies on a comparison of the actual spring if the existing springs are found damaged.
Also refer to following information

[1] 2.5 – 2342 Test equipment for Stator Slot Support System
2.5-2340-0600/2 [2] 2.5 – 2345 Rewedging of Stator Winding
Turbogenerators Stator Slot Support System
Radial Wedge Movements
Inspection Test Record
Project name: Date of test

Sl No: Checked by:
Generator type Deptt:
No of slots Signature
test pressure F
* Radial movement of slot wedges at major overhaul Pump pressure p =
Piston area AK
* Radial movement of slot wedges after rewedging
Slot width NB mm, Length of slot wedge KL mm . . . . (bar) . . . . (cm) . . . . . (cm)
TRS thickness . . . . . mm, No of springs fitted . . . . . p= . . . . .(cm2)
Test pressure F, (see 2.5-2340 Test Instruction for Slot
Support System With Top Ripple Springs)
Piston area AK (see 2.5-2342 Test Equipment for Stator p = . . . . . . . . . bar
Slot Support System)
Slot no 1 = end of phase A top bar at EE, counting to be
continued in counterclockwise direction)
Mean value of radial wedge movement in 1/100 mm derived from readings of two dial indicators ar thrust piece
Slot TE Slot wedge No. EE

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

1111E
Slot TE Slot wedge No. EE
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
41
42
43
44
45
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2.5-2341-0600/2
Turbogenerators Test Equipment for
Inspection
The test equipment consists of two principal For exact setting of the jack pressure, a precision
assemblies: pressure gauge must be provided between the jack and
the pump.
Q Hydraulic system The connections between the pump and jack should
Q Mechanical system consist of hydraulic hoses. Rigid pipe connections are not
The test equipment was designed for use on generators advisable, since the equipment must be suitable for use in
of any size without any significant modifications being the stator bore.
required and can normally be assembled from locally
available standard components. 2 Mechanical System
1 Hydraulic System The mechanical system consists of a light metal tube of

approximately 50 mm dia. x 5 mm (part 2).
The hydraulic system consists of an oil-hydraulic jack To prevent compression marks on the stator core, a
with hand-operated pump. The equipment should be of mating thrust shim of fabric base laminate measuring
moderate size and weight for convenient use in the stator approximately 100 x 100 mm should be provided, taking
bore. care that this size matches the radius of the stator core
(part 1).
1 Mating thrust shim (fabric base laminate) 7 Precision pressure gauge BA = Stator bore
2 Tube Aluminium 8 Dial indicator AK = Effective piston area
3 Hydraulic jack 9 Magnetic stand NB = Effective slot width
4 Thrust piece 10 Stator core KL = Length of slot wedge
5 Hydraulic pump 11 Slot wedge
6 Hydraulic hose
Fig. 1 Test equipment
* Select range depending of pressure

** Attach magnetic stand to stator core in bore. Place dial indicator stud to thrust piece.

1111E
The thrust piece and jack should be connected to the slot width (NB) and the length of the slot wedge (KL) and
tube with intermediate fittings to obtain a single unit for must be approximately 70 mm high to ensure a sufficient
case of handling. resistance to bending (part 4).
The hydraulic pressure is transmitted to the slot wedge Tube, thrust pieces and jack (part 3) should be
through a thrust piece. The thrust piece should match the dimensioned so that the length of the device corresponds
to the stator bore diameter.
3 Pump Pressure
The necessary pump pressure P for the check depends
on test pressure F and the effective piston area Ak (in
cm2) of the available jack (also see rating plate). It is
calculated according to the following formula:
F
P = ——— [bar]
Ak
For test pressure, see [1].
4 Measurement of Radial Movement of Slot

Wedge
The device described transmits test pressure F to

the slot wedge via the thrust piece. The resulting radial
movement of the slot wedge is measured with the dial
indicators located at both ends of the thrust piece. Take
the mean of the two readings and enter this value in the
test record [2].
Fig. 2 Checking the Stator Slot Support System
Fig. 3 Arrangement of dial indicators

[1] 2.5 – 2340 Test Instruction for Stator Slot Support
System With Top Ripple Springs
[2] 2.5 – 2341 Stator Slot Support System radial Wedge
Movements – Test Record
2.5-2342-0600/2
Turbogenerators Instructions for checking the
Operation
1 Stator slot support system configuration
Number X thickness of top ripple springs : 1 X 0.9 mm
Slot width punched (NB) : 53.5 mm

Slot wedge thickness (KD) : 16 mm
Check thickness on site.

Inform BHEL Haridwar in case of deviations
2 Magnetically Induced Slot Forces : PB = 0.207 N/mm2
3 Specific Test Pressure : PF = 18 bar
4 Permissible Radial Wedge Movemen t
≤0.9mm for not less than 60% of measuring points

≤1.1mm for remaining measuring points(max 40 %)
If wedge movement of more than 1.1 mm is measured in one slot , the number of measuring points in this slot should be
doubled.If the value is exceeded at two points , all wedges in this slot (except for end wedges) should be checked to
ensure that not more than two excursions per slot exists.
Note : If the above guiding values are exceeded , consult BHEL Haridwar for advice, who will then isssue recommenda-
tions regarding the need for rewedging under due consideration of:
the Specific relaxation due to setting

the Statistical experience with comparable units
the customers specific requirements in respect of the future inspection intervals.
The test record with the result of the spring deflection check should be forwarded to BHEL Haridwar for evaluation in any
case.

1111E
Turbogenerators
Rewedging of Stator Winding
Inspection
1 Note 3 Checking the Slot Closing Elements Removed
The need for rewedging may arise from the results of All parts of the slot support system, including the top
a check[1]. The results of this check are contained in the ripple springs, can normally be reused.
test record [2]. The permissible values specified in the test Be careful to avoid damage when driving out the slot
instruction [1] include considerable safety margins to closing elements. Slot wedges found with a permanent
ensure reliable operation during the service period until deformation of 0.6 mm and more across their broad side
the next scheduled major overhaul. For this reason, the should be replaced. The cemented end wedges require
decision on any major rewedging should only be taken particular attention. Any end wedges found damaged
after consultation with the BHEL specialists. should be replaced by new wedges made with the same
Rewedging is done by inserting filler strips between dimensions and geometry as the original end wedges. The
the top ripple spring (TRS) and the compression strip to holes for the ventilating slots in the flanks of the end wedge
restore the preloading of the top ripple spring. It is should preferably be provided during the actual rewedging
recommended to have this work performed by BHEL procedure.
specialists or under their supervision. Wear of the top ripple spring is revealed by light
Prior to rewedging, the radial movement of all slot discolorations at the peaks and valleys of the corrugations,
wedges should be measured as recommended in [1]. This these being indicative of separations between the individual
will enable an economical and fast implementation of the glass cloth laminations. This effect has, however, hardly
rewedging work. any influence on the stress-strain characteristics of the
TRS. Replacing such a TRS will normally not be required.
1 2 3 The TRS should only be replaced in case of very serious
separations extending over its entire width and length. A
spring replacement will be indispensable on fracture of
glass cloth laminations which can be easily checked with
the fingernails.
4 Rewedging Procedure
4 5 6 7 Provided that the slot closing elements removed can be

1 Stator core 5 Compression strip reused, rewedging is done by inserting additional filler
2 Slot wedge 6 Top ripple spring (TRS) strips. The thickness of the filter strips depends on the
3 Driving strip 7 Stator bar difference between the radial movement of the slot wedge
4 Filler strip
measured prior to its removal as recorded in the test record
Fig. 1 Stator Slot Support System [2] and the radial movement required after rewedging as
specified in [1]. In the case of units where all slot wedges
2 Removal of Slot Closing Elements were checked, the thickness of the filler strip can be
separately determined for each slot wedges :
It is advisable to adopt a slot-wise approach for
rewedging. As a first step, each slot wedge should be Actual Value = Radial movement of slot
marked with the slot No. and wedge No. on its top, using a wedges measured
felt pen. Marking should be done in accordance with the - Nominal Value = Nominal radial movement of
scheme specified in the test record [2]. slot wedge
In order to remove the slot wedges, start at one end of = Thickness of filler strip
the stator core and remove wedges up to mid-length of
core. Before proceeding with the removal of the remaining Example :
wedges, lock slot material in first half by inserting auxiliary 0.85 (radial movement of slot wedge
wedges with a spacing of 500 mm. Set down each slot measured)
wedge removed together with the associated top ripple - 0.20 (mean of upper and lower limit of
spring and the filler, compression and driving strips (tied nominal value)
together with adhesive tape). = 0.65 mm (approximate thickness of filler strip
= 0.7 mm)

1111E
If only a restricted number of slot wedges is checked experience that a comparison between the force required
(not less than 20 %), adherence to the specified radial for driving in the slot wedge and the radial movement of
movement may not be ensured. The thickness of the filler the slot wedge after rewedging provides information
strip should preferably be determined on the basis of the enabling the fitter to make a correct assessment of the
mean value of the radial wedge movement in the respective necessary thickness of the filler strips. Such information
slot. will be particularly useful on units where not all slot wedges
The filler strips corresponding to BHEL specifications. were checked.
Rewedging should be started at mid-length of the core Then proceed with rewedging of the remaining slots.
in direction towards the core ends. To do this, remove the Provided that sufficient experience is available checking
auxiliary wedges from one half slot section between mid- the radial movement of the slot wedges will not be required
length of core end and then refit original slot wedges in the after rewedging of each slot. A final check [1] should be
correct locations as marked. Proceed with the second half performed after rewedging of all slots has been completed.
section by following the same procedure. After rewedging This check should include not less than 20 % of the total
of both halves of one slot has been completed, it is number of slot wedges.
recommended to check the radial movement of the slot Proceed with cementing of end wedges [3] after
wedges according to [1]. The results will be helpful in completion of this check.
optimizing the rewedging procedure. It is known from
Also refer to the following Information

[1] 2.5 – 2340 Text Instruction for Stator Slot Support
System With Top Ripple Springs
[2] 2.5 – 2341 Stator Slot Support System Radial Wedge
Movements– Test Record
2.5-2345-0600/2 [3] 2.5 – 2346 Cementing Stator Slot End Wedges
Turbogenerators Cementing Stator Slot End Wedges
Inspection at Trubine and Exciter Ends
1 General end wedge must be 60 mm shorter than the end wedge. The
The procedure described in the following presupposes resulting space should be packed with filter strips which
that the end wedges removed can be reused or that new must be cemented together and to the end wedge and
end wedges have been made after the pattern of any compression strip for protection against displacement.
damaged wedges. Cementing the top ripple spring is not permissible.
2 Adhesive 5 Cementing the End Wedges

Metallon E 2082, or equivalent available from BHEL Prior to driving in the end wedge (part 2) roughen
Haridwar. surfaces of compression strip (part 7) with abrasive cloth
over a length of not less than 50 mm from core end, except
3 Preparing the Adhesive for surface in contact with the stator bar, and apply a thin
Press equal lengths of adhesive and hardener on to a coat of adhesive. Roughen filler strips (parts 5 and 6) with
suitable base and mix to a uniform grey color. The prepared abrasive cloth over a length of 50 mm on both surfaces,
mixture is usable for approximately one hour at room brush both surfaces with a thin coat of adhesive and then
temperature. insert filler strips. Roughen driving strip (part 3) with abrasive
At room temperature, the adhesive has a cure time of cloth over a length of 50 mm and brush driving strip surfaces
one to two days. After curing, the material is not brittle but with adhesive. Insert driving strip and top ripple spring.
similar to rubber. Roughen recessed portion of end wedge with abrasive cloth
and apply a thin coat of adhesive prior to driving in the end
4 Preparatory Work wedge with a mallet and hammer. Drive in end wedge, leaving
The end wedges should be cemented to the core on a clearance of approximately 3m between the end wedge
both flanks over a length of not less than 50 mm as referred and the adjacent slot wedge.
to the core end. These portions of the end wedge flanks are Place a suitably shaped piece of Metallon on the
recessed by 0.5 mm to provide reservoirs for the adhesive. compression strip ahead of the filler strips and the end wedge
When checking the installation of the end wedges, make and smoothen Metallon surface.
sure that the end of the end wedge is positioned on the
supporting keyway of the core. If the wedge end coincides Caution: If bond extends over a length of two or three core
with a ventilating slot in the core, the end wedge should be packets, make sure that no Metallon is left in ventilating
shortened by 5 mm. The top ripple spring pertaining to the slots. Remove surplus Metallon prior to curing.
End of core 50 mm 1 2 3 4
3 mm
10 mm C D 5 6 7 8
Notes
1 Stator core 5 Filler A End wedges are positioned on supporting keyway of core
2 End wedge 6 Filler strip B Metallon bon; compression springmust be 10 mm longer than wedge
3 Driving strip 7 Compression strip C Cementing lower surface of compression stripto bar is not permissible
4 Top ripple spring 8 Top bar D Thickness of filler (part 5) when using one top ripple spring : 1mm;
when using two top ripple springs: 2 mm

1111E
Turbogenerators
Treatment of Bolted Contact Surfaces
Inspection
1 General
Metallically-bright cooper contact surfaces should be contacts, make sure that insulating materials including the
coated with contact grease to provide adequate protection insulators of the terminal bushings do not come into contact
against corrosion. with the solvent.
Silver-plated contact surfaces which are Metallically-bright cooper contact surfaces must
exposed to corrosive conditions breaking the contact must be coated with a sufficient amount of contact grease
be also be coated with contact grease. before closing the contact again.When bolting the contact
faces together,excess grease should be forced out evenly
2 Application from the contact point.
The contact surfaces should be coated with Use a clean rag to wipe off the excess grease.
contact grease immediately after breaking the
contact.Prior to re -making the contact ,all contact
surfaces must be cleaned with solvent.In cleaning the

1111E
Turbogenerators
Rotor
Inspection
1 Leakage Test of Field Current Lead 4 Cleaning the Rotor
After each withdrawal, the rotor should be cleaned

Before starting overhaul work and H2 purging, check
thoroughly, even if the visual inspection did not reveal
H2 seals at the field current lead for leakage. To do this,
any contamination. Careful cleaning is important so as
use a leak detector and check coupling flange between
not to damage any of the numerous insulated parts. It
generator and exciter rotors for gas leakage.
is, therefore, recommended to make use of the services
If no H2 gas leak is detected, the exciter should be
of our experienced product service personnel who will
dismantled. The exciter rotor should be uncoupled from
carefully remove any dirt accumulations below the
the generator and a new leakage test of the central field
retaining rings and within the range of the end windings
connection performed.
by means of a special vacuum cleaner. Any inexpert
If a leak is detected during this leakage test, the
use of compressed air involves the risk of cooling duct
manufacturer must be notified. The hydrogen should be
clogging and of damage to insulated parts.
purged from the generator only after completion of the
leakage test.
5 Contact Pins and Plug-in Socket Strips
2 Rotor Wedges and Retaining Rings

The contact pins and plug-in socket strips should be
checked for arc erosion and proper contact resistances.
If the rotor is removed, examine it carefully. The wedges
Proper seating of the contact pins on the plug-in socket
and retaining rings should be inspected for proper
strips can be verified by visual examination.
condition.
6 Coupling
3 Shaft Journals and Shaft Seal Contact Faces
The coupling flange at the rotor should be checked

The shaft journals and shaft seal contact faces should
both at the guide flanges and at the fitting bolt holes.
be checked for grooves. If any irregularities are detected,
The coupling bolts should be inspected for proper
reconditioning should be carried out according to
condition.
instructions from our service personnel.
7 Insulation Resistance Measurement
Prior to recommissioning, the insulation resistance

of the rotor winding should be measured and, if
necessary, improved. Details are given elsewhere in
this manual [1], [2].

[1] 2.5 – 3300 Insulation Resistance Measurements on
Rotor and Exciter Windings
[2] 2.5 – 2310 Drying the Windings

1111E
Turbogenerators
Insulation Resistance Measurements
Inspection on Rotor and Exciter Windings
During manufacture and transport, the insulation of the Note: When the generator is filled with hydrogen, make
rotor winding may have been exposed to moisture which sure that the rotor shaft ends are properly grounded during
would reduce the insulation resistance of the winding. measurement and discharging
The insulation resistance should therefore be measured
prior to initial startup, after prolonged shutdowns and after 100
work on the winding. If required, the generator should be
dried until a sufficient insulation resistance is obtained. K
1 Required Insulation Resistance of Rotor Winding
The insulation resistance should amount to ≥ 1 megohm

at 40oC. 10
At winding temperatures other than 40 oC, a correction
can be made using the curve shown in Fig.1 R 40oC = R m eas x K
2 Measurement of Insulation Resistance
Prior to each measurement, the generator must be de-

excited and any static charges removed by grounding the
1
winding
The insulation resistance should be measured between
a slipring which is electrically connected to the rotor
winding and a second slipring in contact with the shaft,
using a megger with a maximum voltage of 250V. This
voltage will present no danger to any of the devices in the
excitation circuit. The duration of the test should be
0.1
approximately two minutes.
0 10 20 30 40 50 60 70 80 90
After each measurement, the winding capacitance
o
should be discharged for not less than two minutes. Slot Temperature in C
The measurement should be performed with the
measuring brushes for the ground fault detection system Fig. 1 Correction curve for Insulation resistance
lifted off the sliprings. Measured (Rmeas) to a temperature of 40oC

1111E
Turbogenerators
Ultrasonic Examination of
Inspection Rotor Retaining Rings at Power Plant
Austenitic retaining rings manufactured from echoes, resulting in the difficulties in the interpretation
X55MnCr(N)18k steel are sensitive to stress corrosion, of the ultrasonic indications, particularly within the range
if persisting sufficiently long in an unfavourable of the shrink fits and on shapes deviating from the
environment during storage, operation or outages, smooth cylindrical outline. Based on previous
stress corrosion may lead to crack initiation and crack experience and using special probe heads and reference
growth. In addition to preventive measures to avoid blocks, the BHEL specialists are in a position to
stress corrosion, it is advisable to arrange for determine with a high degree of probability the flaw
examination of the retaining rings at the power plant. size from the indications obtained. According to
Such an examination is urgently required after experience so far available, the detectable flaw size is
disturbance during which the retaining rings are exposed far below the critical flaw size that may result in a
to moisture. In the following the use of the ultrasonic sudden forced rupture. If the echoes reflected by a
inspection method for non-destructive examination is flaw are markedly above the spurious echo level of the
outlined and recommendation are given on the test inner periphery and can be interrupted as incipient
procedure. c r a c k s w i t h a h i g h d e g r e e o f p r o b a b i l i t y, i t i s
recommended to pull of the respective retaining ring for
1 Purpose and Scope of Ultrasonic Examination further examination.
Ultrasonic examination of the shrink-fitted retaining 3 Execution of Ultrasonic Examination

rings serves to detect incipient cracks and particularly
those which have already grown to a dangerous size. To perform the examination, the rotor must be
The examination can only be performed with the rotor removed and supported so that an inspection is
withdrawn. It is therefore recommended to subject the practicable on the entire circumference of the retaining
retaining rings to such an examination during a major ring. The coating of the retaining ring should be stripped
overhaul involving the withdrawal of the rotor. with a paint remover. Care should be taken to ensure
In addition, it is recommended to repeat this that the winding and insulating parts do not come into
examination at regular intervals. Any changes detected contact with the paint remover. Openings in the pole
when comparing the test results with the previous areas and the gaps between the retaining ring and rotor
results provide useful information for assessing the body should be sealed.
integrity of the retaining rings. The intervals at which After completion of the examination, the oil-wetted
the examination should be repeated can be the same as portions of the retaining ring should be degreased with
the scheduled inspection intervals but should be a solvent. When performing cleaning work care should
determined on the basis of the inspection facts. be taken to ensure that the winding and insulating parts
do not come into contact with the solvent. The retaining
2 Flaw Detection ring should then be repainted and the rotor reinserted.
Approximately three days are required for
Ultrasonic examination of the shrink fitted retaining preparations and execution of the examination, including
rings inevitably also involves the generation of spurious repainting of the retaining rings.

1111E
Turbogenerators
Hydrogen Cooler
Inspection
1 General Cleaning with High pressure water system

Remove inlet and outlet water channels, connect
The intervals at which the coolers should be cleaned high pressure water cleaning system and insert nozzle
essentially depend on the condition of the cooling water into each individual tube
[1] . If the cooling water is severely contaminated it may
be necessary to clean the coolers every two months.If Chemical cleaning
, however the condition of the cooling water is good - Pumps
(closed cooling system and use of demineralized water) - Vessels
it may not be necessary to clean the coolers for a number - Piping
of years.Note that coolers must be cleaned if the cooler - Shutoff valves
performance detoriates. - Cleaning agents
The first inspection of the hydrogen coolers should
be performed three months after their commisioning.To
be able to check the level of contamination of the tubes
and inlet and outlet water channels , the top sections Connect a circulating pump to the cleaning system via
of the inlet and outlet lines , and the inlet and outlet the water supply and return lines.Fill the system, close
water channels must be removed.Depending on the vent valves and pump cleaning agent through system.
findings , the subsequent inspections can be performed After cleaning , throughly flush the system with water.
at intervals of upto 12 months. The definitive cleaning In the event that requisite expertise for performing a
intervals can , however only be reliably determined after chemical cleaning procedure is not availaible , it is
a number of years of operation. recommended that this work be performed by specialist
contractors.
CAUTION:
hydrogen gas. Do not perform any work on the NOTE:
hydrogen coolers until the generator has been When performing chemical cleaning work be
shut down and is filled with air at atmospheric sure to comply with the instruction for safe
pressure. handling of chemicals.
The hydrogen coolers should be cleaned on the water

side if the inspection reveals increasing cold gas 2 Cleaning on the Gas side
temperatures or the formation of deposits on the inside For this purpose , the cooler sections must be
surface of the tubes. removed [2].
Following their removal , the cooler sections must
2 Cleaning on the Water side be thoroughly checked on their gas side.To remove minor
It is recommended that the cooler sections be contamination , clean the fins and tubes with dry
removed for this purpose [2]. compressed air. If the inspection reveals more severe
One of the following procedures can be applied for fouling , clean the tubes with a high pressure water
water side cleaning : system. Recommended pressure : 120 bar with 3mm
spray nozzle.The distance between the nozzle and the
Cleaning the Brushes tube bundle should be approximately 2 meters.
Slightly lower the water level in the cooler [2] and
then remove the inlet and outlet water channels.Clean For further information , refer to
the tubes by moving specially-designed brushes up and [1] 2.3-5003 Hints for cooler operation
down the individual tubes.Be sure to avoid any damage [2] 2.3-4100 Removal and Installation of an H 2
to the coating when inserting the brush in the lower cooler
return water channel.The debris removed from the tube
surfaces must then be flushed from the tubes , and the .
contaminated water completely removed from the cooling
system

1111E
Turbogenerators Insertion and Removal of
Inspection Hydrogen Coolers
1 General position, the lower wire rope should be removed and

the section positioned over the respective cooler well
Each cooler section consists of a tube bundle, the opening.
upper and lower tubesheets and the inlet/outlet and If no second crane is available for bringing the cooler
return water channels. The upper tubesheet is larger section in vertical position, the sections should be raised
than the cooler well opening and used to fix the cooler. by means of one crane hoist only, exercising utmost
Gastight sealing of this tubesheet is done by a round care. To do this, suitable wooden supports should be
cord packing. The lower tubesheet is sealed but is freely placed on the operating floor in order to protect the
movable and capable of following the differential cooler sections against damage at the tilting edge and
movement of the cooler due to the different thermal to ensure a firm footing of the section on the floor during
expansions. Gastight sealing of the lower tubesheet is tilting.
done by a packing–type seal. The cooler section should be slowly inserted into
the cooler well, taking care that the resilient seal strips
2 Checking the Generator bed against the gas baffle and that the round-cord
packing is correctly positioned in the groove.
Prior to inserting a cooler section, the cooler well The seal strips, which are resiliently mounted to the
should be thoroughly checked for dirt or other foreign side walls of the cooler section, serve to seal the gap
matter. All compartments and surfaces in the well should between the cooler section and the cooler well. In case
be subjected to a vacuum cleaner treatment. Never use these seal strips fail to perform their function, hydrogen
compressed air for this purpose, since the compressed can flow past the cooler section without being cooled.
air will only raise the dirt and carry it to inaccessible For this section, the seal strips should be thoroughly
locations. The flange and sealing faces and the groove checked for proper functioning.
for insertion of the round-cord packing should be After the cooler section has been lowered into
cleaned. Any burrs or compression marks should be position, the wire ropes should be removed and an
removed with a smooth-cut file. alignment check performed at the lower tubesheet.
There must be a uniform spacing between the tubesheet
3 Sealing the Cooler Section at the Upper Half and the cooler well opening on all sides. The upper
Stator End Shield tubesheet should then be firmly bolted.
The round-cord packing should be cemented 5 Sealing the Cooler Section at the Lower
together in accordance with the instructions given Tubesheet
elsewhere in this Manual [1], and then inserted into the
groove. After alignment of the cooler section in the cooler
well and tightening of the flange bolts at the upper
4 Inserting the Coolers tubesheet, the hydrogen gasket should be inserted.
The cooler section to be inserted should be cleaned Note: During operation, the cooler section against
and suspended from the crane hook using the expands in downward direction, requiring a gastight
suspension device of the return water channel. A second sliding contact between the tubesheet and the Vee
wire rope should be attached to the nozzles of the inlet/ gasket over the distance due to thermal expansion.
outlet water channel and suspended from a second For this reason, the compression ring should not be
crane hook The cooler section should be brought in an tightened excessively, as otherwise the sliding motion
upright position. With the cooler section in vertical will be impaired and/or excessive contact.

1111E
Turbogenerators
Bearings
Inspection
The insulation resistance of insulated bearings the bearing may be used further. If a low insulation
should be measured prior to each inspection. The resistance has been previously measured, the
bearings should then be dismantled and cleaned respective bearing should be inspected thoroughly for
thoroughly. Bearing sleeves and shaft journals should any damage by cathodic action.Clean the insulation
be checked for proper condition. If grooves are detected at the bearing saddle ,as otherwise the insulation
the manufacture should be asked for advice whether properties are affected The inspection procedure
described above should be performed at all sleeve
bearings of the turbine generator.

1111E
Turbogenerators
Shaft Seal
Inspection
A differentiation is made between a minor, a medium be carefully and thoroughly cleaned. All points subjects
and a full-scale inspection. A minor inspection includes to natural wear should be inspected closely.
measurement of clearances and a visual examination. A Reassembly of the shaft seals should be performed
medium or full-scale inspection is automatically assumed with utmost care.
if withdrawal of the rotor is required for which purpose During each inspection, a check should be made to
the entire shaft seals will have to be dismantled and ensure that the seal rings are still sufficiently insulated
should be subjected to a close inspection. from the stator frame.
After dismantling, all shaft seal components should

1111E
Inspection
The work to be performed at an inspection is very 3. Safety Valves

difficult to determine in advance. The scope of this work The safety valves should be removed and cleaned
depends on what defects were detected from the date of with turbine oil. Check safety valves for proper
the last inspection. The operating log should be checked performance on pressure gauge panel prior to installation.
to determine which deficiencies should be corrected at
the inspection.
4. Shutoff valves and Check Valves
The following inspection work should normally be
Inspect shutoff valves and check valves for proper
performed:
operation. If necessary, replace the valve inserts.
1. Seal Oil Filters
The filter to be cleaned should be taken out of service 5. Pressure Measuring Points
by changeover to the standby filter. The signal pipes to the pressure gauges should be
Remove cover of seal oil filter and complete screen drained and flushed with clean turbine oil.
inserts. Clean screen inserts with a solvent. To do this,
drive out cotter pin and unscrew knurled unit. Base, fabric- 6. Seal Oil Tank and Float Valves
lined supporting cylinder and screen ring can now be Remove the seal oil tank cover and the intermediate
pulled off the magnetic strainer unit. Rinse the screen oil tank cover and check the float valves for free
inserts with clean turbine oil to thoroughly remove any movement. If the performance of a float valve is
solvent residue. Reassemble using new gaskets. unsatisfactory, the valve should be removed and replaced.
If sludge has accumulated, the seal oil tank should be
2. DifferentIal Pressure Regulating Valves cleaned.
Disconnect the signal pipes from the pressure
regulating valves. Drain the seal oil from the signal pipes. 7. Thermostats and Contacts
Disassemble the valve head and valve yoke. Check thermostats, contacts of pressure gauges and
This work should be performed with utmost care so pressure switches for proper operation.
as to avoid damage to the sliding surfaces. Before All checking, cleaning and reconditioning work
removing the valve yoke, unload the compressing spring. should bet performed with utmost care to ensure reliable
Remove the main bellows and the upper and lower operation of the entire seal oil equipment for a prolonged
sealing bellows. Check all sliding surfaces and valve period of time. When recommissioning the seal oil
cones for damage or wear. If damage or wear is detected system, be sure that all status indications and alarms
on the sliding surfaces, the bushings should be replaced. function properly. All control gear, safety equipment,
Check the main bellows and the upper and lower sealing filters, coolers, signal and pressure sensing pipes should
bellows. be carefully vented at operating pressure.

1111E
Turbogenerators Seal Oil Pumps and
Inspection Bearing Vapor Exhausters
1. Electrical Motors of Seal Oil Pumps 2. Seal Oil Pumps

At the manufacturer’s works, the antifriction bearings Disassemble the seal oil pumps. Check whether the
of the seal oil pump motors are packed with grease dummy pistons, the screws or the deep-groove ball
sufficient to give troublefree service for a period of two to bearing are worn. The passage in the casing insert and
three years. For this purpose, a grease on lithium-soap the sliding rings should also be checked. The seal rings
base with a drop point above 160 0C is used. The period and gaskets should be examined for tight sealing and
will be shorter under onerous service conditions or at replaced, if required.
high ambient temperatures. On expiry of this period, a Prior to recommissioning the seal oil system, add a
thorough cleaning of the bearing interior and an inspection small quantity of turbine oil via the oil filling plugs on the
for wear will be required. This work necessitates a seal oil pumps to ensure proper lubrication of the shaft
withdrawal of the armature, followed by washing the seal and the necessary sealing of the screws for suction.
bearing shield bore, the bearings and the bearing covers
with light petroleum to which a small quantity of oil was
added, until the grease is completely removed. The 3. Bearing Vapor Exhausters
bearings should then be packed with grease of the same The antifriction bearings of the exhauster motors
grade, taking care that both sides of the cages are normally require no maintenance.
covered with grease so that an effective seal is obtained After approximately 8000 operating hours, the
against the ingress of foreign matter. The unit can then bearing vapor exhausters should be thoroughly examined.
be reassembled. After reassembly, a check should be The motor should be disassembled and the bearings
made whether the shaft turns properly in the bearings. cleaned and packed with new high melting point grease
Measure the carbon brush wear on dc motors. If the or replaced by new bearings. Remove the old grease
brushes are heavily worn, new carbon brushes should from the regreasing device and check the packing washer
be installed. and seals for wear. If necessary, replace the packing
Measure the insulation resistance between the washer and seals. Be sure to observe the specified order
windings and ground with a 500 V megger. If the of the spring washers and spacers when reassembling
insulation resistances does not comply with the related the unit. On recommissioning of the unit, measure the
equipment manuals, the motors should be dried in an vacuum in the bearing compartments.
oven at approximately 700C for several hours.

1111E
Turbogenerators Vaccum Pump
Inspection Type S4B
1. Draining 011 From Vacuum Pump Open exhaust filter and clean or replace the filter
Remove the oil drain plug to drain the oil from the element. Clean interior of filter housing and inspect float
pump. When the oil flow decreases, start and immediately valve for free movement. Clean oil filter in vacuum pump
stop the pump to drain the residual oil. after removal of the oil reservoir.
Push the two spring clips in outward direction each
and lift off the holding frame. Then carefully lift off the
2. Draining Oil from Drain T rap and Exhaust Filter filter. Clean filter or replace it with a new filter. Reassemble
Open drain cock at drain trap to drain the liquid from pump.
the trap [1]. Remove the oil drain plug from the exhaust
filter to drain the oil. 4. Filling Vacuum Pump With Oil
After the pump has been completely reassembled,
fill pump with oil via the intake port. Keep the pump
3 Cleaning Pump Components and Replacing Filters
running for not less than 10 minutes and then drain the
A wire mesh strainer placed In the intake port of the
oil. If the oil drained is clean, fill the vacuum pump and
vacuum pump serves to arrest coarse matter. This wire
the exhaust filter with grade N62 special oil or an
mesh strainer should be removed and cleaned.
equivalent mineral oil up to the maximum oil level marks.

1111E
Inspection
1 General 2 Work to be performed
The work to be performed at an inspection is very 2.1 Dust Filters before the Pressure
difficult to determine in advance. The scope of this work reducers
depends on what defects were detected from the date Clean the dust filters before the pressure
of the last inspection. The operating log should be reducers replace , if required.
checked to determine which deficiencies should be
corrected at the inspection. 2.2 Pressure Reducer
The main purpose of an inspection of the gas system Check and , if required , replace the pressure
is to restore a satisfactory gastightness. All pipe reducer diaphragms.
connections of the gas system should be checked for
leaks [1] before the unit is shut down. All leaks should 2.3 Valves
be marked and corrected during the inspection. Check all valves of the gas system for leaks.If
In addition, the scope of inspection work depends required,replace the diaphragms and valve inserts
on the intervals between inspections, the scope of the
work performed during the preceding inspection and on 2.4 Gas Dryer
the time available. During a full-scale inspection the parts Properly installed and operating, the dryer
listed under items a, b and c should always be replaced. requires a minimum of care to be provided for many
Depending on the inspection conditions, the following years of reliable service. A regular m a i n t e n a n c e
work should normally be performed. programme will add to the life of the Dryer and prevent
problems with your compressed air system. Regular
maintenance procedures should include daily monitoring
o f Dryer operations.
On air cooled models,
blowing out or cleaning of dirt and dust from the air
cooled refrigeration condensing unit, and especially
the refrigeration condenser, monthly or as required
depending on conditions of the area in which the dryer
is installed.
Use Stabilized Voltage to prevent abnormal
electrical component / Compressor failure.
After completion of all inspection work on the gas

system,the gas system and generator should be leak
tested.
The electrical purity meter system should be
calibrated with pure CO and H .
2 2

[1] 2.5 – 0310 Leakage Tests

1111E
Inspection
The work to be performed at an inspection is very During a large-scale inspection, the packings of the
difficult to determine in advance. The operating log valves should be replaced.
should be checked to determine what faults need to be
corrected.
The following inspection work should normally be 4 Level Monitoring System
performed after draining of the primary water circuit :
The probe rods in the primary water tank should be
1 Primary Water Filters removed, cleaned and reinstalled using new seals.
1.1 Main Filter [1] 5 Conductivity Meter System

Open the filter housing and remove the insert. [2]
At each inspection, the transmitters of the
1.2 Fine Filter [1] conductivity meter system should be removed, cleaned
The cartridge in the filter should be replaced at each according to a separate instruction [1] and reinstalled
overhaul[1]. using new seals.
2 Ion Exchanger 6 Controllers
Depending on the condition of the ion exchanger Check the thermostats for proper operation.
resins, they should be replaced by new or reactivated All checking, cleaning and reconditioning work
resins. The replacement of the resins should be done in should be performed with utmost care to ensure reliable
accordance with a separate instruction [2]. operation of the entire primary water system for a
prolonged period of time. When recommissioning the
3 Valves primary water system, be sure that all status indications
and alarm function properly.
Inspect all valves for proper operation.

[1] 2.4 – 4740 Primary Water Filters
[2] 2.3 – 9782 Conductivity in Primary Water System

1111E
Turbogenerators Primary Water Pumps
Inspection
1 Electric Motors for Primary Water Pumps 2 Primary Water Pumps
After 8,000 operating hours, the bearings of the 2.1 Bearings

electric motors should be removed, cleaned and packed The primary water pumps are equipped with
with high melting point grease. Worn bearing should be lubricated bearings. The oil level in the bearings can be
replaced by new ones. checked at an oil slight glass. After approx. 3000 hours
of operation, the oil should be changed. For this purpose,
Measure the installation resistance between the only a good quality oil (SAE 20/30) should be used.
windings and ground with a 500 V megger. If the During intermediate inspections, the bearings should
insulation resistances do not comply with the related be checked. Worn out bearings should be replaced.
equipment manuals, the motors should be dried for When replacing the bearings, the seal rings should also
several hours in an oven at approx. 70°C (160°F). be replaced. The bearing caps should be remounted
using new gaskets (0.1 mm = 0.0004 in. thick).
Check the coupling between motor and pump and
replace worn parts. 2.2 Sliding Ring Gland
During minor and major inspections, the sliding ring
gland should be replaced. For this purpose, the pump
impeller must be pulled off.

1111E
Turbogenerators Treatment and Cleaning of Pipes
in Primary Water Circuit
Inspection
1 General
up to 20 mm from the weld. On completion of the
welding work, the discolored portions of the pipes
The pipes of corrosion-resistant resistant chrome-
should be cleaned mechanically on the outside and
nickel steel used in the primary system t of water-cooled
as far as accessible, on the inside, too. Use only
generators are welded according to the GTAW method
brushes of corrosion resistant chrome-nickel steel
with SAS 2IG, using argon (99.9 %) as shielding gas
for such mechanical cleaning work. For grinding
and purging gas N 2H 292/8 or 90/10.
work use only new grinding wheels or wheels that
Any required pipe bends should be made only by
have been in contact with corrosion-resistant
cold bending on the pipe bending machine or pipe elbows
materials only.
should be welded in.
2 Treatment of welds
3 Flushing the Complete Piping System
After welding, the welds should be treated as

Prior to commissioning the complete piping system
follows:
should be flushed in completely assembled condition.
Q Fusion check
(Liquid penetrant test)
The fusion check is to be carried out on each weld
according to the liquid penetrant method.
Q Mechanical treatment or cleaning of pipes discolored
by welding.
Even when using a shielding gas, the pipes discolor

1111E
Turbogenerators Flushing External Part of
Primary Water Circuit
Inspection
1 General
Prior to startup of the generator, the complete piping primary water system.
system should be flushed in the assembled condition in Ensure that the pressure in the primary water tank
order to remove any foreign particles from the main does not exceed the full scale value of pressure gauges
filter MKF80 CP011 and MKF80 CP511.For this reason,Keep
drain valve MKF80 AA412 open during filling and flushing
2 Preparatory Work procedures and adjust the filling rate accordingly.
The system should be flushed for 8 to 12 hours
Prior to flushing, the following work should be
with water at 45 to 50 °C.During the flushing process,all
performed:
pipes should be tapped throughly to facilitate the removal
of any contaminants.
Install bypass pipes between inlet and outlet of
The entire flushing water should then be drained
Q
stator winding,terminal bushings,generator main

from the system.The main filter should be opened
leads (if provided),generator circuit breakers (if ,cleaned and reassembled.
provided).Seal above components by fitting closure
The flushing procedures should be repeated until
discs.
the filter is free from any contaminants.
Q Remove all orifices plates ,vanes and strainers.
Q Ensure that tank MKF35 AT001 is not filled with resins
and has been drained.
4 Preparing Primary Water System for Leakage
Q Remove filter element from filter MKF35 AT011. Te s t
Q Isolate N 2 supply line and vent gas line by closing
shutoff valves MKF01 AA251 and MKF80 AA061. Following completion of the final flushing procedure
Q Check that primary water pumps are ready for and the subsequent filter check,all filters should be
operation. Heat up the water by operating both reassembled using new gaskets.
pumps in parallel after the primary water system Any orifice plates,vanes and strainers should be
has been filled. reinstalled prior to performing the leak test.The bypass
lines should be removed.
3 Flushing the Complete Piping System The leak test should be performed in accordance
with the specifications set forth in the generator
The primary water system should be filled with
manual[1].
demineralized water of up to 50°C via the filler valve
in accordance with the specifications for filling the
[1] 2.5 – 7384 Leakage Test of External Primary Water

Circuit.

1111E
Turbogenerators Leakage Test of External
Primary Water Circuit
Inspection
1 General
4 Applying the T est Pressure
The external section of the primary water system

The Primary water tank should be filled with nitrogen
must be subjected to leak testing after every major
until a gas cushion with a pressure of 10 bar is
overhaul.
established above the water level .The gas should be
admitted from a nitrogen bottle and a pressure reducer
2 Preparatory Work
connected to the primary water tank gas supply line.
Prior to admitting gas to the tank and increasing the
As a rule,the external section of thr primary water
gas pressure to the level , it must be ensured that
system is cleaned prior to performing any leak test [1].
shut off valve MKF80 AA061 is closed and shut off
Since the leak testing is restricted to the external
valve MKF01 AA251 is open.The pressure increase in
section of the system only, the stator winding section
the system can be monitored on the connected
as well as the terminal bushings and phase connectors
pressure gauge MKF80 CP511.As soon as the pressure
should be isolated from the external section by means
in the system reaches a gauge pressure of 10 bar, shut
of closure plates.
off valve MKF01 AA251 should be closed.
For the duration of the leak test , pressure gauge
MKF80CP511 in the waste gas line should be replaced
5 Leak Detection
by a pressure gauge conforming to accuracy class 0.6
with a measuring range of > 10 bar.
All flanged, bolted and welded joints in primary water
All other pressure gauges and pressure transmitters
system as well as the associated valves should be
with a range of less than 10 bar should be isolated from
inspected for any leak while maintaining a constant
the primary water system by means of appropriate
pressure in the system.Any leaks should be repaired
valves.
and leak test repeated.
All shutoff and gas valves in the primary water
circuit should be opened.
6 Terminating the Leakage T est
3 Filling the Circuit

The primary water circuit may be considered as tight
if the visual examination of the system does not reveal
The systemt should be filled with demineralized
any findings and if the pressure gauge MKF80 CP511
water via the water supply line (shutoff valve MKF37
does not indicate a pressure drop during a test period
AA261) and then properly vented. It must be insured
of 10 minutes (after thermal equilibrium has been
that all drain valves are closed before filling
reached). Following completion of the leak test,the
the system.
external section of the primary water system be
The Primary water tank should be filled up to
promptly reassembled.
approximately 300 mm and it must be ensured that
Place primary water system in operation immediately
all water lines connected to the primary water tank are
after the system has been restored to its previous
filled with water.
condition.

[1] 2.5 – 7382 Flushing External Primary Water Circuit.

1111E
Turbogenerators Excitation System
Exciter
Inspection
1 General 6 Makeup Air Filters
The scope of work to be performed during an The filter mats of the makeup air filters should
inspection depends mainly on the equipment on which be cleaned or replaced. Slightly contaminated air filters
defects have been detected since the last inspection. It should be beaten out or washed in a water bath (approx
will therefore be necessary to extract from the operating 30°C) adding a suitable detergent (Washing-up liquid).
log all deficiencies to be corrected during the inspection. When placing the filter mats in the water bath, make
In accordance with the inspection schedule [1], the sure that the air inlet side points downward. After
following inspection work should be performed. washing, the filter mats should be rinsed with clean
water.
2 Dismantling and Cleaning the Exciter 7 Bearing and Labyrinth Rings
Remove exciter rotor. The coupling flange at the rotor Check the insulation of the bearing, pipe connections
should be checked both at the guide flange and at the and, labyrinth rings. For details see the respective
coupling bolt holes. Check coupling bolts for proper instruction [4].
condition and take dimensions. If the bearing babbitt is found grooved, our erection
Any accumulations of dirt in the ventilating air ducts engineer should be consulted regarding further use of
of the rotor, at the diodes, fuses and heat sinks must be the bearing.
removed. Cleaning should be done very carefully to avoid The strips of the labyrinth rings should be checked
damage to the numerous insulated parts. It is, therefore, for proper condition and replaced, if required.
recommended to remove these contaminations with a
brush, cloth (non-linting) and a vacuum cleaner. 8 Checking the Contact Pins and Plug-In Socket
Particular care should be exercised when cleaning the Strips
porcelain bodies of the diodes.
A check should be made to ensure that the projecting
3 Measuring the Insulation Resistances of the contacts of the plug-in socket strips are spirally
Windings distributed on the entire circumference of the contact
sleeve.
Disconnect cables at stator terminal boards of the
pilot and main exciters.
Remove measuring brushes of ground fault detection
system from slip rings.
The insulation resistances to ground of the individual
windings should be measured with a megger. For details,
see the respective instructions [2].
4 Drying the Windings
If the exciter dryer is not in operation due to special

circumstances during a prolonged outage of the exciter
,the resulting formation of a moisture film on the surface
of the winding may lead to reduced insulation resistance.
If the dryer cannot be placed in opeartion,hot air should
be admitted into the exciter by means of a fan forced
heater with a rating of approx 2 KW.
5 Checking the Diodes, Fuses and Rectifier

Wheels
For details, see the respective instruction [3].

1111E
9 Checking the Condition and Performance of
the Ground Fault Detection System
Use a vacuum cleaner to remove any dirt and

carbon dust from the measuring sliprings and the corre-
sponding insulating components.The measuring sliprings and
insulating components should be cleaned with a non-fluff
cloth which has been soaked with a suitable liquid cleaning
agent (Rivolta or equivalent )
It is recommended to replace the carbon brushes of
the ground fault detection system at each inspection.
Ensure to insert the carbon brushes of the specified
grade which match the slip ring contour(see 2.4-4990).
After complete assembly of the exciter, the complete
ground fault detection system should be subjected to a
functional test.
10 Cleaning the Exciter Coolers

Depending on the degree of fouling on the water
1 Insulation
and air sides , the coolers should be removed and 2 Contact sleeve
cleaned. (see 2.4-4940) 3 Plug-in contact strip
Fig. 3 Section Through Contact Sleeve
2.5-9000-0600/2
Checking the Insulation Resistance
Inspection of Heat Sink Insulation
Regular inspection work should include checking the would then no longer be ensured, resulting in a phase-
insulating sections, between the diode heat sinks and to-phase fault in the main exciter circuit.
rectifier wheels [1]. Leakage paths may be formed at After removal of the fuses, the insulation resistance
these points as a result of dirt deposits, rendering the between points a and b or a 1 and b 1 respectively, can
fuses connected after the diodes ineffective in the event be measured by means of a megger, applying a voltage
of a failure. of 500 to 1000V. The insulation resistance between the
In the event of a diode losing its blocking capability, heat sink and rectifier wheel should not be less than 10
an interruption of the respective bridge arm by the fuse M(.

[1] 2.5 – 9011 Checking the Insulation at Rectifier
Wheels

1111E
Checking the Insulation at Rectifier Wheels
Inspection
10 1 2 3 4 5 6 7 8 9
Current path
1 Fuse
2 Heat sink
3 Diode
4 Rectifier wheel (-ve polarity)
5 Terminal bolt
6 Tension bolt 3 1 9
7 Hot air outlet
8 Rectifier wheel (+ve polarity)
9 AC lead
10 DC lead
Detail X
4,8

1111E

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OPERATION & MAINTENANCE

Project :2X600 MW TPP AT DERANG,ANGUL,ORISSA

Customer : JINDAL INDIA THERMAL POWER LTD.

BHEL Order no : Unit -1 10597P12901

BHARAT HEAVY ELECTRICALS LIMITED

Cover Sheet 0.0-0000 Stator End Shields . . . . . . . . . . . . . . . . . 2.1-2150

Seal Oil System 2.1-7100 Introduction. . . . . . . . . . . . . . . . . . . . . . . . 2.1-8400

The manual contains a Table of Contents together Identification number

Identification Number 2.0 - 0040 - 0009 / 1

The materials, which are scrapped during b) Insulation:

Residue of fluoro-elastomer products, obtained by

Project name: 2 X 600 MW TPP AT DERANG, ANGUL , ORISSA

BHARAT HEAVY ELECTRICALS LTD

KW 600,000 R.P.M 3000

P.F. 0.85 LAG Hz 50

KVA 705,900 Phase 3

Volts 21000 Coolant : Hydrogen & Water

Volts 413 Insulation : Class F

MADE IN INDIA Division: Haridwar

1 General 3 Hydrogen Cooling System

1 Stator 3 Stator Frame (Inner Frame)

BHEL, Haridwar 2.1-1210-0600/1

BHEL, Haridwar 2.1-1230-0600/1

1. Rotor Shaft The slot wedges are made of high-conductivity material

Fig.1 Arrangement of hydrogen cooler .

BHEL, Haridwar 2.1-1440-0600/1

The sleeve bearings are provided with hydraulic

1 Connection for shaft lift oil

The points where the rotor shaft passes through

BHEL, Haridwar 2.1-1460-0600/1

BHEL, Haridwar 2.1-1510-0600/1

Fig. 1. Simplified Diagram for Single Flow Seal Oil System

1. Seal oil storage tank 8. Seal oil cooler

BHEL, Haridwar 2.1-1511-0600/1

Operation Gas System

• N 2 supply 4 Compressed Air Supply

• Pressure gauges To remove CO2 from the generator, compressed air

• To ensure that the primary water in the pump

• To ensure that the primary water circuit is at a

BHEL, Haridwar 2.1-1520-0600/1

General Simplified Diagram

1 H2 bottle 10 Gas drier fan

Operation Primary Water Supply

6 Primary W ater Treatment System

3 Primary Water Pumps

BHEL, Haridwar 2.1-1530-0600/1

General (Simplified Diagram)

Primary water circuit, general

1 Primary water tank 7 Bypass line

Rated Data and Outputs Turbogenerator Main Exciter Pilot Excitor

Resistance in Ohms at 20°C Turbogenerator Main Excitor Pilot Excitor

Description Mechanical Data

Torques, Critical Speed etc. Torques and Units

Maximum short-circuit torque of stator at

Moment of inertia of generator rotor shaft 10966 kgm2

Generator Volume and Filling Quantities Volume Units

Weights Weight units

Component Material Component Material

Description Seal Oil System

DC Seal oil pump (MKW 13 AP 001)

Vacuum Pump (MKW10 AN001 and MKW10 AN002)

Capacity 162 LPM